Clarke C18 Manual

Operation and Maintenance
Instructions Manual
C18 MODEL ENGINES
With NSR or Brazed Heat-Exchanger
FOR CONSTANT SPEED FIRE PUMP APPLICATIONS
DOCUMENT ID:
C137833
Rev H
01/23
Clarke UK, Ltd.
Unit 1, Grange Works
Lomond Road
Coatbridge
ML5 2NN
United Kingdom
TEL: [phone]
FAX: [phone]
Clarke Fire Protection Products Inc.
100 Progress Place
Cincinnati, OH
45246
USA
TEL: [phone] Ext. 427
FAX: [phone]

3
1. Introduction ................................................................................................................................................................................5
Scope of Supply ....................................................................................................................................................................5
Identification / Nameplate...................................................................................................................................................5
Safety, Caution and Warnings.............................................................................................................................................6
2. Installation...................................................................................................................................................................................9
Typical Installation.................................................................................................................................................................9
Engine Storage......................................................................................................................................................................9
Installation Instructions...................................................................................................................................................... 11
Specific Flywheel Coupling Alignment Instructions..................................................................................................... 12
3. Operation................................................................................................................................................................................. 15
Starting from the Pump Controller.................................................................................................................................. 15
Manual Start from the Engine Instrument Panel ........................................................................................................... 15
Soft Start............................................................................................................................................................................... 16
To Stop the Engine ............................................................................................................................................................ 16
Describing Engine Instrument Panel .............................................................................................................................. 17
Weekly Test ......................................................................................................................................................................... 25
4. Fuel System.............................................................................................................................................................................. 26
Diesel Fuel Specification................................................................................................................................................... 26
Bleeding the Fuel System ................................................................................................................................................. 27
Changing the Fuel Filters.................................................................................................................................................. 28
Fuel Tanks............................................................................................................................................................................ 29
5. Air/Exhaust System................................................................................................................................................................. 30
Ambient Conditions........................................................................................................................................................... 30
Ventilation............................................................................................................................................................................ 30
Standard Air Cleaner ......................................................................................................................................................... 30
Crankcase Ventilation........................................................................................................................................................ 31
Exhaust System ................................................................................................................................................................... 32
6. Lubrication System ................................................................................................................................................................. 33
Checking Sump Oil............................................................................................................................................................ 33
Changing Engine Oil......................................................................................................................................................... 33
Changing Oil Filter Cartridge .......................................................................................................................................... 33
Oil Specification ................................................................................................................................................................. 33
Oil Capacities (Including Filter)........................................................................................................................................ 33
7. Cooling System....................................................................................................................................................................... 34
Engine Operating Temperature ...................................................................................................................................... 34
Heat Exchanger .................................................................................................................................................................. 34
Engine Coolant................................................................................................................................................................... 34
8. Electrical System ..................................................................................................................................................................... 42
Wiring Diagram .................................................................................................................................................................. 42
Checking Drive Belt Tension and Adjustment .............................................................................................................. 42

4
Overspeed........................................................................................................................................................................... 42
Field Simulation of Pump Controller Alarms ................................................................................................................. 43
Battery Requirements ........................................................................................................................................................ 43
Engine Speed Adjustment................................................................................................................................................ 43
9. Maintenance Schedule .......................................................................................................................................................... 44
Weekly Maintenance Items............................................................................................................................................... 44
6 Month Maintenance Items............................................................................................................................................. 44
1 Year Maintenance Items ................................................................................................................................................ 45
2 Year Maintenance Items ................................................................................................................................................ 45
5 year Maintenance Items................................................................................................................................................. 45
NSR Heat Exchanger Maintenance ................................................................................................................................. 45
10. Troubleshooting ..................................................................................................................................................................... 48
General Troubleshooting Information............................................................................................................................ 48
Diagnostic Trouble Codes (DTC’s).................................................................................................................................. 48
11. Parts Information..................................................................................................................................................................... 50
Spare Parts........................................................................................................................................................................... 50
Engine Maintenance Parts List ......................................................................................................................................... 50
12. Owner Assistance ................................................................................................................................................................... 50
13. Warranty................................................................................................................................................................................... 50
General Warranty Statement............................................................................................................................................ 50
Clarke Warranty .................................................................................................................................................................. 50
Caterpillar Warranty........................................................................................................................................................... 51
14. Installation & Operation Data ............................................................................................................................................... 53
15. Wiring Diagrams..................................................................................................................................................................... 53
16. Parts Illustration Drawing....................................................................................................................................................... 53
17. Declaration of Incorporation................................................................................................................................................. 54
18. Appendix A.............................................................................................................................................................................. 55

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1. Introduction
Scope of Supply
The following paragraphs summarize the “Scope of Supply” of the Engine:
•The CLARKE Engine supplied has been designed for the sole purpose of driving a stationary
Emergency Fire Pump. It must not be used for any other purpose.
•Shall not be subjected to Horsepower requirements greater than the certified nameplate rating (for
UL/cUL/FM/LPCB only).
•Engines must be sized to cover fully the maximum power absorbed by any particular driven equipment
together with a safety factor on no less than 10%. (For Non-listed only).
•De-rates for elevation and temperature need to be considered for maximum pump power.
•Fuel delivery settings are factory set with-in the injection pump and must not be tampered with or
adjusted. Minor RPM adjustments to meet pump requirements are permissible.
•The engine shall be installed and maintained in accordance with the guidelines stated in this manual.
•Periodic running checks to ensure functionality should be kept to a maximum of ½ hour per week.
Identification / Nameplate
Throughout this manual, the terms “Engine” and “Machine” are used. The term “Engine” refers solely to the
diesel engine driver as supplied by CLARKE. The term “Machine” refers to any piece of equipment with which
the engine might interface.
This manual provides all the information necessary to operate your newly acquired engine safely and efficiently
and perform routine servicing correctly. Please read it carefully.
Model Numbering & Identification
There are two identification plates attached to each engine. Clarke Identification Plate: Engine Model, Serial
Number, Rating and Date of Manufacture are shown on this identification plate. The C18 Series identification
plate is mounted on the back of the left rear engine mounting foot. (See Figure #1-1)
Caterpillar Identification Label: The second identification tag contains the Caterpillar Feature Code and Serial
Number. On the C18 Series, the Caterpillar identification tag is located on the left-hand side of the engine
forward of the air intake.
Clarke Identification Plates
USA Listed/Approved
Figure 1-1

6
The Clarke model numbers reflects the base engine type, number of cylinders, cooling system, approval listing,
manufacturing location, emissions code and a power rating code.
Example: C18H0-UFAC28
•C = Caterpillar base engine
•18 = base engine displacement (18.1 liter)
•H = Heat Exchanger cooled (R = Radiator)
•0 = Non-Hazardous Location
•UF = Underwriters Laboratories Listed/ Factory Mutual Approved, (NL = Non-Listed)
•A = Manufacture Location (United States)
•C = Tier 2, D = Tier 3, A = Non-Emissionized
•28 = Power Rating Code
Safety, Caution and Warnings
ATTENTION: This engine has components and fluids that reach very high operating temperatures and is
provided with moving pulleys and belts. Approach with caution. It is the responsibility of the builder of the
machine using a Clarke engine to optimize the application in terms of maximum end user safety.
Basic Rules
The following recommendations are given to reduce the risk to persons and property when an engine is in
service or out of service.
Engines must not be used for applications other than those declared under “Scope of Supply”.
Incorrect handling, modifications and use of non-original parts may affect safety. When lifting the engine, take
care to use suitable equipment to be applied to the points specially provided as shown on the appropriate
Engine Installation Drawing. Engine weights are shown in Figure #1-2
Engine Model
Weight lbs (kg)
All C18H0 models
4100 (1860)
Figure1-2
Figure #1-3 shows the typical lifting arrangement of a bare engine. Note the lifting points on the engine are for
lifting the ENGINE only. Caution, when lifting, lift point should always be over the equipment Center of Gravity.
Figure #1-4 shows the typical lifting arrangement of a base mounted engine and pump set when the base (or
module) is furnished with lifting holes.
Figure 1-3
Figure 1-4
When Clarke furnishes the base (or module) for the engine and pump set, the combined weight of the engine
and base (or module) will be indicated on the unit. Caution, when lifting, lift point should always be over the
equipment Center of Gravity.

7
Hearing Protection. The engine produces a noise level exceeding 70 dB(a). When performing the weekly
functional test, it is recommended that hearing protection be worn by operating personnel.
Declaration of Incorporation
CLARKE UK provides the machine manufacturer with a “Declaration of Incorporation” for the Engine, when
required, a copy of which is enclosed in the manual. This document clearly states the machine manufacturers’
duties and responsibilities with respect to health and safety. Refer to section 17
What to do in an Emergency
Any user of the Engine who follows the instructions set out in this manual and complies with the instructions on
the labels affixed to the engine are working in safe conditions. If operating mistakes cause accidents call for
help immediately from the EMERGENCY SERVICES. In the event of an emergency, and while awaiting the arrival
of the EMERGENCY SERVICES, the following general advice is given for the provision of first aid.
FIRE. Put out the fire using extinguishers recommended by the manufacturer of the machine or the installation.
BURNS. Put out the flames on the clothing of the burns victim by means of: drenching with water, use of powder
extinguisher, making sure not to direct the jets onto the face, blankets or rolling the victim on the ground
Do not pull off strips of clothing that are sticking to the skin. In the case of scalding with liquids, remove the
soaked clothing quickly but carefully. Cover the burn with a special anti-burn packet or with a sterile bandage.
CARBON MONOXIDE POISONING (CO). Carbon monoxide contained in engine exhaust gases is odorless and
dangerous because it is poisonous and with air, it forms an explosive mixture. Carbon monoxide is very
dangerous in enclosed premises because it can reach a critical concentration in a short time. When attending a
person suffering from CO poisoning in enclosed premises, ventilate the premises immediately to reduce the
gas concentration. When accessing the premises, the person providing the aid must hold his breath, not light
flames, turn on lights or activate electric bells or telephones so as to avoid explosions. Take the victim to a
ventilated area or into the open air, placing him on his side if he is unconscious.
CAUSTIC BURNS. Caustic burns to the skin are caused by acid escaping from the batteries. Remove the clothes,
wash with running water, being careful not to affect injury-free areas. Caustic burns to the eyes are caused by
battery acid, lubricating oil and diesel fuel. Wash the eye with running water for at least 20 minutes, keeping the
eyelids open so that the water runs over the eyeball and moving the eye in all directions.
ELECTROCUTION. Electrocution can be caused by the engine’s electrical system (12/24 VDC) or the electrical
coolant pre-heating system (115/230 Volt AC) if supplied. In the first case, the low voltage does not involve high
current flows through the human body; however, if there is a short circuit, caused by a metal tool, sparks and
burns may occur. In the second case, the high voltage causes strong currents, which can be dangerous. If this
happens, break the current by operating the switch before touching the injured person. If this is not possible,
bear in mind that any other attempt is highly dangerous also for the person assisting; therefore, any attempt to
help the victim must be carried out without fail using means that are insulating.
WOUNDS AND FRACTURES. The wide range of possible injuries and the specific nature of the help needed
means that the medical services must be called. If the person is bleeding, compress the wound externally until
help arrives. In the case of fracture do not move the part of the body affected by the fracture. When moving an
injured person permission from that person must be received until you can help him. Unless the injury is life
threatening, move the injured person with extreme care and then only if strictly necessary.

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Warning Labels
Warning labels, in picture form, are applied to the engine. Their meanings are given below.
Important Note: Labels that show an exclamation mark indicate that there is a possibility of danger.
Heat Exchanger Maximum
Working Pressure
Coolant Mixture
Lifting Point
Automatic Start
Rotating Parts
Jacket Water Heater Voltage
Air Filter Installation

9
2. Installation
Typical Installation
A typical Fire Pump installation is shown in Figures #2-1 & 2-2.
1. Pump/Engine set
2. Main Pump Controller
3. Pump discharge
4. Air louver
5. Entrance door with air louver
6. Exhaust silencer
7. Exhaust system supports
8. Exhaust outlet pipe
9. Concrete base
10. Exhaust flexible connection joint/pipe
11. Air Discharge Duct from Radiator
NOTE: For radiator cooled engines, the
total air supply path to the pump room,
which includes any louvers or dampers,
shall not restrict the flow of the air more
than 0.2” (5.1mm) water column.
Likewise, the air discharge path, which
includes any louvers, dampers, or
ducting, shall not restrict the flow of air
more than 0.3” (7.6mm) water column.
Figure #2-1
Typical Installation: Heat Exchanger
Figure #2-2
Typical Installation: Radiator
Engine Storage
Coolant System
Completely fill the cooling system before storage. (It is common for Clarke to ship the engine pre-filled with
coolant.) Clarke Coolant (part # C054129).The only acceptable substitute is COOL-GARD II part number
TY26575. Warranty is contingent on utilizing the indicated coolant.
Storage less than 1 year
Storing engines requires special attention. Clarke engines, as prepared for shipment, may be stored for a
minimum of one year. During this period, they should be stored indoors in a dry environment. Protective
coverings are recommended provided they are arranged to allow for air circulation. The stored engine should
be inspected periodically for obvious conditions such as standing water, part theft, excess dirt buildup or any
other condition that may be detrimental to the engine or components. Any such conditions found must be
corrected immediately.
Extended Storage Maintenance Procedure
After a one-year storage period or if the engine is being taken out of service for more than 6 months, additional
preservation service must be performed as follows:
Clean the engine of any dirt, rust, grease, and oil. Inspect the exterior. Paint areas that contain paint damage
with a good quality paint.
Remove dirt from the air cleaners. Check all seals, gaskets, and the filter element for damage.
Apply lubricant to all points in this Operation and Maintenance Manual, "Maintenance Interval Schedule".
Drain the crankcase oil. Replace the crankcase oil and change the oil filters. For the proper procedure, refer to
this Operation and Maintenance Manual.
If the engine is equipped with an air starting motor, fill the reservoir with the following mixture: 50 percent
volatile corrosion inhibitor oil (VCI oil) and 50 percent engine oil.
Add VCI oil to the crankcase oil. The volume of VCI oil in the crankcase oil should be 3 to 4 percent.
Note: If the engine crankcase is full, drain enough engine oil so the mixture can be added.
Remove the air filter elements. Turn the engine at cranking speed with the throttle control in FUEL OFF position.
Use a sprayer to add a mixture of 50 percent VCI oil and 50 percent engine oil into the air inlet or turbocharger
inlet. Note: The mixture of VCI oil can be added to the inlet by removing the plug for checking turbocharger

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boost pressure. The minimum application rate for the VCI oil mixture is 5.5 mL per L (3 oz per 1000 cu in) of
engine displacement.
Use a sprayer to apply a mixture of 50 percent VCI oil and 50 percent crankcase oil into the exhaust openings.
The minimum application rate for the oil mixture is 5.5 mL per L (3 oz per 1000 cu in) of engine displacement.
Seal the exhaust pipe and seal any drain holes in the muffler.
Remove the fuel from the secondary fuel filter housing. Alternately, empty and reinstall the spin-on fuel filter
element in order to remove any dirt and water. Drain any sleeve metering fuel pump. Clean the primary fuel
filter. Fill with calibration fluid or kerosene. Install the primary fuel filter and operate the priming pump. This
procedure will send clean oil to the secondary filter and the engine.
Remove the fuel nozzles or spark plugs. Apply 30 mL (1 oz) of the mixture of oils (50 percent VCI oil and
50 percent engine oil) into each cylinder. Use a bar or a turning tool in order to turn over the engine slowly. This
procedure puts the oil on the cylinder walls. Install all fuel nozzles or spark plugs and tighten to the correct
torque.
Spray a thin amount of a mixture of 50 percent VCI oil and 50 percent engine oil onto the following
components: flywheel, ring gear teeth and starter pinion. Install the covers in order to prevent evaporation of
the vapors from the VCI oil.
Apply a heavy amount of Cat Multipurpose Grease (MPGM) to all outside parts that move, such as rod
threads, ball joints, linkage. Note: Install all covers. Ensure that tape has been installed over all openings, air
inlets, exhaust openings, the flywheel housing, the crankcase breathers, the dipstick tubes. Ensure that all
covers are airtight and weatherproof. Use a waterproof weather resistant tape such as Kendall No. 231 or an
equivalent. Do not use duct tape. Duct tape will only seal for a short time.
Under most conditions, removing the batteries is the best procedure. As an alternative, place the
batteries in storage. As needed, periodically charge the batteries while the batteries are in storage. If the
batteries are not removed, wash the tops of the batteries until the tops are clean. Apply an electrical charge to
the batteries in order to obtain a specific gravity of 1.225. Disconnect the battery terminals. Place a plastic cover
over the batteries. Note: For additional information, refer to Special Instruction, SEHS7633, "Battery Test
Procedure".
Loosen all belts.
Place a waterproof cover over the engine. Ensure that the engine cover is secure. The cover should be
loose enough to allow air to circulate around the engine in order to prevent damage from condensation.
Attach a tag with the storage date to the engine.
Remove the waterproof cover at 2 month or 3 month intervals in order to check the engine for
corrosion. If the engine has signs of corrosion, repeat the protection procedure.
Removal from Storage
Remove all outside protective covers.
Change the oil and filters.
Check the condition of the fan and alternator belts. Replace the belts, if necessary. Refer to this Operation and
Maintenance Manual, "Belts - Inspect/Adjust/Replace" for the correct procedure.
Replace the fuel filter elements.
Remove the plastic covers from the air cleaner elements.
Use a bar or a turning tool in order to turn the engine in the normal direction of rotation. The procedure ensures
that no hydraulic locks or resistance exist.
Before starting the engine, remove the valve cover or covers. Put a large amount of engine oil on the camshaft,
cam followers, and valve mechanism in order to prevent damage to the mechanism.
Pressure-lubricate the engine before starting the engine. Pressure lubricating the engine ensures immediate
lubrication and prevents damage to the engine during the first few minutes of engine operation. If the engine is
not equipped with a prelube pump, contact your Cat dealer for information about lubrication of the engine
before starting the engine.
Check the condition of all rubber hoses. Replace any worn hoses. Replace any damaged hoses.
Before start-up, test the cooling system for a 3 percent to a 6 percent concentration of coolant
conditioner. Add liquid coolant conditioner or a coolant conditioner element, if equipped. Test the coolant
mixture for proper nitrite level. If necessary, adjust the coolant mixture. Prime the engine with clean diesel fuel
before starting.
Ensure that the cooling system is clean. Ensure that the system is full. Ensure that the system has the
correct amount of supplemental cooling system conditioner.
On the first day of operation, check the entire engine several times for leaks and correct operation.

11
If the engine was removed from storage in which temperatures of less than -12°C (10°F) were
encountered, refer to Service Manual, SEBU5898, "Cold Weather Recommendations Operation and
Maintenance".
Installation Instructions
The correct installation of the engine is very important to achieving optimum performance and extended
engine life. In this respect, the engine has certain installation requirements, which are critical to how it performs.
These requirements are generally associated with the cooling, exhaust, induction air, and fuel systems. This
section of the manual should be read in conjunction with the relevant Installation and Operation Data Sheets. If
there is any doubt about an installation, contact should be made with Clarke Customer Support giving exact
details of the problem. All installations should be clean, free of any debris and dry. Care should be taken to
ensure that there is easy access to the engine for maintenance and repair. The safety of personnel who may be
in the area of the engine when it is running is of paramount importance when designing the installation layout.
Secure pump set to foundation and complete installation in accordance with pump manufacturer’s instructions.
Perform engine to pump coupling alignment. Lubricate Falk coupling with supplied grease or driveshaft
universal joints with NLGI grade #1 or #2 grease at the (3) zerk fittings. (Refer to section 2.4.3 for specific
alignment instructions).
Install the heat exchanger discharge pipe (Engine with Heat Exchanger Cooling). The discharge pipe should be
no smaller than the outlet connection on the heat exchanger. Discharge water piping should be installed in
accordance with applicable codes. All plumbing connecting to the heat exchanger must be secured to
minimize movement by the engine. Cooling loop water pressure to the heat exchanger must not exceed the
limit that is stated on the heat exchanger supplied with the engine.
Install all engine cooling system draincocks and plugs.
Qty
Description
Location
1
⅛” Draincock
Coolant heater inlet tube
1
¼ “ Draincock
Water Pump Inlet
1
Electrode plug
Bottom of heat exchanger
Engine is typically provided with premixed coolant installed. If engine is not provided with coolant or there is a
need to top off, fill engine cooling system with Clarke Coolant 0C054129. The only acceptable substitute is
COOL-GARD II TY26575. Refer to Figure #7-3 in section 7.3.3 for cooling system capacity. Refer to section 7.3.4
filling procedure.
Engine is shipped with oil installed. For make-up oil specifications refer to section 6 Lubrication System.
Connect fuel supply and return line to fuel supply tank plumbing. Reference the Fuel System section of the
Installation and Operation Data in (See clarkefire.com), for piping size, maximum allowable fuel pump suction,
and maximum allowable fuel head requirements. Fill supply tank with #2 diesel fuel (ASTM D-975) or BS 2869
Class A2 “Red” diesel fuel, bleed supply system of air and check for leaks.
CAUTION: Biodiesel fuel is not recommended for stand-by equipment that can have minimal fuel consumption
(such as standby generators, fire protection, etc.). For standby applications, use only petroleum based diesel
fuel with Caterpillar approved fuel conditioners/ additives. For fuel conditioners/additives, check with your local
CAT dealer or Clarke. Fuel supply level must meet applicable code requirements. Do not use a copper based
or galvanized material for any component of a diesel fuel system. The fuel will chemically react with the zinc
resulting in clogged fuel filters and injector systems.
Remove protective covering on air cleaner element.
Connect jacket water heater (if supplied) to AC power source. Connect the supplied heater connection wire
directly to a customer supplied electrical junction box. The electrical supply requirements are indicated on the
connection box. Connect to the heater directly to the junction box at the end of the heater only. Supply wiring
should never be routed through the engine gauge panel. Severe damage to critical engine control components
could result. Energize heater only after step #4 is completed.
Connect exhaust system to flexible connection on the engine. The exhaust system plumbing must be supported
by the building structure and not the engine. The exhaust flexible connection is provided only for the purpose
of thermal expansion and vibration isolation, not for misalignment or directional change.
Make electrical DC connections between the engine gauge panel terminal strip (if supplied) and the controller
per the controller manufacturer’s instructions. Refer to the wiring diagram sticker located on the inside door of
the engine gauge panel for proper connection of the water solenoid.

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Fill batteries with electrolyte per battery manufacturer’s instructions. Connect cables between engine and
batteries only after electrolyte is installed. Refer to the wiring diagram inside the engine gauge panel door (if
supplied), or appropriate wiring diagram, for correct positive and negative connections.
Connect negative cables directly to the ground stud. Connect each positive cable to the large outer post of the
manual starting contactors. Connect negative cables directly to the engine block. Connect each positive cable
to the large outer post of the manual starting contactors.
Note: Clarke Operation and Maintenance Instructions Manual is located inside the document bag hanging on
the side of the engine.
IMPORTANT! In order to obtain prompt Warranty Service and to comply with Emissions regulations, this engine
must be registered to the final installation name and address. To register this engine, go to www.clarkefire.com
and select Warranty Registration.
Specific Flywheel Coupling Alignment Instructions
Listed Driveshafts. Refer to Listed Driveshaft Installation, Operation and Maintenance Manual C132355
Driveshaft Installation. To check the alignment of the pump shaft and engine crankshaft centerlines for proper
Parallel Offset and Angular tolerance, the driveshaft must be installed between the flywheel drive disc and the
flanged hub on the pump shaft. Before removing the driveshaft guard, disconnect the negative battery cable
from both batteries. Before beginning the alignment, checks and making any necessary corrections, install the
driveshaft and re-torque all driveshaft connection bolts to the values given in the following table:
MODELS
DRIVE SHAFT
BOLT SIZE /MATERIAL GRADE
TIGHTENING TORQUE ft-lbs (N-m)
C18H0-UFAD10, C18H0-UFAD18
C18H0-UFAD20, C18H0-UFAD28
C18H0-UFAD30, C18H0-UFAD38
C18H0-UFAD40, C18H0-UFAD48
C18H0-UFAD50, C18H0-UFAD70*
SC2160A
M16, Class 10.9 (Metric) (Hi-Tensile)
100-105 (135-142) (See Note #2)
C18H0-UFAD58, C18H0-UFAD68
C18H0-UFAD70**, C18H0-UFAA78
C18H0-UFAD78, C18H0-UFAC10
C18H0-UFAC18, C18H0-UFAC20
C18H0-UFAC28
2390A
M16, Class 10.9 (Metric) (Hi-Tensile)
210-220 (285-298) (See Note #2,3)
Note 1: It is recommended that a medium strength thread-locker (Loctite 243–blue) be used in the assembly
and torqueing of all hardware. This may be purchased as part number C126758, 50ml bottle.
Note 2: Four of the hi-tensile bolts and/or nuts, that are used to connect the driveshaft to the drive disc and that
connect the driveshaft to the pump companion flange, will require a “crow’s foot” wrench attached to a
standard torque wrench in order to apply the required tightening torque. A standard socket will not work due
to close proximity of the bolts and/or nuts with the driveshaft yoke. The tightening torque values listed for these
bolts and/or nuts have been corrected for using a “crow’s foot” adapter which extends the standard torque
wrench’s length.
Note 3 –For the high torque required for these nuts it is recommended that a boxed end crows foot be used.

13
Driveshaft Alignment.
The following steps describe the proper way to check alignment. A small pocket scale or ruler with millimeter
markings is recommended to make all measurements. (Clarke Pocket Scale part number C125781)
(Step A) To check the Horizontal Parallel Offset, the driveshaft must be in the proper orientation.
Rotate the shaft so the reference “AB” on the flywheel adapter disc or the circumference of the drive
shaft flange (against the flywheel adapter disc) is in the 12 o’clock position shown on figure #2-3.
Measure from the face of the flywheel adapter disc to point E. (Point E is on the bearing bore as shown
in Figure #2-3). This measurement must:
Measurement
Driveshaft
123.5 ± 1.5mm
SC2160A
142.5 ± 1.5mm
SC2390A
Figure 2-3
(Step B) With the driveshaft in the same orientation as the previous step (Step A), check the Horizontal Angular
alignment of the shafts.
Measure from the mating surface of the companion hub to point G shown on figure #2-4. (Point G is the
furthermost point on the bearing bore). This measurement must be equal to the measurement at point
E + 0.5 mm.
Figure 2-4

14
(Step C) To check the Vertical Parallel Offset, the driveshaft must be re-orientated.
Rotate the shaft 90°so the reference “CD”on the flywheel adapter disc or the circumference of the
drive shaft flange (against the flywheel) is in the position shown on Figure 2-5.
Measure from the face of the flywheel adapter disc to point H. (Point H is the furthermost point on the
bearing bore diameter). The measurement must be:
Measurement
Driveshaft
126.5 ± 1mm
SC2160A
145.5 ± 1.5mm
SC2390A
Figure 2-5
(Step D) With the driveshaft in the same orientation as the previous step (Step C), check the Vertical alignment
of the shafts.
Measure from the mating surface of the pump companion hub of the drive shaft to point J as shown in
figure 2-6. (Point J is the same as point G, with the driveshaft rotated 90°). This measurement must be
equal to the measurement at point H ± 1.
Figure 2-6
Note: Reinstall all guards and grease fittings before reconnecting the battery cables.
Driveshaft Maintenance
To service the driveshaft disconnect the negative battery cables, remove the top of guard and set aside.
Rotate engine shaft manually so the u-joint grease fittings are accessible.
Using a hand-held grease gun with N.L.G.I. grade 1 or 2 grease position on grease fitting. Pump with grease
until grease is visible at all four cap seals.
Verify all driveshaft connecting bolts remain tight. Re-torque per 2.4.2 if necessary.
Reinstall top of guard and connect negative battery cables.
Other Coupling Types
Consult Factory or Clarke website at www.clarkefire.com for additional information.

15
3. Operation
Starting and Stopping the Engine
Before starting the engine for the first time, review section 7.3.5 to ensure there is an adequate Raw Water
Supply to the Engine Heat Exchanger.
Starting from the Pump Controller
On UL/FM engines, use main pump controller for starting and stopping the engine. Should the main pump
controller become inoperable, the engine can be manually started and stopped from the engine gauge panel.
Manual Start from the Engine Instrument Panel
IMPORTANT: Main pump controller selector should be in the OFF position when starting from engine gauge
panel. Be sure to return selector on main pump controller and engine gauge panel to AUTOMATIC after
completing manual run.
To manually start the engine with the instrument panel controls, position the mode selector switch to manual
run (Figure 3-1 item 3).
Lift and hold the manual crank #1 switch (Figure 3-1 item 8) until the engine starts, or release after 15 seconds. If
the engine fails to start, wait 15 seconds. Lift and hold the manual crank #2 switch (Figure 3-1 item 9) until the
engine starts, or release after 15 seconds. Repeat.
NOTE: If the raw water is not flowing or the engine temperature is too high, open the cooling loop bypass
manual valves. (applies to heat exchanger cooled engines only).
Figure 3-1
1 - PowerView Gauge
6 - Alternate ECM Indicator Warning Light
2 - Momentary Display On Switch
7 - Manual Stop Switch
3 - Automatic/Manual Mode Selector Switch
8 - Manual Crank Switch –Battery #1
4 - ECM Selector Switch
9 - Manual Crank Switch –Battery #2
5 - Manual Mode Indicator Warning Light
10 –Service Tool Connector

16
Soft Start.
During installation of the sprinkler system or initial commissioning, it may be desirable to start the engine at a
reduced speed. Reducing the speed reduces the pressure of the pump discharge. This allows leak detection
to be performed at reduced system pressure and reduces the likelihood of water hammer at start. The process
is simple with a mechanical engine as it has a mechanical linkage that can be removed. No provision exists on
most electronic engines.C18 models from Clarke are equipped with a “Soft Start” feature to allow operation at a
reduced speed. To use the feature, the engine should be started manually from the engine gauge panel. To
use the feature:
Switch the main fire pump controller to the OFF position.
Switch the MODE SELECTOR to MANUAL RUN. (Refer to Figure #8).
Open the engine gauge panel and locate the “Soft Start” switch. It is a momentary toggle switch located in the
upper part of the panel interior. (See Figure #9B).
With your left hand, pull the toggle switch towards you and maintain that position. Then lift and hold the
MANUAL CRANK #1 on the front of the engine gauge panel with your right hand. Release it when the engine
starts.
The engine will run at 1100 rpm until the “Soft Start” toggle is released. Once the toggle is released, the engine
will increase speed at the rate of 10 rpms per second until it reaches rated speed. The “Soft Start” toggle can
be activated again and the engine will immediately return to 1100 rpm.
To Stop the Engine
If engine is started from pump controller use pump controller to stop the engine.
If engine is started from engine instrument panel, lift and hold the Manual Stop Switch (Figure 3-1 item 7).
Close cooling system manual by-pass valve if opened.
IMPORTANT: DO NOT leave the MODE SELECTOR switch in the MANUAL RUN position during AUTOMATIC
operation. (The controller will be unable to stop the engine and DAMAGE MAY RESULT). Note: On C18
Engines you can also start the engine using the manual contactors.
Interior view of engine gauge panel door - BASE dual ECM auto-switching device and green LED
Figure #3-2
Interior view of engine gauge panel.
Figure #3-3

17
Describing Engine Instrument Panel
ECM Selector Switch and Primary/Alternate ECM
Clarke UL/FM Engines come equipped with dual ECMs and an ECM Selector Switch on engine gauge panel.
(Item #6). Default position of ECM selector switch is to the Primary ECM. In the event of a failure of the Primary
ECM, where-by the engine shuts down or will not start, it will become necessary to manually switch to the
Alternate ECM position. When the ECM Selector Switch is positioned to the Alternate ECM position a warning
light will illuminate at the engine gauge panel. Also, the main controller will display a warning light and an
audible alarm. The engine should then be re-started manually. (See section 3.2.1). Contact a Clarke
Authorized Service Dealer immediately when this situation occurs to troubleshoot. (See section 10.0).
Information displayed on the PowerView diagnostic gauge will come from either the Primary or Alternate ECM
depending upon the position of the ECM Selector Switch. If a fault code(s) is displayed and comes from the
Primary ECM, and then the ECM selector switch is moved to the Alternate ECM position, it may be necessary to
“crank” the engine for the Alternate ECM to pick-up the same fault code(s).
Dual ECM Automatic Switching
Engine models utilizing dual ECMs are equipped with a BASE unit (Board for Auto-Switching ECMs) that can
detect failure on either primary or alternate ECM. The BASE monitors two separate heartbeat signals from each
of the ECMs. If the BASE fails to detect BOTH of these signals, the BASE will recognize this as an ECM failure
and initiate the automatic ECM switching process. If the BASE fails to detect only one of these signals, the
automatic ECM switching process will not initiate however an indication will be made by a green status LED on
the BASE.
Normal Operation: LED Flashes at 1/10 Hz or 1 time in 10 seconds
Primary heartbeat failure only: Led Flashes at ½ Hz or 5 times in 10 seconds.
Secondary heartbeat failure only: LED Flashes at 1 ½ Hz or 15 times in 10 seconds.
Double ECM failure: LED Flashes at 2 ½ Hz or 25 times in 10 seconds.
If the currently selected ECM experiences a failure detected by the BASE unit, an ECM warning alarm will be
sent to the fire pump controller via interconnect terminal 303 and will automatically switch to the other
functional ECM. If the automatic switching devices switches to alternate ECM, a visual indication light will
illuminate on the engine control panel, and an alternate ECM alarm will be sent to the fire pump controller via
interconnect terminal 301. Upon failure of the second ECM, the automatic switching device will alarm an ECM
failure alarm to the fire pump controller via interconnect terminal 304. Additionally, the BASE status LED will
flash at rate of 2 ½ Hz or 25 times in 10 seconds.
If an ECM failure occurs during engine operation, the automatic switching device will control engine shutdown
and will prevent starter motor re-engagement while the engine is shutting down. After the engine safely comes
to a stop the automatic switching device will switch to the other functional ECM and will then allow starter motor
re-engagement control from the fire pump controller. The automatic ECM switching process will not initiate
upon failure of any primary, alternate, or non-critical engine sensors as per UL/FM. After ECM repair, activate
the ECM Failure reset switch to the down position for 3 seconds and release. This will de-activate the ECM
Warning and Failure alarms to the fire pump controller at interconnect terminals 303 and 304. The hand
operated ECM selector switch allows for manual selection of either primary or alternate ECM. In the event of
failure of the BASE unit while the ECMs are functional, a Diagnostic Trouble Code of SPN 2145 FMI 9 will be
displayed on the diagnostic gauge.
Programming ECM with Automatic Switching Device
This procedure will be performed by Clarke Certified Service Dealer or a Cat Dealer.
In the event of a failed or damaged ECM, programming will be required on the replacement unit. The
diagnostic tool will be connected to the Service Tool Connector (#10 in Figure #8). In addition to the typical
programming procedure used on Caterpillar engines, some extra steps are required.
To program the Primary ECM:
In manual operation mode, select the Primary ECM with the ECM SELECTOR (Item #4 on Figure #3-1).
Unplug the BASE dual ECM auto-switching device on the back side of the engine gauge panel door.
(See Figure #3-4.)
This will prevent the BASE from switching to Alternate ECM during the software re-flashing process.
Complete the programming process as normal.
Plug the BASE back in.

18
To program the Alternate ECM:
Unplug the BASE dual ECM auto-switching device on the back side of the engine gauge panel door.
Insert the service tool, provided in the engine gauge panel, into the connector removed from the BASE.
(See Figure #3-5)
This will force the panel into Alternate ECM mode.
Complete the programming process as normal.
Plug the BASE back in.
BASE connector
Service Tool
Figure 3-4
Figure 3-5

19
Using the PowerView Gauge
The PowerView gauge (reference Figure #3-6) allows the operator to view operating conditions and diagnostic
trouble codes (DTC’s). Press the menu key (C) to access the various engine functions in sequence. The displays
can be selected as either customary English or metric units. The following menu of engine parameters can be
displayed on the power view (refer to Figure #9E).
Engine rpm*
Coolant temperature*
Oil pressure*
Machine hours*
System voltage (battery #1)*
System voltage (battery #2)*
Percent engine load at the current rpm
Oil temperature
Intake manifold temperature
Fuel temperature
Engine torque
Fuel level
Active diagnostic codes
Stored diagnostic codes from the engine
Set the units for display
View the engine configuration parameters
* These six parameters are fixed for the power-up display. (See Figure #3-7)
The PowerView gauge includes a liquid crystal display (LCD) screen. The display is programmed to show six
NFPA required engine parameters simultaneously. The diagnostic gauge uses two arrow keys (A) and (B) for
scrolling through the engine parameter list and viewing the menu list. An enter key (E) is used for selecting
highlighted items. The (D) key is an escape option to leave a menu without making a change. The red (G) and
amber (F) lights are used to signal active trouble codes received by the diagnostic gauge.
NOTE:
•Red indicator light (G) indicates a serious condition. Correct problem before restarting.
•Amber indicator light (F) indicates an abnormal condition. It is not necessary to shutdown engine
immediately but problem should be corrected as soon as possible.
Figure 3-6
Figure 3-7
Main Menu Navigation
NOTE: The display gauge must be powered to navigate the diagnostic gauge screens. This is achieved by
starting the engine or maintaining upward pressure on switch #2 from Figure #3-1. If engine start up is desired
see: Starting the Engine. All the engine values illustrated in this example, on the diagnostic gauge, indicate the
engine is running.
Starting at the default six-up engine display, press the “Menu” (C) key. (Figure 3-6)
The six items of the “Main Menu” will be displayed.
Pressing the “Arrow” (A&B) keys will scroll through the menu selections. (Figure 3-8)

20
Figure 3-8
Figure 3-9
User Settings Adjustment
From the “Main Menu” screen you can select “User Settings” by highlighting the text and pushing the “Enter” (E)
key.
The User Settings Screen will appear. This allows user adjustment of Brightness, Contrast, Temperature Units,
and Pressure Units
Each of these parameters can be adjusted by highlighting the item with use of the “Arrow” (A&B) keys and then
pressing the “Enter” (E) key to bring up the adjustment screen. See below for an example of adjusting the
“Brightness”.
The “Arrow” (A&B) keys become the add and subtract functions for brightness. Press the “Enter” (E) key to store
the adjustment.
Press the “Menu” (C) key to return to the six-up display.
Figure 3-10