Clarke C32H Manual

Operation and Maintenance
Instructions Manual
C32H MODELS
ELECTRONIC ENGINES
FOR
FIRE PUMP APPLICATIONS
This manual covers Caterpillar Engines
Prepared by Clarke
for fire pump service
Clarke Fire Protection Products, Inc. Clarke Fire Protection Products, Ltd.
100 Progress Place Unit 1, Grange Works
Cincinnati, OH 45246 Lomond Road
U.S.A. Coatbridge
ML5 2NN
United Kingdom
TELE: +1.513.475.3473
FAX: [phone]
TELE: [phone]
FAX: [phone]
www.clarkefire.com
C138229
02/23
RevC

1
CONTENTS
SUBJECT PAGE
1.0 INTRODUCTION 4
1.1 IDENTIFICATION/NAMEPLATE 4
1.2 SAFETY/CAUTION/WARNINGS 5
1.3 PRECAUTIONS FOR WELDING 9
2.0 INSTALLATION/OPERATION 10
2.1 TYPICAL INSTALLATION 10
2.2 ENGINE STORAGE 10
2.2.1 Storage Less than 1 year 10
2.2.2 Extended Storage Maintenance Procedure 10
2.2.3 Coolant System 11
2.2.4 Removal from Storage 11
2.3 INSTALLATION INSTRUCTIONS 12
2.4 SPECIFIC FLYWHEEL COUPLING ALIGNMENT INSTRUCTIONS 13
2.4.1 Driveshaft 13
2.5 WEEKLY TEST 16
2.6 STARTING/STOPPING THE ENGINE 16
2.6.1 To Start Engine 16
2.6.1.1 Start Engine for Test Purposes (“Soft Start”) 16
2.6.2 To Stop Engine 17
2.6.3 Describing Engine Gauge Panel 18
2.6.3.1 ECM Selector Switch and Primary/Alternate Electronic Control Modules (ECM’s) 18
2.6.3.2 Dual ECM Automatic Switching 18
2.6.3.3 Programming ECM with Automatic Switching Device 19
2.6.3.4 Using Power View Gauge 19
3.0 ENGINE SYSTEMS 29
3.1 FUEL SYSTEM 29
3.1.1 Diesel Fuel Specification 29
3.1.2 Bleeding the Fuel System 30
3.1.2.1 C32 Engine Series after Filter Change 30
3.1.2.2 C32 Engine Series After Engine was Run Out of Fuel 31
3.1.3 Changing Fuel Filters 31
3.1.3.1 C32 Engine Series 31
3.1.4 Fuel Tanks 32
3.2 AIR/EXHAUST SYSTEM 32
3.2.1 Ambient Conditions 32
3.2.2 Ventilation 32
3.2.3 Standard Air Filter 32
3.2.4 Crankcase Ventilation 33

2
3.2.5 Exhaust System 34
3.3 LUBRICATION SYSTEM 34
3.3.1 Checking Sump Oil 34
3.3.2 Changing Engine Oil 35
3.3.3 Changing Oil Filter Cartridge 35
3.3.4 Oil Specification 35
3.3.5 Oil Capacities 35
3.4 COOLING SYSTEM 35
3.4.1 Intended Engine Operating Temperature 35
3.4.2 Engine Coolant 35
3.4.3 Water 36
3.4.4 Coolant Capacities 36
3.4.5 Coolant Inhibitors 36
3.4.6 Procedure for Filling Engine 37
3.4.7 Providing Adequate Raw Water Supply to the Engine Heat Exchanger 37
3.4.7.1 Raw Water Supply 37
3.4.7.2 Cooling Loop 37
3.4.7.3 Setting Raw Water Flow Rate 39
3.4.7.4 Raw Water Outlet 39
3.4.7.5 Raw Water Quality Strainers and Deterioration of Heat Exchanger (CAC) 39
3.4.7.6 Backflow Preventers 40
3.4.7.7 Raw Water Outlet Temperature 40
3.4.8 Flow Paths of Engine Cooling System 40
3.4.9 Important Service Notice 42
3.4.9.1 Water Pump Cavitation 42
3.5 ELECTRICAL SYSTEM 42
3.5.1 Wiring Diagrams 42
3.5.2 Checking Drive Belt Tension and Adjustment 42
3.5.3 Engine Overspeed 42
3.5.4 Field Simulation of Pump Controller Alarms 43
3.5.5 Battery Requirements 43
3.6 ENGINE SPEED ADJUSTMENT 43
4.0 MAINTENANCE SCHEDULE 44
4.1 ROUTINE MAINTENANCE 44
5.0 TROUBLE SHOOTING 44
5.1 DIAGNOSTIC TROUBLE CODES 45
6.0 PARTS INFORMATION 46
6.1 SPARE PARTS 46
6.2 ENGINE MAINTENANCE PARTS LIST 46
7.0 OWNER ASSISTANCE 46

3
8.0 WARRANTY 46
8.1 GENERAL WARRANTY STATEMENT 46
8.2 CLARKE WARRANTY 47
8.3 CATERPILLAR WARRANTY 47
9.0 INSTALLATION & OPERATION DATA 47
10.0 WIRING DIAGRAMS 47
11.0 PARTS ILLUSTRATION & DRAWINGS 47
12.0 KEYWORD INDEX 48
13.0 APPENDIX “A” C32 Models Parts Matrix 49
14.0 APPENDIX “B” Caterpillar Limited Warranty 50
15.0 APPENDIX “C” PLD Maintenance and Operation 52
Check factory availability for a manual in one of the following languages:
Spanish
German
French
Italian
NOTE
The information contained in this book is intended to assist operating personnel by providing information
on the characteristics of the purchased equipment. It does not relieve the user of their responsibility of
using accepted practices in the installation, operation, and maintenance of the equipment.
NOTE: CLARKE FPPG Reserves the right to update the contents of this publication without notice.

4
1.0 INTRODUCTION
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 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 ambient and
temperature need to be considered for
maximum pump power.
 Fuel delivery settings are factory set 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.
1.1 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 tags attached to each
engine. Clarke Identification Plate: Engine Model,
Serial Number, Rating and Date of Manufacture are
shown on this identification plate. The C32 Series
identification plate is mounted on the back of the left
rear engine mounting foot. (See Figure #1)
Clarke Identification Plates
USA Listed/Approved
Figure #1
Clarke model number reflects the base engine type,
engine displacement, cooling system, environmental
suitability, approval listing, engine speed, and a
power rating code.
Example: C32H0-UFAC28
 C = Caterpillar base engine
 32 = base engine displacement (32.1 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
Caterpillar Identification Label: The second
identification tag contains the Caterpillar Feature
Code and Serial Number. On the C32H Series, the
Caterpillar identification tag is located on the
righthand side of the engine, on the center valve
cover.

5
1.2 SAFETY/CAUTION/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 #4.
Figure #2 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 #2
Figure #3 shows the typical lifting arrangement of a
base mounted engine and pump set when the base (or
module) is furnished with lifting holes.
Figure #3
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.
Note: 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.
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 Figure #5.

6
ENGINE MODEL WEIGHT lbs. (kg)
C32H0-UFAC10 7200
(
3266
)
C32H0-UFAC18 7200
(
3266
)
C32H0-UFAC20 7200
(
3266
)
C32H0-UFAC28 7200
(
3266
)
C32H0-UFAC30 7200
(
3266
)
C32H0-UFAC38 7200
(
3266
)
C32H0-UFAC40 7200
(
3266
)
C32H0-UFAC48 7200
(
3266
)
C32H0-UFAC50 7200
(
3266
)
C32H0-UFAC58 7200
(
3266
)
C32H0-UFAC60 7200
(
3266
)
C32H0-UFAC68 7200
(
3266
)
*C32H0-UFAC12-D 7200
(
3266
)
*C32H0-UFAC22-D 7200
(
3266
)
*C32H0-UFAC32-D 7200
(
3
266
)
*C32H0-UFAC42-D 7200
(
3266
)
*C32H0-UFAC52-D 7200
(
3266
)
*C32H0-UFAC62-D 7200
(
3266
)
Figure #4
* Clarke PLD Model

7
Figure #5

8
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 an accident, 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
1) Extinguish the flames on the clothing of the
burn 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
2) Do not pull off strips of clothing that are
sticking to the skin.
3) In the case of scalding with liquids, remove the
soaked clothing quickly but carefully.
4) 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 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
1) 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
2) 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:
1) The engine’s electrical system (24VDC)
2) The coolant pre-heating system 120/240 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 for the person assisting.
Any attempt to help the victim must be carried out
using means to insulate the rescuer from the electrical
current.
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
before you can help him. Unless the injury is life
threatening, move the injured person with extreme care
and then only if strictly necessary.
WARNING LABELS
Warning labels, in picture form, are applied to the
engine. Their meanings are given below.

9
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
1.3 PRECAUTIONS FOR WELDING
IMPORTANT: ALWAYS disconnect electronic
Control Module (ECM) connectors before welding.
High currents or electrostatic discharge in electronic
components, from welding, may cause permanent
damage. Connect the welder ground close to the
welding point and be sure ECM or other electronic
components are not in ground path.

10
2.0 INSTALLATION/OPERATION
2.1 TYPICAL INSTALLATION
A typical Fire Pump installation is shown in Figure #6.
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
Figure #6
Typical Installation
2.2 ENGINE STORAGE
2.2.1 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.
2.2.2 Long-Term Storage
Note: It is recommended that a Clarke Service Dealer
perform the steps outlined in this section.
If an engine is not used, oil can run off the following
parts that normally receive lubrication: cylinder walls,
piston rings, main bearings, connecting rod bearings,
crankshaft and gears.
This lack of lubricant allows corrosion to begin to
appear on the metal. This condition is worse in areas of
high humidity.
When the engine is started again, metal to metal
contact will cause wear before the surfaces receive oil.
To minimize this wear, use the starter to turn the
engine with the throttle in the FUEL OFF position.
When oil pressure is shown on the pressure gauge, start
the engine.
1. Clean the engine of any dirt, rust, grease, and
oil. Inspect the exterior. Paint areas that
contain paint damage with a good quality
paint.
2. Remove dirt from the air cleaners. Check all
seals, gaskets, and the filter element for
damage.
3. Apply lubricant to all points in this Operation
and Maintenance Manual, "Maintenance
Interval Schedule".
4. Drain the crankcase oil. Replace the crankcase
oil and change the oil filters. For the proper
procedure, refer to this Operation and
Maintenance Manual.
5. 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.
6. 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.
7. 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 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.

11
8. 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.
9. 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.
10. 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.
11. 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.
12. 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.
13. 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".
14. Loosen all belts.
15. 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.
16. Attach a tag with the storage date to the
engine.
17. 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.
2.2.3 Coolant System
Completely fill the cooling system before storage. (It
is common for Clarke to ship the engine pre-filled with
coolant.)
Refer to the Operation and Maintenance Manual,
"Fluid Recommendations" (SEBU8598) for more
information about coolants.
2.2.4 Removal from Storage
1. Remove all outside protective covers.
2. Change the oil and filters.
3. 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.
4. Replace the fuel filter elements.
5. Remove the plastic covers from the air cleaner
elements.
6. 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.

12
7. 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.
8. 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.
9. Check the condition of all rubber hoses.
Replace any worn hoses. Replace any damaged
hoses.
10. 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.
11. 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.
12. On the first day of operation, check the entire
engine several times for leaks and correct
operation.
13. 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".
2.3 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 around the engine,
when it is running, is of paramount importance when
designing the installation layout.
1) Secure pump set to foundation and complete
installation in accordance with pump
manufacturer’s instructions. Perform engine-
to-pump coupling alignment. Lubricate
driveshaft universal joints with NLGI grade #1
or #2 grease at the (3) Zerk fittings. (Refer to
section 2.4 for specific alignment instructions).
2) Install the heat exchanger discharge pipe. 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.
3) Install all engine cooling system draincocks
and plugs. Close all drain cocks.
Qty Description Location
Engine
Model
2 1/4”
draincock
Coolant heater
inlet tube
s
C32H
1 1/4”
draincock
Water pump
inlet tube
C32H
2 1/4”
drain plug
Bottom of heat
exchanger
s
C32H
4) Fill engine cooling system with premixed 50%
water / 50% coolant solution. Use only
coolants meeting ASTM-D6210 specifications
for heavy-duty diesel engines. Never use light-
duty or automotive coolants in the engine that
are stated as ASTM-D3306 only. (Refer to
Section 3.4.3 of this manual for cooling
system capacity.) Fill expansion tank per
figure #18, Section 3.4.5 of Instruction
Manual.
5) Engine is shipped with oil installed. For
make-up oil specifications refer to section 3.3
Lubrication System.

13
6) 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 EN 590 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.
7) Remove protective covering on air filter
element.
8) Connect jacket water heater (if supplied) to
AC power source. For C32H Series, 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.
9) 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.
10) Make electrical DC connections between the
engine gauge panel terminal strip (if supplied)
and the controller per the controller
manufacturer’s instructions.
11) 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 cover
(if supplied), or appropriate wiring diagram
(see Page 5), for correct positive and negative
connections. Connect negative cables directly
to the engine block. Connect each positive
cable to the large outer post of the manual
starting contactors.
12) Note: Clarke Operation and Maintenance
Instructions Manual, C138229, is located
inside the engine gauge panel.
13) Note: During commissioning of the engine,
the final speed setting must be performed on
both the Primary and Alternate ECM’s. Refer
to section 3.6 Speed Adjustment.
14) IMPORTANT! 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.
2.4 SPECIFIC FLYWHEEL COUPLING
ALIGNMENT INSTRUCTIONS
2.4.1 Driveshaft
To check the alignment of the pump shaft and engine
crankshaft centerlines for proper Parallel Offset and
Angular tolerance, the drive shaft must be installed
between the flywheel and the flanged hub on the pump
shaft.
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 tables.

14
MODELS
DRIVE
SHAFT
BOLT
SIZE
/GRADE
TIGHTEN-
ING
TORQUE
ft-lbs
(N
-
m)
C32H0-
UFAC10
C32H0-
UFAC18
C32H0-
UFAC20
C32H0-
UFAC28
C32H0-
UFAC30
C32H0-
UFAC38
C32H0-
UFAC40
C32H0-
UFAC48
C32H0-
UFAC50
C32H0-
UFAC58
C32H0-
UFAC60
C32H0-
UFAC68
SC2390A
M16,
Class 10.9
(Metric)
(Hi-
Tensile)
210 - 220
(285 - 298)
(see note #2,
#3)
Note 1 – It is recommended that a medium strength
threadlocker (Loctite 243–blue) be used in the
assembly and of all hardware. This may be purchased
as part number C126758, 50ml bottle.
Note 2 – 4 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 to apply the required tightening
torque. A standard socket will not work due to
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.
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.
Before removing the drive shaft guard, disconnect the
negative battery cable from both batteries.
A) To check the Horizontal Parallel Offset, the
driveshaft must be in the proper orientation.
1. 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 #7a.
2. Measure from the face of the flywheel adapter
disc to point E. (Point E is on the bearing bore
as shown in Figure #7a). This measurement
must be:
Measurement
Driveshaft
142.5 + 1.5mm SC2390A
Figure #7a
B) With the driveshaft in the same orientation as the
previous step (Step A), check the Horizontal
Angular alignment of the shafts.
1. Measure from the mating surface of the
companion hub to point G shown on figure
#7b. (Point G is the furthermost point on the
bearing bore). This measurement must be
equal to the measurement at point E + 0.5 mm.

15
Figure #7b
C) To check the Vertical Parallel Offset, the
driveshaft must be re-orientated.
1. 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#7c.
2. 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
145.5
+
1.5
mm.
SC2390
A
Figure #7c
D) With the driveshaft in the same orientation as the
previous step (Step C), check the Vertical
alignment of the shafts.
1. Measure from the mating surface of the pump
companion hub of the drive shaft to point J as
shown in figure #7d. (Point J is the same as
point G, with the driveshaft rotated 90o). This
measurement must be equal to the
measurement at point H + 1 mm.
Re-install all guards and grease fittings before
reconnecting the battery cables.
Figure#7d
DRIVESHAFT MAINTENANCE
1. To service the driveshaft, disconnect the
negative battery cables, remove the top of
guard and set aside.
2. Rotate engine shaft manually so the u-joint
grease fittings are accessible.
3. 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.
4. Verify all driveshaft connecting bolts remain
tight. Re-torque per 2.4.1 if necessary.
5. Reinstall top of guard and connect negative
battery cables.
2.5 WEEKLY TEST
An experienced operator should be present during the
weekly test.
NOTE: This engine is designed to operate at rated load
conditions. For testing purposes the engine can be run
at lower load (lower flow) conditions. Running times
in any one period should not exceed a maximum of 30
minutes. Before starting the engine make sure of the
following:
1) The operator has free access to stop the engine
in an emergency.
2) The plant room ventilation ducts are open and
the engine has good access for air.

16
3) All the guards are in position and, if not, for
whatever reason, any rotating parts will be free
and clear without restriction.
4) Battery covers are in place and there is nothing
on top of or touching the engine, which is not
part of the original supply specification.
5) The raw water supply for cooling is available
without restriction. Typically, restriction
occurs from a plugged cooling loop strainer.
When engine is running make sure that the coolant
temperature, oil pressure and raw cooling water flow
are within the limits specified on the relevant
Installation & Operation Data Sheet (see Page 5).
If the coolant temperature is excessive, check:
a) Cooling loop strainers
b) Proper functioning of thermostat
c) Condition of heat exchanger tube bundle
2.6 STARTING/STOPPING THE ENGINE
2.6.1 To Start Engine
Use main pump controller for starting. Follow
instructions provided by controller manufacturer.
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. For manual starting and stopping of an engine
with a gauge panel: Position MODE SELECTOR to
MANUAL RUN. (Refer to Figure #8). Lift and hold
MANUAL CRANK #1, until engine starts, or release
after 15 seconds. If unit fails to start, wait for 15
seconds, use MANUAL CRANK #2 and repeat step.
If RAW COOLING WATER is not flowing or
engine COOLANT
TEMPERATURE is too HIGH, open cooling system
manual by-pass valves.
Note: On C32H Engines you can also start engines
using manual starting contactors.
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.
2.6.1.1 Start Engine for Test Purposes (“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.
C32H 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:
1) Switch the main fire pump controller to the
OFF position.
2) Switch the MODE SELECTOR to
MANUAL RUN. (Refer to Figure #8).
3) Press the “menu key” on the PV380 display
gauge.
4) Toggle down the list of menu options and
highlight “Soft Start”, then press the “Enter”
key.
5) The next screen will display one choice,
“Request Soft Start”. Press the “Enter” key.
6) The next screen will allow initiation of Soft
Start or the choice to cancel the process. To
proceed with the Soft Start, crank and start the
engine with one of the Manual Crank switches
on the front of the panel.
7) The engine will start and run at 1100 rpm until
the “Confirm” key is pressed. Once the
“Confirm” key is pressed, the engine will
increase speed at the rate of 10 rpms per
second until it reaches rated speed.
2.6.2 To Stop Engine
If engine is started from main pump controller use
main pump controller to stop the engine.
If engine is started from engine gauge panel: Lift and
hold MANUAL STOP SWITCH, until engine stops.
Close cooling system manual by-pass valve if opened.
Note: This is NOT the switch to use during cycle-
crank testing. This switch will allow the engine to
briefly start, before stopping the engine.
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).

17
Figure #8
1 - PowerView Gauge
2 - Momentary Display On Switch
3 - Automatic/Manual Mode Selector Switch
4 - ECM Selector Switch
5 - Manual Mode Indicator Warning Light
6 - Alternate ECM Indicator Warning Light
7 - Manual Stop Switch
8 - Manual Crank Switch – Battery #1
9 - Manual Crank Switch – Battery #2
10 – Service Tool Connector
11 – PLD Harness Connector
2.6.3 Describing Engine Gauge Panel
2.6.3.1 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 #4). 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 2.6.1). Contact a Clarke Authorized Service
Dealer immediately when this situation occurs to
troubleshoot. (See section 7.0).
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

18
necessary to “crank” the engine for the Alternate ECM
to pick-up the same fault code(s).
2.6.3.2 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.
Interior view of engine gauge panel door - BASE
dual ECM auto-switching device and green LED
Figure #9A
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.
2.6.3.3 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:
1) In manual operation mode, select the Primary
ECM with the ECM SELECTOR (#4 on
Figure #8).
2) Unplug the BASE dual ECM auto-switching
device on the back side of the engine gauge
panel door. (See Figure #9B.)
BASE &
green status
LED

19
Figure #9B
3) This will prevent the BASE from switching to
Alternate ECM during the software re-flashing
process.
4) Complete the programming process as normal.
5) Plug the BASE back in.
To program the Alternate ECM:
1) Unplug the BASE dual ECM auto-switching
device on the back side of the engine gauge
panel door.
2) Insert the service tool, provided in the engine
gauge panel, into the connector removed from
the BASE. (See Figure #9C)
Figure #9C
3) This will force the panel into Alternate ECM
mode.
4) Complete the programming process as normal.
5) Plug the BASE back in.
2.6.3.4 Using the PowerView Gauge
The PowerView gauge (reference Figure #9D) 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).
1. Engine rpm*
2. Coolant temperature*
3. Oil pressure*
4. Machine hours*
5. System voltage (battery #1)*
6. System voltage (battery #2)*
7. Percent engine load at the current rpm
8. Oil temperature
9. Intake manifold temperature
10. Fuel temperature
11. Engine torque
12. Fuel level
13. Active service (diagnostic) codes
14. Store service (diagnostic) codes from the
engine
15. Set the units for display
16. View the engine configuration parameters
* These six parameters are fixed for the power-up
display. (See Figure #9E)
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.