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Clarke ZE User Manual

Clarke ZE
41 pages
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C136142 revH
11/18
Operation and Maintenance
Instructions Manual
ZE / ZF MODEL ENGINES
FOR
FIRE PUMP APPLICATIONS
Clarke UK, Ltd. Clarke Fire Protection Products, Inc.
Unit 1, Grange Works 100 Progress Place
Lomond Road Cincinnati, OH 45246
Coatbridge U.S.A.
ML5 2NN
United Kingdom
TELE: +44(0)1236 429946
FAX: +44(0)1236 427274
TELE: +1.513.771.2200 Ext. 427
FAX: +1.513.771.5375
www.clarkefire.com

Table of Contents

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Clarke ZE Specifications

General IconGeneral
Cooling SystemAir Cooled
Starting SystemRecoil Start
Fuel Tank Capacity3.6 Litres
Oil Capacity0.6 Litres
Engine Type4-stroke, single cylinder, OHV
FuelUnleaded Gasoline
Engine Stroke4-stroke

Summary

1.0 INTRODUCTION

1.1 IDENTIFICATION/NAMEPLATE

Defines "Engine" and "Machine," and explains the manual's purpose.

MODEL NUMBERING & IDENTIFICATION

Details engine model numbering conventions and identification plates.

1.2 SAFETY/CAUTION/WARNINGS

Covers essential safety precautions and warnings for operating the engine.

BASIC RULES

Provides fundamental safety recommendations to minimize operational risks.

2.0 INSTALLATION/OPERATION

2.1 TYPICAL INSTALLATION

Illustrates a standard fire pump installation layout and identifies components.

2.2 ENGINE STORAGE

Details procedures for storing engines for short and extended periods.

2.3 INSTALLATION INSTRUCTIONS

Specifies critical installation requirements for optimal engine performance.

2.4 SPECIFIC FLYWHEEL COUPLING ALIGNMENT INSTRUCTIONS

Guides on checking and performing flywheel coupling alignment procedures.

2.4.1 Listed Driveshafts

Refers to specific installation manual for listed driveshafts.

2.4.2 Driveshaft

Explains how to check pump and crankshaft alignment using the driveshaft.

2.4.3 Other Coupling Types

Directs users to consult factory or website for other coupling types.

2.5 STARTING/STOPPING THE ENGINE

Provides instructions on how to start and stop the engine.

2.5.1 To Start Engine

Details the step-by-step process for starting the engine.

2.5.1.1 Optional Pneumatic Starting System

Describes the procedure for using an optional pneumatic starting system.

2.5.2 To Stop Engine

Explains how to stop the engine using the main pump controller or gauge panel.

2.5.3 Emergency Stop Instructions

Provides instructions for emergency engine shutdown procedures.

2.6 WEEKLY TEST

Outlines the procedure and checks required for weekly engine testing.

3.0 ENGINE SYSTEMS

3.1 FUEL SYSTEM

Covers all aspects of the fuel system, including specifications and maintenance.

3.1.1 Diesel Fuel Specification

Specifies approved diesel fuel types and quality requirements.

3.1.2 Bleeding the Fuel System

Details the procedure for removing air from the fuel system.

3.1.3 Changing the Fuel Filter Cartridges

Explains how to change fuel filter cartridges and bleed the system.

3.1.3.1 Fuel Filters

Provides specific steps for replacing fuel filters.

3.1.4 Fuel Tanks

Advises on fuel tank maintenance to prevent condensation and sediment.

3.1.5 Fuel Injection Pump Components

Mentions components related to the fuel injection pump.

3.2 AIR/EXHAUST SYSTEM

Covers engine air intake and exhaust system requirements.

3.2.1 Ambient Conditions

Discusses the impact of ambient conditions on engine performance.

3.2.2 Ventilation

Specifies ventilation requirements for the engine room.

3.2.3 Standard Air Cleaner

Describes the reusable air cleaner and its service.

3.2.4 Crankcase Ventilation

Explains the crankcase ventilation system and its function.

3.2.5 Exhaust System

Details exhaust system requirements and backpressure considerations.

3.3 LUBRICATION SYSTEM

Covers engine oil level checks, changes, and filter replacement.

3.3.1 Checking Sump Oil

Provides instructions for checking the engine oil level using the dipstick.

3.3.2 Changing Engine Oil

Details the procedure for draining and refilling engine oil.

3.3.3 Changing Oil Filter Cartridge

Explains how to replace the engine oil filter cartridge.

3.3.4 Oil Specification

Specifies the required oil type and viscosity for the engine.

3.3.5 Oil Capacities (Including Filter)

Lists the oil capacity for different engine models.

3.4 COOLING SYSTEM

Covers engine coolant requirements, capacities, and procedures.

3.4.1 Intended Engine Operating Temperature

States the normal operating temperature range for the engines.

3.4.2 Engine Coolant

Discusses the requirements for suitable water/glycol coolant mixtures.

3.4.3 Water

Explains water quality requirements and the need for inhibitors.

3.4.4 Coolant Capacities

Lists the coolant capacity for different engine models.

3.4.5 Coolant Inhibitor

Emphasizes the importance of coolant inhibitors and their concentrations.

3.4.6 Procedure for Filling Engine

Details the process of filling and purging air from the cooling system.

3.4.7 Providing adequate Raw Water Supply to the Engine Heat Exchanger

Explains the necessity of raw water supply for heat exchanger cooling.

3.4.7.1 Raw Water Supply

Discusses raw water requirements for heat exchanger cooled engines.

3.4.7.2 Cooling Loop

Details the standard NFPA 20 cooling loop piping arrangement.

3.4.7.3 Setting Raw Water Flow Rate

Guides on setting the correct raw water flow rate for cooling.

3.4.7.4 Raw Water Outlet

Discusses raw water outlet flow and requirements for suction reservoirs.

3.4.7.5 Raw Water Quality, Strainers and Deterioration of Heat Exchanger (or CAC)

Covers raw water quality, strainer maintenance, and heat exchanger care.

3.4.7.6 Backflow Preventers

Mentions backflow preventers in cooling loop as per NFPA20.

3.4.8 Flow Paths of Engine Cooling System

Illustrates the flow paths of coolant within the engine cooling system.

3.4.9 IMPORTANT SERVICE NOTICE

Provides critical service notices regarding high coolant temperature alarms.

3.4.9.1 Cavitation

Explains cavitation, its causes, and potential damage to engine components.

3.5 ELECTRICAL SYSTEM

Covers various electrical system components and diagnostics.

3.5.1 Wiring Diagrams (Only with Engine Gauge Panel)

Refers to wiring diagrams for engines with a gauge panel.

3.5.2 Checking Drive Belt Tension and Adjustment

Details how to check and adjust drive belt tension for optimal operation.

3.5.3 Speed Switch (when supplied)

Explains the function of the speed switch and overspeed events.

3.5.4 Magnetic Pick-Up (when supplied)

Describes the magnetic pick-up's role in providing speed signals.

3.5.5 Mechanical Engine Control and Alarm Board (MECAB) Speed Switch Troubleshooting

Provides troubleshooting steps for MECAB speed switch malfunctions.

3.5.6 FIELD SIMULATION OF PUMP CONTROLLER ALARMS

Outlines how to simulate various pump controller alarms for testing.

3.5.7 BATTERY REQUIREMENTS

Specifies the battery requirements for the engines.

3.6 ENGINE SPEED ADJUSTMENT

Details how to adjust engine speed using the governor.

4.0 MAINTENANCE SCHEDULE

4.1 ROUTINE MAINTENANCE

Provides a schedule for routine maintenance tasks based on usage.

5.0 TROUBLE SHOOTING

6.0 PARTS INFORMATION

6.1 SPARE PARTS

Instructs on how to order genuine Clarke spare parts and what information to provide.

6.2 ENGINE MAINTENANCE PARTS LIST

Refers to Appendix "A" for a list of engine maintenance parts.

7.0 OWNER ASSISTANCE

8.0 WARRANTY

8.1 GENERAL WARRANTY STATEMENT

Outlines the general warranty principles and commitment to customer satisfaction.

8.2 CLARKE WARRANTY

Details the warranty duration and coverage for Clarke components.

8.3 DEUTZ WARRANTY

Covers the warranty policy for DEUTZ engine components.

FIRE PUMP POWER RATING

Explains DEUTZ fire pump engine rating guidelines and application.

APPLICATION OF WARRANTY CLAIMS

Details the procedure and required information for submitting warranty claims.

REMOVED PARTS

Specifies requirements for handling removed parts related to warranty claims.

RECEIVING INSPECTION AND STORAGE OF THE ENGINES

Guides the buyer on inspecting and storing received engines.

PERFORMANCE OF SERVICES BY BUYER

Outlines buyer responsibilities for maintenance and repair services.

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