Operation and Maintenance

Instructions Manual

JU/JW MODEL ENGINES
FOR
FIRE PUMP APPLICATIONS



This manual covers John Deere Engines
prepared by Clarke
for fire pump service





Clarke UK, Ltd. Clarke Fire Protection Products, Inc.
Unit 1, Grange Works 3133 E. Kemper Road
Lomond Road Cincinnati, OH 45241
Coatbridge U.S.A.
ML5 2NN
United Kingdom
TELE: +44(0)1236 429946
FAX: +44(0)1236 427274
TELE: +1.513.771.2200
FAX: +1.513.771.0726


www.clarkefire.com







MP-7 12/06
C13960 rev G




Page 2 of 38
CONTENTS
SUBJECT PAGE
1.0 INTRODUCTION 4
1.1 IDENTIFICATION/NAMEPLATE 4
1.2 SAFETY/CAUTION/WARNINGS 5
2.0 INSTALLATION/OPERATION 9
2.1 TYPICAL INSTALLATION 9
2.2 ENGINE STORAGE 10
2.2.1 Storage Less than 1 year 10
2.2.2 Extended Storage Maintenance Procedure 10
2.3 INSTALLATION INSTRUCTIONS 10
2.4 SPECIFIC FLYWHEEL COUPLING ALIGNMENT INSTRUCTIONS 12
2.4.1 Driveshaft 12
2.4.2 Other Coupling Types 13
2.5 WEEKLY TEST 14
2.6 STARTING/STOPPING THE ENGINE 14
2.6.1 Special Notes to Equipment Installer of an LPCB Approved (LPS1239) Engine Model 14
2.6.2 To Start Engine 14
2.6.3 To Stop Engine 17
3.0 ENGINE SYSTEMS 17
3.1 FUEL SYSTEM 17
3.1.1 Bleeding the Fuel System 17
3.1.1.1 JU4/6 UF, NL 17
3.1.1.2 JU4/6 LP 18
3.1.1.3 JW6 UF, NL 18
3.1.2 Draining the Condensate from the Fuel Filter 20
3.1.3 Changing Fuel Filter Cartridge 20
3.1.3.1 JU4/6 UF, NL 20
3.1.3.2 JU4/6 LP 21
3.1.3.3 JW6 UF, NL 21
3.1.4 Fuel Tanks 22
3.1.5 JU Fuel Injection Pump Components 22
3.1.6 JW Fuel Injection Pump Components 23
3.2 AIR/EXHAUST SYSTEM 23
3.2.1 Ambient Conditions 23
3.2.2 Ventilation 23
3.2.3 Standard Air Cleaner 23
3.2.4 Crankcase Ventilation 24
3.2.4.1 Open Crankcase Ventilation 24
3.2.4.2 Crankcase Ventilation System 24


Page 3 of 38
3.2.5 Exhaust System 25
3.3 LUBRICATION SYSTEM 25
3.3.1 Checking Sump Oil 25
3.3.2 Changing Engine Oil 26
3.3.3 Changing Oil Filter Cartridge 26
3.3.4 Oil Specification 26
3.3.5 Oil Capacities 27
3.4 COOLING SYSTEM 27
3.4.1 Engine Coolant 27
3.4.2 Water 27
3.4.3 Coolant Capacities 27
3.4.4 Coolant Inhibitors 27
3.4.5 Procedure for Filling Engine 28
3.4.5.1 Engines without Coolant Recovery Tank 28
3.4.5.2 Engines with Coolant Recovery Tank 29
3.5 ELECTRICAL SYSTEM 30
3.5.1 Wiring Diagrams 30
3.5.2 Checking Drive Belt Tension and Adjustment 30
3.5.3 Speed Switch 30
3.5.4 Magnetic Pick-Up 31
3.6 ENGINE SPEED ADJUSTMENT 31
4.0 MAINTENANCE SCHEDULE 31
4.1 ROUTINE MAINTENANCE 31
5.0 TROUBLE SHOOTING 32
6.0 PARTS INFORMATION 32
6.1 SPARES 32
6.2 ENGINE MAINTENANCE PARTS LIST 32
7.0 OWNER ASSISTANCE 33
8.0 WARRANTY 33
8.1 GENERAL WARRANTY STATEMENT 33
8.2 CLARKE WARRANTY 33
8.3 JOHN DEERE WARRANTY 33
9.0 ATCM CALIFORNIA EMISSION REGULATIONS FOR STATIONARY ENGINES 35
10.0 INSTALLATION & OPERATION DATA (See Technical Catalog C13965) 36
11.0 WIRING DIAGRAMS (See Technical Catalog C13965) 36
12.0 PARTS ILLLUSTRATION (See Technical Catalog C13965) 36
13.0 APPENIX (Alpha Index) 37






Page 4 of 38
Check factory availability for a manual in one of the following languages:


































































































Spanish MP-7 C13961
French MP-7 C13962
German MP-7 C13963
Italian MP-7 C13964
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.


Page 5 of 38
1.0 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).

Derates 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 and technical catalog (C13965).

Periodic running checks to ensure
functionality should be kept to a maximum of
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 plates attached to each
engine. Clarke Identification Plate: Engine Model,
Serial Number, Rating and Date of Manufacture are
shown on this identification plate. The JU Series
identification plate is mounted on the flywheel
housing at the rear of the engine. The JW Series
identification plate is mounted on right rear engine
mount.
Note that there are five types of identification plates,
dependent on whether the engine is a Non-Listed
or Listed/Approved Model. These are typical
examples. (See Figure #1).

Clarke Identification Plates
USA Non Listed USA Listed/Approved

UK Non-Listed UK Listed/Approved

Figure #1









Page 6 of 38
UK Listed/Approved

Figure #1 contd

Clarke model numbers reflects the base engine type,
number of cylinders, cooling system, approval listing
and a power rating code.

Example: JU6H-UF50
J = John Deere base engine prepared by
CLARKE
U = base engine series (4.5 liter 4 cylinder or
6.8 liter 6 cylinder)
6 = number of cylinders
H = Heat Exchanger cooled (R = Radiator)
UF = Underwriters Laboratories Listed/
Factory Mutual Approved, (LP = LPCB Loss
Prevention Council Board Approved, NL =
Non-Listed)
50 = A power rating code

John Deere Identification Plate: The second
identification plate contains the John Deere Model
Number and Serial Number. On the JW Series, the
John Deere Serial identification plate is located on
the left-hand side of the engine between the intake
manifold and starting motor. On the JU Series, the
John Deere identification plate is located on the right
side of the cylinder block behind the fuel filter.

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 #2

ENGINE MODEL WEIGHT lbs (kg)
JU4H-UF10, 12, 20, 22
JU4H-NL20, 22
JU4H-LP20,24
910 (413)
JU4H-UF30, 32, 40, 42, 50, 52,
8H, H0, H2, 58
JU4H-NL30, 32, 40, 42
JU4H-LP50,54
935 (424)
JU4H-LP84
1085 (492)
JU4R-UF09, UF11,13,19,21,23
956 (434)
JU4R-UF40, 49, 51, 53
982 (445)
JU6H-UF30, 32, 50, 52
D0, D2, G8, M8, M0, M2, 58
JU6H-NL30, 32, 50, 52
JU6H-LP50,54
1657 (750)
JU6H-UF60, 62, 68
JU6H-LP60,84
1693 (766)
JW6H-UF30 (JDFP-06WA), 38
JW6H-NL30
2012 (910)
JW6H-UF40 (JDFP-06WR), 48
JW6H-NL40
2003 (906)
JW6H-UF50, 60, 58
JW6H-NL50, 60
2053 (929)
Figure #2

Figure #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.


Page 7 of 38

Figure #3

Figure #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 #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.

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.




Page 8 of 38





GRANGE WORKS, LOMOND ROAD, COATBRIDGE, UNITED KINGDOM, ML5 2NN

TEL: 0044 1236 429946
FAX: 0044 1236 427274

DECLARATION OF INCORPORATION

We hereby declare that the following engine is intended to be incorporated into other machinery and must not be put into service until
the relevant machinery, into which it is to be incorporated has been declared in conformity with the essential health and safety
requirements of the Machinery Directive 89/392/EEC.

Description: - DIESEL ENGINES

Model: -

Serial Number: -

Contract No: -

Customers order no:

NOTE: - This engine has moving parts, areas of high temperatures, and high temperature fluids under pressure. In addition it has an
electrical system, which may be under strong current.

The engine produces harmful gases, noise vibrations and as a result it is necessary to take Suitable precautionary measures when moving,
installing and operating the engine to reduce risks connected with the characteristics stated above.

The engine must only be used in accordance with the scope of supply and the intended application.

STANDARDS AND TECHNICAL SPECIFICATIONS

Signed: ____________________________ Date: ____________________________

REGISTERED IN SCOTLAND NO: 81670

C13896, Rev C, 3 Jan 2003
Figure #5


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
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
1) Put out the flames on the clothing of the
burns victim by means of:
drenching with water



Page 9 of 38
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 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

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 engines electrical system (12/24
VDC)
2) The electrical coolant pre-heating system
120/240 Volt AC (if supplied) AC current.

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.

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.








Page 10 of 38
Heat Exchanger Maximum Working Pressure


Coolant Mixture


Lifting Point


Automatic Start


Rotating Parts






Jacket Water Heater Voltage


Air Filter Installation


2.0 INSTALLATION/OPERATION

2.1 TYPICAL INSTALLATION

A typical Fire Pump installation is shown in Figure
#6 & 6A.
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


Figure #6
Typical Installation
Heat Exchanger Cooled Engine



Page 11 of 38

Figure #6A
Typical Installation
Radiator Cooled Engine

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 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:

1) Drain the engine oil and change the oil filter.
2) Refill the engine crankcase with MIL-L-
21260 preservative oil.
3) Change the fuel filter.
4) Install the coolant plugs and install coolant in
the normal mix percentage of 50% coolant,
50% water, premixed.
5) Remove the protection from the intake and
exhaust openings.
6) Prepare a container as a fuel source using a
mixture of Mobilarma or Sta-Bil with Diesel
#2 fuel or Red diesel fuel (ASTM D-975)
or BS2869 Class A2.
7) Disconnect the coupling or drive shaft from
the pump.
8) Start and run the engine at a slow speed for
1-2 minutes being careful not to exceed the
normal operating temperature.
9) Drain the oil and coolant.
10) Replace the protective plugs that were used
for shipping and storage.
11) Attach to the engine a visible card, specifying
ENGINE WITHOUT OIL DO NOT
OPERATE.

IMPORTANT: THIS TREATMENT MUST BE
REPEATED EVERY 6 MONTHS
************************
PUTTING ENGINE INTO SERVICE AFTER
ADDITIONAL PRESERVATION SERVICE:
To restore the normal operation running conditions of
the engine, carry out the following:

1) Fill the engine sump with the normal
recommended oil, to the required level.
2) Remove the protective plugs used for
shipping and storage.
3) Refill cooling water to proper level.
4) Remove the card ENGINE WITHOUT OIL,
DO NOT OPERATE.
5) Follow all steps of the Installation
Instructions when the engine will be put into
service.

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 in the area of the
11



Page 12 of 38
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
manufacturers 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 for specific alignment
instructions).
2a) Engine with Heat Exchanger Cooling:
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.
2b) Engine with Radiator Cooling:
Connect radiator air discharge ducting to
radiator duct flange. Discharge ducting
should be installed in accordance with
applicable codes. A flexible duct section
should be provided to isolate engine from
building.
3) Install all engine cooling system draincocks
and plugs.

Qty

Description

Location
Engine
Model
1 1/8
draincock
Water Heater
inlet tube
JU4/6H,
JU4/6R
1 1/8
draincock
Coolant heater
inlet tube
JDFP,
JW6
1 Plug
RE46686
Oil Cooler JU4/6H,
JU4/6R
1 3/8 pipe plug Heat exchanger JDFP,
JW6
1 Electrode
plug
Bottom of heat
exchanger
JU4/6H

4) Fill engine cooling system with premixed
50% water / 50% coolant solution. Use only
coolants meeting ASTM-D4985
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 Figure #34 in section 3.4.3
for cooling system capacity. Refer to section
3.4.5 for filling procedure.
5) Engine is shipped with oil installed. For
make-up oil specification refer to section 3.3
Lubrication System.
6) Connect fuel supply and return line to fuel
supply tank plumbing. Reference the Fuel
System section of the Installation and
Operation Data in the Technical Catalog, 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. 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 cleaner
element.
8) Connect jacket water heater (if supplied) to
AC power source. For JU4/6 Series the
electrical supply requirements are indicated
on the heater body. Connect the supplied
heater connection wire directly to a customer
supplied electrical junction box. For
JDFP/JW6 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
manufacturers instructions. Note that the
W terminal is used only for the UL/FM
cooling water solenoid (if supplied). Refer to



Page 13 of 38
the wiring diagram sticker located on the
inside cover of the engine gauge panel for
proper connection of the water solenoid.
11) Fill batteries with electrolyte per battery
manufacturers 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
in the Technical Catalog C13965, for correct
positive and negative connections. Connect
negative cables directly to the engine block.
On JU4/6 Series connect each positive cable
to the large electrical post of the starter
motor. Note: the JU4/6 Series have a
separate starter motor for each battery set.
On the JDFP/JW6 Series connect each
positive cable to the large outer post of the
manual starting contactors.
12) Note: Clarke Operation and Maintenance
Instructions Manual and Clarke parts
illustration pages are located inside the
engine gauge panel.
13) 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.

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 driveshaft must be installed
between the flywheel drive disc (no drive disc on
JW6 models) 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
TIGHTENIN
G TORQUE
ft-lbs
(N-m)
JU4-UF09,
10,11,12,13,19,
20,2122,23
JU4-LP 20,24

SC41

7/16-20
Grade 8
(Hi-Tensile)

50 + 55
(68 75)
JU4-UF
30,32,40,42,50,
51,52,53, H8,
H0, H2, 58
JU4-LP 50,54

SC55

1/2-20
Grade 8
(Hi-Tensile)

75 + 82.5
(102 112)


All JU6
& JW6



SC2130

M12,Class
10.9
(Metric)

(Hi-Tensile)
90 + 99
(122 134)
(see note #1)

86 94
(117 - 128)
(see note #2)

Note 1 It is recommended that a medium strength
threadlocker (i.e. Loctite blue #64040) be used in
the assembly and torquing of all hardware. This may
be purchased as part number 23509536.

Note 2 4 of the hi-tensile bolts and/or nuts, that are
used to connect the driveshaft to the drive disc (all
JU6 models) or flywheel (all JW6 models) and that
connect the driveshaft to the pump companion flange,
will require a crows 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 standard crows foot adapter.

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.

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 disc or the circumference of the
drive shaft flange (against the flywheel) is in
the 12 oclock position shown on figure# 7.
2. Measure from the rear face of the flywheel
drive disc or the drive shaft flange to point A.
(Point A is on the bearing bore as shown in



Page 14 of 38
Figure 7, on the instrument panel side of the
engine). This measurement must be:
MEASUREMENT MODELS
58 + 2mm. JU4-UF
09,10,11,12,13,19, 20,
21,22,23
JU4-LP20,24
68 + 4mm. JU4-UF30, 32, 40, 42,
49, 50, 51, 52, 53, 8H,
H0, H2, 58
JU4-LP 50,54
76 + 3mm. All JU6 & JW6
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 front face of the drive shaft
flange on the pump end to point B. (Point B
is the bearing bore on the exhaust side of the
engine). This measurement must be equal to
the measurement at point A + 1 mm.
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 drive disc or the circumference
of the drive shaft flange (against the
flywheel) is in the position shown on
Figure#8.
2. Measure from the rear face of the flywheel
drive disc or the drive shaft flange to point C.
(Point C is the same as point A with the
driveshaft rotated 90). The measurement
must be:
MEASUREMENT MODELS
60 + 1mm. JU4-UF 09,10,11,12,13,
20,21,22,23
JU4-LP20,24
71 + 1mm. JU4-UF30, 32, 40, 42,
49,50,51,52,53, 8H, H0,
H2, 58
JU4-LP 50,54
78 + 1mm. All JU6 & JW6
D) With the driveshaft in the same orientation as the
previous step (Step C), check the Vertical
alignment of the shafts.
1. Measure the front face of the drive shaft
flange on the pump end to point D. (Point D
is the same as point B, with the driveshaft
rotated 90). The measurement must be equal
to the measurement at point C + 1 mm.

Re-install all guards and grease fittings vefore
reconnecting the battery cables.


Figure #7

Figure #8

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.


2.4.2 Other Coupling Types
Consult Factory or Clarke website at
[email protected] for additional
information.





Page 15 of 38
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
30 minutes maximum.

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.
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.
5a) Heat Exchanger Cooling: The water supply
for coolant is available again without
restriction.
5a) Radiator Cooling: The air supply for cooling
is available again without restriction.

When engine is running make sure that the coolant
temperature and oil pressure raw cooling water flow
are within the limits specified on the relevant
Installation & Operation Data Sheet in the Technical
Catalog, C13965.

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 Special Notes to Equipment Installer of an
LPCB Approved (LPS1239) Engine Model

Any device fitted to the engine or controller, which
could prevent the engine starting automatically, shall
return automatically to the normal position after
manual application. The electrical fuel shutoff
actuator shall be connected to an Engine Stop button
on the main pump controller.

The main pump controller shall de-energize the start
motor when the engine has achieved 700-1000 rpm.

2.6.2 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
#9). 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 COOLING WATER is not
flowing or engine TEMPERATURE is too HIGH,
open cooling system manual by-pass valves (applies
to heat exchanger cooled engines only).
Note: On JW Engines you can also start engines
using manual starting contactors.

On LPCB engines, use main pump controller for
starting and stopping the engine. Should the main
pump controller become inoperable, the engine can
be manually started from the engine gauge panel.
For manual starting of an engine with a gauge panel.
(Refer to Figure #9A): Lift and hold MANUAL
CRANK #1, until engine starts, or release after 15
seconds. If unit fails to start, wait for 10 seconds, use
MANUAL CRANK #2 and repeat step. If
COOLING WATER is not flowing or engine
TEMPERATURE is too HIGH, open cooling
system manual by-pass valves (applies to heat
exchanger cooled engines only).









Page 16 of 38

UL/FM Instrument Panel


Figure #9

1 Emergency Operating Instructions 4 Overspeed Reset
2 Automatic-Manual Mode Selector 5 Warning Light
3 Manual Crank Controls 6 Overspeed Verification




Page 17 of 38



LPCB Instrument Panel

Figure #9A


1 Emergency Operating Instructions
2 Manual Crank Controls




1
2

2
2


Page 18 of 38
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.

2.6.3 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: Return
MODE SELECTOR switch to
AUTOMATIC/MANUAL STOP position, engine
will stop. 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).

Engines not equipped with an engine gauge panel,
and LPCB engines, have a manual shutdown lever
on the engine for shutdown.

3.0 ENGINE SYSTEMS

3.1 FUEL SYSTEM

3.1.1 Bleeding the Fuel System

CAUTION: Escaping fluid under pressure can
penetrate the skin causing series injury. Relieve
pressure before disconnecting fuel or other lines.
Tighten all connections before applying pressure.
Keep hands and body away from pinholes and
nozzles, which eject fluids under high pressure.
Use a piece of cardboard or paper to search for
leaks. Do not use your hand.
If ANY fluid is injected into the skin, it must be
surgically removed within a few hours by a doctor
familiar with this type injury or gangrene may
result. Doctors unfamiliar with this type of injury
may call the Deere & Company Medical
Department in Moline, Illinois, or other
knowledgeable medical source. Ref figure #10


Whenever the fuel system has been opened up for
service (lines disconnected or filters removed), it will
be necessary to bleed air from the system.

3.1.1.1 JU4/6-UF,NL Engine Series:

1) Loosen the air bleed vent screw (A) two full
turns by hand on fuel filter base. Ref. Figure
#11
2) Operate supply pump primer lever (B) until
fuel flow is free from air bubbles. Ref.
Figure #12.
3) Tighten bleed plug securely; continue
operating hand primer until pump action is
not felt. Push hand primer inward (toward
engine) as far as it will go.
4) Start engine and check for leaks.

Figure #11

Figure #10
A


Page 19 of 38
Figure # 12

If engine will not start, it may be necessary to bleed
air from fuel system at fuel injection pump or
injection nozzles as explained next.

At Fuel Injection Pump:

1) Slightly loosen fuel return line connector (A)
at fuel injection pump. Ref figure #13
2) Operate fuel supply pump primer lever until
fuel, without air bubbles, flows from fuel
return line connection.
3) Tighten return line connector at 16N-m (12
lb-ft).
4) Leave hand primer in the inward position
toward cylinder block. Ref. Figure #14.

Figure # 13

Figure #14

3.1.1.2 JU4/6 LP Engine Series






Photo to follow later







3.1.1.3 JDFP/JW6 Engine Series:

Refer to Figure #19 for system components location.

A Primary Fuel Filter
B Secondary Fuel Filter
C Fuel Injection Pump
D Speed Adjustment

At Round Primary Fuel Filter/Water Separator:

1) Drain water and contaminants from clear
sediment bowl.
2) Loosen air bleed vent screw (A) on fuel filter
base (Figure# 15)
3) Operate and primer (B) until fuel flow is free
from air bubbles (Figure#15)
4) Tighten vent screw as hand primer is held in
downward pumping position.

B
A
B


Page 20 of 38
Figure # 15

At Rectangular Final Fuel Filter:

1) Loose bleed plug (A) on fuel filter base
(figure#16).
2) Operate hand primer (B) on fuel supply
pump (figure#17), until a smooth flow of
fuel, free of bubbling, comes out of the plug
hole.
3) Simultaneously stroke the hand primer down
and close the filter port plug. This prevents
air from entering the system. Tighten plug
securely. DO NOT over tighten.
4) Start engine and check for leaks.

Figure #16

Figure #17

If engine will not start, it may be necessary to bleed
air from fuel system at injection nozzles as explained
below.

At Fuel Injection Nozzle

1) Loosen fuel line connection at no. 1 injection
nozzle (A) (figure#18)
2) Crank engine with starting motor (but do not
start engine), until fuel free from bubbles
flows out of loosened connections. Retighten
connection.
3) Start engine and check for leaks.
4) If engine does not start, repeat procedure at
remaining injection nozzles (if necessary)
until enough air has been removed from fuel
system to allow engine to start.

Figure #18

A
B
A
A


Page 21 of 38

Figure #19

3.1.2 Draining the Condensate from the Fuel Filter

Drain the condensate from the fuel filter. Fuel filters
have a drain (B) located at the bottom of their body
(A) figure#20, these filters should be drained each
week to relieve built up water.


Figure #20

3.1.3 Changing the Fuel Filter Cartridges

Changing the cartridges and bleed any air from the
fuel system as per instructions given in section 3.1.1.
Fuel filter changes should take place as per
recommendations and only using approved filters. It
may also be necessary to change filters out with the
recommendations in the event of:

1) The engine has had an overhaul.
2) The quality of the fuel is questionable.
3) The engine has been subjected to temporary
adverse conditions outwith it normal
operating parameters.
4) The fuel tank condensation trap has not been
drained in line with manufacturers
recommendations.

3.1.3.1 JU4/6-UF,NL Engine Series

1) Close fuel shut-off valve, if equipped
2) Thoroughly clean fuel filter assembly and
surrounded area.
3) Loosen drain plug (C) and drain fuel into a
suitable container. Ref figure#21

Note: Lifting up on retaining ring and rotate it helps
to get past raised locators.

4) Firmly grasp the retaining ring (A) and rotate
it counterclockwise turn. Remove ring
with filter element (B). Ref figure#21
5) Inspect filter mounting base for cleanliness.
Clean as required.

Note: Raised locators on fuel filter canister must be
indexed properly with slots in mounting base for
correct installation.

6) Install new filter element onto mounting
base. Be sure element is properly indexed
and firmly seated on base. It may be
necessary to rotate filter for correct
alignment.

If equipped with water separator, remove filter
element from water separator bowl. Drain and clean
separator bowl. Dry with compressed air. Install
water separator bowl onto new element. Tighten
securely.

7) Align keys on filter element with slots in
filter base.
8) Install retaining ring onto mounting base
making certain dust seal is in place on filter
base. Hand tighten ring (about 1/3 turn) until
it snaps into the detent. DO NOT over
tighten retaining ring.

Note: The proper installation is indicated when a
click is heard and a release of the retaining ring is
felt.

A plug is provided with the new element for plugging
the used element.

A
B
C
D
A
B


Page 22 of 38
9) Open fuel shut-off valve and bleed the fuel
system. Tighten bleed plug (D). Reference
Figure #21


Figure #21

3.1.3.2 JU4/6 LP Engine Series

3.1.3.3 JDFP/JW6 Engine Series

Each engine has two fuel filters. For the purpose of
identity, the primary filter incorporates the
transparent water separator.

Replacing (round) Primary Fuel Filter/Water
Separator

1) Close fuel shut-off valve at bottom of fuel
tank, if equipped.
2) Thoroughly clean fuel filter/water separator
assembly and surrounding area.

Note: Lifting up on retaining ring (F) as it is rotated
helps to get it past retaining dent. Ref. Figure #22

3) Rotate retaining ring counterclockwise
turn. Remove ring with filter element.
4) Remove water separator bowl (G) from filter
element (E). Drain and clean separator bowl.
Dry with compressed air. Ref. Figure #22
Note: Notice raised locators on filter element. These
locators insure proper alignment of filter element to
filter base.
5) Install water separator bowl onto new filter
element. Tighten securely.
6) Index filter element until longer, vertical
locator (D) is oriented opposite mounting
base. Insert filter element into base securely.
It may be necessary to rotate filter for correct
alignment. Ref. Figure #22
7) Install retaining ring to filter base, making
certain dust seal (C) is in place on filter base.
Tighten retaining ring until it locks into
detent position and a click sound can be
heard. Ref. Figure #22
8) Bleed fuel system.




















Figure #22

Replacing (rectangular) Secondary Fuel Filter
Element

1) Close fuel shut-off valve at bottom of fuel
tank, if equipped.
2) Loosen bleed plug (C) on side of filter base.
Remove drain plug (B) to drain from fuel
filter. Ref. Figure #23

Note: Keep a small container under drain plug to
catch draining fuel.

3) With fuel filter firm against base, lift up on
top retaining spring and pull down on bottom
retaining spring. Pull fuel filter off guide
pins of fuel filter base and discard.
4) Install new fuel filter onto guide pins of fuel
filter base. Hold filter firmly against base.
5) Secure bottom filter retaining spring first,
then secure top retaining spring (four
arrows).
C
B
A
D


Page 23 of 38
6) Install new drawn plug, shown installed.
Tighten bleed plug and drain plug securely.
Do not over tighten.
7) Open fuel shut-off valve and bleed the fuel
system. Ref. Figure #23
Figure #23

3.1.4 Fuel Tanks

Keep the fuel tank filled to reduce condensation to a
minimum. Open drain at the bottom of the fuel tank
once a week to drain off any possible water and/or
sediment. Fill tank after each test run.

Note: Per NFPA 25 standards, the fuel tank level
must never be less than 67% of its capacity.

3.1.5 JU4/6 Fuel Injection Pump Components

THIS TAG IS SUPPLIED ON ALL J U4 AND J U6
ENGINES


The above tag is stamped to identify the As
Built Components. Refer to the next two tables
to identify:
Table 1) Droop Spring Part Number by Engine
Model and Speed.
Table 2) Run-Stop Solenoid (Internal to Injection
Pump) Part Number by engine voltage.
Injection Pump
Droop Spring Part Number
RPM 1760
2100
2350
2350
2600
2800
2960
3000
MODEL
J U4H-UF10
J U4R-UF09
J U4R-UF11
J U4H-UF20
J U4R-UF19
J U4R-UF21
J U4H-LP20
J U4R-UF23


13563
or
C02353





J U4R-UF13
J U4H-UF14

J U4H-UF24

24339
J U4H-UF12
J U4H-UF22
J U4H-UF32
J U4H-UF42

J U4R-UF51
J U4H-UF52
J U4H-UFH2


13563
or
C02353

J U4H-UF34
J U4H-UF44
J U4H-UF54

J U4R-UF53
J U4H-LP54
J U4H-UF84





24339
J U4H-UF30
J U4H-UF40
J U4R-UF40
J U4H-UF50
J U4H-UFH8
J U4H-UFH0
J U4H-UF58
J U4R-UF49
J U4H-LP50




20357


J U6H-UF30
J U6H-UFD0
J U6H-UFG8
J U6H-UFM8
J U6H-UFM0
J U6H-UF58
J U6H-UF50
J U6H-UF68
J U6H-UF60
J U6H-LP50
J U6H-LP60





13558


J U6H-UF32
J U6H-UFD2
J U6H-UFM2
J U6H-UF52
J U6H-UF62

13563
or
C02353

J U6H-UF34
J U6H-UF54
J U6H-UF84



24339





B
C


Page 24 of 38
Run-Stop Solenoid Part Number
ETR ETS
12 Volt SD26214 or
C07853
SD26921 or
C07827
24 Volt SD26387 or
C07826
SD26922 or
C07828
Legend:
ETR Energized to Run
ETS Energized to Stop
SD # - Stanadyne Part Number
C # - Clarke Part Number

3.1.6 JW6 Fuel Injection Pump Components

For Droop Spring and Run-Stop Solenoid (external to
Injection Pump) part numbers consult factory.

3.2 AIR/EXHAUST SYSTEM

3.2.1 Ambient Conditions

Clarke engines are tested in accordance with SAE
J1349 (Clarke USA) or ISO 3046 (Clarke UK). In
this capacity they may be derated to meet certain site
conditions, failure to do so can seriously impede the
performance of the engine and could lead to
premature failure.

3.2.2 Ventilation

The engine must be provided with adequate
ventilation to satisfy the requirements of the
combustion system, radiator cooling systems where
fitted, and allow adequate dissipation of radiated heat
and crankcase emissions. For all this data refer to
Installation & Operation Data in Technical Catalog,
C13965. This data can be used for proper sizing of
inlet and outlet louvers.

3.2.3 Standard Air Cleaner

The standard air cleaner is a reusable type. Should a
situation occur where the air cleaner becomes
plugged with dirt (starving the engine of air), loss of
power and heavy black smoke will result; the air
cleaner should be serviced immediately. See figure
#39 for air cleaner part numbers by Clarke Engine
Model.

CAUTION: Do not attempt to remove the air
cleaner while an engine is running nor run the engine
while the air cleaner is off. Exposed components
could cause severe injury to personnel and major
internal engine damage could occur should any
foreign matter be drawn into the engine.

The air cleaner manufacturer recommends the
following:
1. The pre-oiled reusable elements are serviced
with a special oil. The elements can be
serviced or replaced.
2. Figure #24 shows the air filter service
instructions.
3. When servicing the element is not practical,
you can improve filter efficiency by re-
spraying with oil.

NOTE: Do not attempt this while engine is running

NOTE: Do not over oil the reusable element




Figure #24



Page 25 of 38

Figure #24 (contd)

3.2.4 Crankcase Ventilation

3.2.4.1 Open Crankcase Ventilation (Refer to
fig#27b)

Vapors which may form within the engine are
removed from the crankcase and gear train
compartment by a continuous, pressurized ventilation
system.

A slight pressure is maintained within the engine
crankcase compartment. Vapors expelled through a
vent pipe attached to the rocker cover breather
element. Ref. Figure #25, 26, & 27.

Figure #25
JU4-UF10, 12, 20, 22, JU4-LP20, 24

Figure #26
JU4-UF30, 32, 40, 42, 50, 52, H8, H0, H2, 58
JU4-LP50, 54 & JU6 All

Figure #27
JDFP/JW6

3.2.4.2 Crankcase Ventilation System

A crankcase ventilation system allows for the
recirculation of vapors (expelled through a vent pipe
attached to the rocker cover breather element) to the
combustion air inlet. Refer to figure 27a.


Figure #27a







Page 26 of 38
Engine
Model
Open
Crankcase
Ventilation
Crankcase
Ventilation
System
J U4R-UF09
J U4H-UF10
J U4R-UF11
J U4H-UF12
J U4R-UF19
J U4H-UF20
J U4H-LP20
J U4R-UF21
J U4H-UF22
J U4R-UF23
J U4H-UF30
J U4H-UF32
J U4H-UF40
J U4R-UF40
J U4H-UF42
J U4R-UF49
J U4H-UF50
J U4H-LP50

J U4R-UF51
J U4H-UF52
J U4H-UF58
J U4H-UFH2
J U4H-UFH8
J U4H-UFH0
J U6H-UF30
J U6H-UF32
J U6H-UF50
J U6H-LP50
J U6H-UF52
J U6H-UF58
J U6H-UF62
J U6H-UF68
J U6H-UF60
J U6H-LP60
J U6H-UFD0
J U6H-UFG8
J U6H-UFM8
J U6H-UFM0
J U6H-UFD2
J U6H-UFM2















Standard
















Optional
Figure #27b

Engine
Model
Open
Crankcase
Ventilation
Crankcase
Ventilation
System
J U4H-UF34
J U4H-UF44
J U4H-UF54

J U4R-UF53
J U4H-LP54
J U4H-UF84
J U6H-UF34
J U6H-UF54
J U6H-UF84



Standard
Figure #27b contd




3.2.5 Exhaust System

Excessive back pressures to the engine exhaust can
considerably reduce both engine performance and
life. It is therefore important that exhaust systems
should be the proper diameter and be as short as
possible within the minimum amount of bends. Refer
to Installation & Operating Data in Technical Catalog
C13965 for exhaust data.

The installation of the exhaust system should consist
of the following:
Personnel protection from hot surfaces.
Adequate supports to prevent strain on the
engine exhaust outlet and minimize
vibration.
Protection against entry of water and other
foreign matter.

While the engine is running inspect exhaust pipe
outlet outside of the pump room itself for
environmental hazards such as excessive smoke
conditions. The following could be used as a guide
for general engine operating conditions.

1) Blue Smoke Possible engine oil
consumption.

2) White Smoke Possibility of water in
cylinders, water in fuel or internal engine
problem.

3.3 LUBRICATION SYSTEM

3.3.1 Checking Sump Oil

Check the sump oil level using the dipstick on the
engine as shown in Figure #28 &29.
This level must always be between the dipstick marks
Min. and Max. with the engine not running.

Figure #28
JU4/6


Page 27 of 38

Figure #29
JDFP/JW6

3.3.2 Changing Engine Oil

1) Operate the engine until it is warm.
2) Stop the engine. Remove the sump drain
plug and drain the lubricating oil from the
sump. Fit the drain plug tighten the plug to
34 Nm (25lbf-ft) / 3.5 kgf-m.
3) Fill the sump to the FULL mark on the
dipstick with new and clean lubricating oil of
an approved grade.
4) Return the unit back into service by returning
the AEC selector to automatic position and
the manual operating lever to manual stop
position.
5) Dispose used oil properly.

3.3.3 Changing Oil Filter Cartridge

1. Turn engine off.
2. Put a tray under the filter to retain spilt
lubricating oil.
3. Remove the filter with a strap wrench or
similar tool. Then dispose of the filter
properly (Ref Figure #30).
4. Clean the filter head.
5. Add clean engine lubricating oil to the new
filter. Allow the oil enough time to pass
through the filter element.
6. Lubricate the top of the filter seal with clean
engine lubricating oil.
7. Fit the new filter and tighten it by hand only.
Do not use a strap wrench.
8. Ensure that there is lubricating oil in the
sump. On turbocharged engines, ensure that
the engine will not start and operate the
starter motor until oil pressure is obtained.
9. Operate the engine and check for leakage
from the filter. When the engine has cooled,
check the oil level on the dipstick and put
more oil into the sump, if necessary.
10. Return the unit back into service by returning
the main pump controller selector to
automatic position and the manual
operating lever to AUTO-OFF position.

Figure #30

3.3.4 Oil Specification

This engine is factory-filled with John Deere
Engine Break-in Oil.

Important: Do not add makeup oil until the oil
level is BELOW the add mark on the dispstick.

Break-in period is 1 year from engine start-up.

Low Speed engine models (Nameplate RPM is less
than or equal to 2600 RPM) are shipped from Clarke
with John Deere Break-in oil installed. Break-In Oil
(TY22041, 10W30) should be used to make up any
oil consumed during the break-in period.

High speed engine models (Nameplate RPM is
greater than 2600 RPM) are shipped with CI-4,
15W40 oil. On these models any make up oil should
meet the requirements of CF-4, CG-4, CH-4, or CI-4,
Viscosity Grade 15W40.







Page 28 of 38
Oil spec to be used after break-in period, all engine
models:

Figure #31

3.3.5 Oil Capacities (Including Filter)
ENGINE
MODEL
OIL CAPACITY
QUARTS (LITERS)
JU4 All Models 14.3 (13.5)
JU6 All Models 20.1 (19)
JW6 All Models 30.1 (28.5)
Figure #32

3.4 COOLING SYSTEM

3.4.1 Engine Coolant

The following information is provided as a guide for
John Deere Engine users in the selection of a suitable
coolant.

The water/ethylene glycol/inhibitor coolant mixture
used in John Deere engines must meet the following
basic requirements:
Provide for adequate heat transfer.
Provide protection from cavitation damage.
Provide a corrosion/erosion-resistant
environment within the cooling system.
Prevent formation of scale or sludge deposits
in the cooling system.
Be compatible with engine hose and seal
materials.
Provide adequate freeze and boil over
protection.

WARNING
A water and anti-freeze solution is required for
pump installations. Premixing this solution prior
to installing is required. This prevents possible
pure anti-freeze chemical reactions to block
heater elements which can burnout the element.
Please see the technical data section for proper
cooling system capacities of each model.

3.4.2 Water

Water can produce a corrosive environment in the
cooling system, and the mineral content may permit
scale deposits to form on internal cooling surfaces.
Therefore, inhibitors must be added to control
corrosion, cavitation, and scale deposits.

Chlorides, sulfates, magnesium and calcium are
among the materials which make up dissolved solids
that may cause scale deposits, sludge deposits,
corrosion or a combination of these. Chlorides
and/or sulfates tend to accelerate corrosion, while
hardness (percentage of magnesium and calcium salts
broadly classified as carbonates) causes deposits of
scale. Water within the limits specified in figure #33
is satisfactory as an engine coolant when properly
inhibited. Use of distilled water is preferred.



Materials

Parts per
Million
Grains
per
Gallon
Chloride (Max.) 40 2.5
Sulfates (Max.) 100 5.8
Total Dissolves Solids
(Max.)

340

20
Total Hardness (Max.)
170

10
Figure #33

3.4.3 Coolant Capacities

Use an ethylene glycol coolant (low silicate
formulation) that meets the standard of either the GM
6038-N formulation (GM1899-M performance) or
ASTM D4985 requirements.

A 50% coolant water solution is recommended. A
concentration over 70% is not recommended because
of poor heat transfer capability, adverse freeze
protection and possible silicate dropout.
Concentrations below 30% offer little freeze, boil
over or corrosion protection.

IMPORTANT
Never use automotive-type coolants (such as those
meeting only ASTM D3306 or ASTM D4656).
These coolants do not contain the correct additives
to protect heavy-duty diesel engines. They often
contain a high concentration of silicates and may
damage the engine or cooling system.




Page 29 of 38
ENGINE
MODEL
COOLANT CAPACITY
QUARTS (LITERS)
JU4H-All Models 15 (14.2)
JU4R- All Models 20 (19)
JU6H-All Models 20 (19)
JDFP-06WA/JW6-UF30 22 (21)
JDFP-06WR/JW6-UF40 23 (22)
JW6-UF50, 60 23 (22)
Figure #34

3.4.4 Coolant Inhibitor

The importance of a properly inhibited coolant
cannot be over-emphasized. A coolant which has
insufficient or no inhibitors at all, invites the
formation of rust, scale, sludge and mineral deposits.
These deposits can greatly reduce the cooling
systems efficiency and protection capabilities.

Recommended supplemental coolant inhibitors are a
combination of chemical compounds which provide
corrosion protection, cavitation suppression, pH
controls and prevents scale. These inhibitors are
available in various forms, such as liquid packages or
integral parts of anti-freeze.
It is imperative that supplemental inhibitors be added
to all John Deere engine systems. A pre-charge
dosage must be used at the initial fill and the
maintenance dosage used at each service interval.
Serious damage will occur unless inhibitors are used.
Some of the more common corrosion inhibitors are
borates, nitrates and silicates.
Inhibitors become depleted through normal
operation; additional inhibitors must be added to the
coolant as required to maintain original strength
levels. Refer Figure #35 for proper concentrations of
inhibitors.
Min.
PPM
Max
PPM
Boron (B) 1000 1500
Nitrite (NO
2
) 800 2400
Nitrates (NO
3
) 1000 2000
Silicon (Si) 50 250
Phosphorous (P) 300 500
PH 8.5 10.5
Figure #35

Do not use soluble oils or chromate inhibitors in John
Deere engines. Detrimental effects will occur.
To properly check inhibitor concentrations it may be
necessary to contact your local Service/Dealer for
assistance. Refer to Parts Information Section to
obtain the part number for the factory Coolant
Analysis Kit. This kit can be purchased for a
nominal fee for analyzing the conditions of the
engines coolant.

3.4.5 Procedure for Filling Engine

During filling of the cooling system, air pockets may
form. The system must be purged of air prior to
being put in service. This is best accomplished by
filling with a pre-mix solution.

Caution: Do not overfill cooling system.
A pressurized system needs space for heat
expansion without overflowing.

3.4.5.1 Engines without Coolant Recovery Tank
(Figure #35A)

Install the pressure cap, start and run engine for
approximately 5 minutes in order to purge the air
from the engine cavities.

When verifying that the coolant is at a safe operating
level, it is best to wait until the engine temperature
drops to approximately 120F (49C), or lower,
before removing the pressure cap.

Remove the pressure cap and refill to the proper fill
level. To continue the deaeration process start and
run engine until the temperature stabilizes at
approximately 160-200 (71-93 C) or run engine
for 25 minutes, whichever is longer. During this
warming process, you may see coolant coming from
the overflow tube attached at the pressure cap
location. Allow engine to cool, then remove the
pressure cap and refill to the proper fill level.

Caution: Do not remove pressure cap while coolant
is at normal operating temperatures. Possible
personal injury could result from the expulsion of hot
coolant.




Page 30 of 38


Figure #35A









3.4.5.2 Engines with Coolant Recovery Tank
(Figure #35B & #35C)

Remove pressure cap from heat exchanger and fill
the cooling system with a 50/50 coolant mixture to
pressure cap sealing surface.

Note: Use a fill rate of no more than 10 liters/min (3
gpm). Replace heat exchanger pressure cap.



Figure #35B

Remove cap from coolant recovery tank and fill the
coolant recovery tank with a 50/50 coolant mixture to
a level of 100mm (4) from bottom of the tank.
Replace cap.



Figure #35C

Start and run engine with fire pump in a no flow or
low flow condition. Run engine for approximately 1
minute. Carefully remove heat exchanger pressure
cap while engine is running.

Note: Caution should always be taken when
removing a cap from a system under pressure.

Refill cooling system to the pressure cap sealing
surface. Replace heat exchanger pressure cap.

Complete deaeration will take several warm up/ cool
down cycles. Always check appropriate coolant level
in coolant recovery bottle.



Cap
Coolant
Recovery Tank
Heat Exchanger


Page 31 of 38
3.5 ELECTRICAL SYSTEM

3.5.1 Wiring Diagrams (Only with Engine Gauge
Panel)
Run/Stop
Solenoid
Drawing
No.
Description
(DC Voltage)
Reference
Document


ETR






ETR





ETS



C07575
(JU4/6)





C07602
(JW6)




U071016
NFPA-20 and
UL/FM
engine gauge
panel
(NL Models -
Optional)

NFPA-20 and
UL/FM
engine gauge
panel
(NL Models -
Optional)

LPCB
Engine Gauge
Panel




See
Technical
Catalog
C13965

ETR = Energized to Run

Drawing No. Description
(AC Voltage)
Reference
Document
C07591
(JU4/6)






C07651
(JDFP/JW6)
NFPA-20,
UL/FM, and LPCB
Engine Jacket
Water Heater
(NL Models -
Optional)

Optional Engine
Jacket Water
Heater
(NL Models -
Optional)




See Technical
Catalog
C13965
Figure #36

3.5.2 Checking Drive Belt Tension and Adjustment

All drive belts must be adequately tightened to secure
that both the engine water pump and battery charging
alternator (when fitted) are operating efficiently.
Refer to Figure #37.


A

Figure #37

To adjust Belt Tension:
Check belt tension:
- Give at arrow must be .4 - .6 (10-15mm).
To increase tension of the water pump driving belts:
- Loosen alternator or belt tensioner mounting
bolts A and B.
- Adjust to proper belt tension.
- Tighten mounting bolts A and B.

3.5.3 Speed Switch (when supplied)

In the event of an engine overspeed, the speed switch
signals the main pump controller and also affects an
engine shutdown. The OVERSPEED RESET
(figure# 9) switch is included on the instrument
panel. Should an overspeed condition occur,
investigate the cause and make necessary corrections
before placing engine back in service. The
OVERSPEED RESET must be manually lifted to
reset.
NOTE: This reset operation must be
completed to allow a restart. If not, the
engine will not start thru the main pump
controller or manually.

OVERSPEED VERIFICATION

Hold the OVERSPEED VERIFICATION switch in
the up position. This will provide the main pump
controller with an overspeed signal and engine
shutdown at 67% of the set overspeed RPM.

Start the engine via the main pump controller; the
speed switch will generate an overspeed signal and
shutdown protecting both the engine and pump.

EXAMPLE
Rated Speed: 1760 RPM
Overspeed Shutdown: 2112 RPM (120% of
1760 RPM)
A
B
B


Page 32 of 38
Verification Shutdown: 1410 RPM (67% of
2112 RPM)

CAUTION-after verification of overspeed, lift the
OVERSPEED RESET switch and reset the main
pump controller to re-instate normal operation of the
engine and speed switch.

3.5.4 Magnetic Pick-Up (when supplied)

A magnetic pick-up, mounted in the flywheel
housing, provides the input signal for the tachometer
overspeed switch, and/or the main pump controller.
There should be a 0.03" air gap between the top of
the ring gear and the center of the magnetic pick-up.
With one tooth centered in the magnetic pick-up hole,
thread the pickup in until it touches the gear tooth
and then back it out 1/2 turn. Tighten jam nut while
holding the pickup in position. Reconnect to wiring
harness.

3.6 ENGINE SPEED ADJUSTMENT

A mechanical governor controls the engine speed.
The governor is built into the fuel injection pump. All
governors are adjusted to the rated speed at
nameplate power or maximum allowed pump load
before leaving Clarke. During Start-Up Inspection or
when placing reconditioned units into service, some
minor speed adjustment may be required. It is
recommended that this adjustment be performed by
the authorized Service Dealer representative.

To adjust the speed of the engine:

A. Start the engine by following the To Start
Engine Procedure in this manual.
B. Let the engine warm-up. Loosen the jam
nut(s) (Figure #38).
C. While observing the instrument panel tach
rotate the long adjustor clockwise to lower
the RPM and counter clockwise to raise the
RPMs until desired speed is obtained. Ref.
Figure #38.
D. Holding secure the long adjustor with a
wrench tighten the jam nut.
E. Stop engine by following To Stop Engine
Procedure in this manual.




Figure #38

4.0 MAINTENANCE SCHEDULE

4.1 ROUTINE MAINTENANCE

NOTE: The following Routine Maintenance schedule
is based on an engine usage rate not exceeding 2
hours per month. For UL/FM engine models, also
refer to NFPA25.
LEGEND:
Check
Clean
Replace
o Lubricate
WEEKLY
Air Cleaner
Battery
Coolant Hoses
Coolant Levels
Cooling Water Solenoid Valve
Exhaust System
Fuel Tank
General Inspection
Governor Run-Stop Control
Jacket Water Heater
Lubrication Oil Level
Operating Gauges
Remove Water from Fuel Filter
Run Engine
Warning Light
Radiator Core Debris
EVERY 6 MONTHS
Batteries
Battery Charging Alternator
Belts
Cooling Water Strainers
Driveshaft U-Joints
Fuel Lines
EVERY 1 YEAR
Air Cleaner
Coolant Inhibitor


Page 33 of 38
Crankcase Vent System
o Driveshaft U-Joints
Fuel & Oil Filters
Heat Exchanger Electrode
Lubricating Oil
Mounting Isolators
Wiring System
EVERY 2 YEARS
Air Cleaner
Batteries
Belts
Coolant Hoses
Coolant

IMPORTANT: Set main pump controller to OFF
while servicing engine. Before turning the main
pump controller to the "OFF" position, check with
the maintenance and security supervisors to verify
that all the departments concerned will be alerted of
the temporary interruption of their fire protection
equipment for normal maintenance or testing. Also,
alert the local fire department in the event that the
main pump controller is connected by silent alarm to
headquarters. When servicing is complete, return
main pump controller selector to "Automatic"
position and the mode selector on the engine to
Automatic position. Advise the appropriate
personnel the engine has been returned to the
Automatic.

5.0 TROUBLE SHOOTING

Consult Clarke Service Dealer or Factory. Service
dealers can be located by going to our website:
www.clarkefire.com.

6.0 PARTS INFORMATION

6.1 SPARE PARTS

To ensure best operation and efficiency of all engine
components, always use genuine Clarke spare parts.

Orders should specify:
Engine Model Number - See Engine General
Engine Serial Number - Specification
Part Number(s) Refer to Engine Maintenance
Parts List section 6.2 or Parts Illustration in
Technical Bulletin in C13886.

Contact numbers for spare parts:
www.clarkefire.com
Phone USA: (513) 719-2352 (calling within USA)
Phone UK: (44) 1236 429946 (calling outside USA)
Fax USA: (513) 771-0726 (calling within USA)
Fax UK: (44) 1236 427274 (calling outside USA)
E-Mail USA: [email protected]
E-Mail UK: [email protected]


6.2 ENGINE MAINTENANCE PARTS LIST

ENGINE
MODEL

OIL
FILTER
FUEL
FILTER
PRIMARY
FUEL
FILTER
SECONDARY

AIR
FILTER
J U4R-UF09
J U4H-UF10
J U4R-UF11
J U4H-UF12
J U4R-UF19
J U4H-UF20
J U4R-UF21
J U4H-UF22
J U4H-UF28
J U4H-UF30
J U4H-UF32
J U4H-UF40
J U4R-UF40
J U4H-UF42
J U4R-UF49
J U4H-UF50
J U4R-UF51
J U4H-UF52
J U4H-UF58
J U4H-UFH2
J U4H-UFH8
J U4H-UFH0
J U4H-AP50









C04440
or
RE59754









C02359
or
RE60021










C03249
J U4R-UF13
J U4H-UF14
J U4R-UF23
J U4H-UF24
C04521
or
RE504836
C02549
or
RE62418


C03249
J U4H-LP20
J U4H-LP50
C04440
or
RE59754

C02533

C03249
J U4H-LP24
J U4H-LP54
C04521
or
RE504836

C02533

C03249
J U4H-UF34
J U4H-UF44
J U4H-UF54
J U4R-UF53
J U4H-UF84
J U4H-AP54

C04521
or
RE504836

C02550
or
RE520842


C03249
J U6H-UF30
J U6H-UF32
J U6H-UF50
J U6H-UF52
J U6H-UF58
J U6H-UF62
J U6H-UF68
J U6H-UF60
J U6H-UFD0
J U6H-UFG8
J U6H-UFM8
J U6H-UFM0
J U6H-UFD2
J U6H-UFM2
J U6H-AP30
J U6H-AP50
J U6H-AP60






C04440
or
RE59754






C02359
or
RE60021










C03396
J U6H-LP50
J U6H-LP60
C04440
or
RE59754

C02533

C03396


Page 34 of 38
J U6H-LP54
J U6H-LP84
C04521
or
RE504836

C02533

C03396
J U6H-UF34
J U6H-UF54
J U6H-UF84
J U6H-AP34
J U6H-AP54
J U6H-AP84

C04521
or
RE504836

C02550
or
RE520842

C03396
J W6H-UF30
J W6H-UF38
J W6H-UF40
J W6H-UF48
J W6H-UF50
J W6H-UF58
J W6H-UF60
J W6H-AP30
J W6H-AP40
J W6H-AP50
J W6H-AP60





RE57394






RE508633





AR86745





C03244

ENGINE MODEL
Air Filter
Service Kit
Air Filter Oil
All 99-55050 C121157
Figure #39

7.0 OWNER ASSISTANCE

Consult Clarke Service Dealer or Factory. Service
Dealers can be located by going to our website:
www.clarkefire.com.

8.0 WARRANTY

8.1 GENERAL WARRANTY STATEMENT

The satisfactory performance of Clarke engines and
the goodwill of owners / operators of Clarke engines
are of primary concern to the Engine Manufacturer,
the Engine Service Dealer and Clarke. All provide
support of these products after final installation of the
complete fire pump and sprinkler system.

Warranty responsibility involves both Clarke and the
John Deere service organizations worldwide.

The Engine Manufacturer (John Deere) provides
Warranty for the basic engine components and Clarke
provides warranty on the accessories added to meet
the NFPA-20 specifications and FM/UL certification
requirements.

8.2 CLARKE WARRANTY

All Clarke warranted components have warranty
duration of 12 months beginning at the Start-up date
of the fire pump system. The warranty coverage
includes replacement of the part and reasonable cost
of labor for installation. Components failed due to
improper engine installation, transportation damage,
or misuse is not covered under this warranty.
For additional warranty details, see the specific
warranty statement John Deere New Engine
Warranty on the following page. Also contact
Clarke direct if you have any questions or require
additional information.

Clarke is not responsible for incidental or
consequential costs, damage or expenses which the
owner may incur as a result of a malfunction or
failure covered by this warranty.

8.3 JOHN DEERE WARRANTY

Warranty Duration

Unless otherwise provided in writing, John Deere*
makes the following warranty to the first retail
purchaser and each subsequent purchaser (if purchase
is made prior to expiration of applicable warranty) of
each John Deere new off-highway engine marketed
as part of a product manufactured by a company
other than John Deere or its affiliates:
12 months, unlimited hours of use, or
24 months and prior to the accumulation of 2000
hours of use;
and on each John Deere engine used in an off-
highway repower application:
12 months, unlimited hours of use.
Note: In the absence of a functional hourmeter,
hours of use will be determined on the basis of 12
hours of use per calendar day.

(*John Deere means Deere Power Systems Group
with respect to users in the United States, John Deere
Limited with respect to users in Canada, and Deere &
Company or its subsidiary responsible for marketing
John Deere equipment in other counties where the
user is located)

Warranty Coverage

This warranty applies to the engine and to integral
components and accessories sold by John Deere.

All John Deere-warranted parts and components of
John Deere engines which, as delivered to the
purchaser, are defective in materials and/or
workmanship will be repaired or replaced, as John
Deere elects, without charge for parts or engine repair
labor, including reasonable costs of labor to remove
and reinstall non engine parts or components of the


Page 35 of 38
equipment in which the engine is installed, and, when
required, reasonable costs of labor for engine
removal and reinstallation, if such defect appears
within the warranty period as measured from the date
of delivery to the first retail purchaser, if the delivery
is reported to John Deere within 30 days of the
delivery.

Emissions Warranties

Emissions warranties appear in the operation and
maintenance instructions furnished with the
engine/machine.
Obtaining Warranty Service

Warranty service must be requested of the nearest
authorized John Deere engine service outlet before
the expiration of the warranty. An authorized service
outlet is a John Deere engine distributor, a John
Deere engine service dealer, or a John Deere
equipment dealer selling and servicing equipment
with an engine of the type covered by this warranty.

Authorized service outlets will use only new or
remanufactured parts or components furnished or
approved by John Deere.

Authorized service locations and the name of the
John Deere division or subsidiary making this
warranty are listed in the Parts and Service Directory
for John Deere Engines.
At the time of requesting warranty service, the
purchaser must be prepared to present evidence of the
date of delivery of the engine.

John Deere reimburses authorized service outlets for
limited travel expenses incurred in making warranty
service repairs in non-John Deere applications when
travel is actually per formed. The limit, as of the date
of publication of this statement, is US $300.00 or
equivalent. If distances and travel times are greater
than reimbursed by John Deere, the service outlet
may charge the purchaser for the difference.

Warranty Exclusions

John Deeres obligations shall not apply to fuel
injection pump and nozzles during the pump and
nozzle manufacturers warranty period on the pump
and nozzles, components and accessories which are
not furnished or installed by John Deere, nor to
failures caused by such items. When the pump
manufacturers warranty is less than the engine
warranty, John Deere will reimburse pump repair
costs for warrantable-type failures during the
remainder of the original engine warranty period,
when so documented by the pump manufacturers
approved service outlet.

Purchasers Responsibilities

The cost of normal maintenance and depreciation.

Consequences of negligence, misuse, or accident
involving the engine, or improper application,
installation, or storage of the engine, or improper
application, installation, or storage of the engine.

Consequences of service performed by someone
other than a party authorized to perform warranty
service, if such service, in John Deeres judgment,
has adversely affected the performance or reliability
of the engine.
Consequences of any modification or alteration of the
engine not approved by John Deere, including, but
not limited to, tampering with fuel and air delivery
systems.

The effects of cooling system neglect as manifested
in cylinder liner or block cavitation (pitting,
erosion, electrolysis).
Any premium for overtime labor requested by the
purchaser.
Costs of transporting the engine or the equipment in
which it is installed to and from the location at which
the warranty service is performed, if such costs are in
excess of the maximum amount payable to the
service location were the warranty service performed
at the engines location.

Costs incurred in gaining access to the engine; i.e.,
overcoming physical barriers such as walls, fences,
floors, decks or similar structures impeding access to
the engine, rental of cranes or similar, or construction
of ramps or lifts or protective structures for engine
removal and reinstallation.
Incidental travel costs including tolls, meals, lodging,
and similar.

Service outlet costs incurred in solving or attempting
to solve non-warrantable problems.

Services performed by a party other than an
authorized John Deere engine service dealer, unless
required by law.


Page 36 of 38
Charges by dealers for initial engine start-up and
inspection, deemed unnecessary by John Deere when
operation and maintenance instructions supplied with
the engine are followed.

Costs of interpreting or translating services.

No Representations or Implied Warranty

Where permitted by law, neither John Deere nor any
company affiliated with it makes any guaranties,
warranties, conditions, representations or promises,
express or implied, oral or written, as to the
nonoccurrence of any defect or the quality or
performance of its engines other than those set forth
herein, and DOES NOT MAKE ANY IMPLIED
WARRANTY OR CONDITIONS OF
MERCHANTABILITY OR FITNESS otherwise
provided for in the Uniform Commercial Code or
required by any Sale of Goods Act or any other
statute. This exclusion includes fundamental terms.
In no event will a John Deere engine distributor or
engine service dealer, John Deere equipment dealer,
or John Deere or any company affiliated with John
Deere be liable for incidental or consequential
damages or injuries including, but not limited to, loss
of profits, loss of crops, rental of substitute
equipment or other commercial loss, damage to the
equipment in which the engine is installed or for
damage suffered by purchaser as a result of
fundamental breaches of contract or breach of
fundamental terms, unless such damages or injuries
are caused by the gross negligence or intentional acts
of the foregoing parties.

Remedy Limitation

The remedies set forth in this warranty are the
purchasers exclusive remedies in connection with
the performance of, or any breach of guaranty,
condition, or warranty in respect of new John Deere
engines. In the event the above warranty fails to
correct purchasers performance problems caused by
defects in workmanship and/or materials, purchasers
exclusive remedy shall be limited to payment by John
Deere of actual damages in an amount not to exceed
the cost of the engine.

No Sellers Warranty

No person or entity, other than John Deere, who sells
the engine or product in which the engine has been
installed makes any guaranty or warranty of its own
on any engine warranted by John Deere unless it
delivers to the purchaser a separate written guaranty
certificate specifically guaranteeing the engine, in
which case John Deere shall have no obligation to the
purchaser. Neither original equipment manufacturers,
engine or equipment distributors, engine or
equipment dealers, nor any other person or entity, has
any authority to make any representation or promise
on behalf of John Deere or to modify the terms or
limitations of this warranty in any way.

Additional Information

For additional information concerning the John Deere
New Off-Highway Engine Warranty, see booklet
Engine Owners Warranty Worldwide.

9.0 ATCM CALIFORNIA EMISSIONS
REGULATIONS FOR STATIONARY ENGINES

NOTICE AND DISCLAIMER
FOR STATIONARY COMPRESSION
IGNITION ENGINES INSTALLED IN
CALIFORNIA AFTER JANUARY 1, 2005

1. This Notice and Disclaimer is an addendum
to, and made a part of, Clarkes Fire
Protection Products, Inc.s (Clarke)
Standard Terms and Conditions of Sale and,
in all respects not inconsistent therewith, also
applies to all sales of stationary compression
ignition engines installed in California after
January 1, 2005.
2. Stationary diesel-fueled compression ignition
engines installed in California after January
1, 2005 are subject to Californias Airborne
Toxic Control Measure for Stationary
Compression Ignition Engines (the
ATCM), Cal. Code Regs. Title 17, Section
93115. The California Air Resources Board
(CARB) has reviewed the emissions
estimation methodology provided by Clarke
Fire Protection Products, Inc. (Clarke) and
has concluded that Clarke has used a valid
methodology for estimating the emissions
from engines supplied by Clarke and that the
engines presumptively comply with the
ATCMs emissions standards. Clarkes
methodology used existing emissions test
data associated with similar engines to
estimate the emissions produced by the
emergency fire pump engines supplied by
Clarke.


Page 37 of 38
3. CARBs determination is not binding on the
local air districts, which have primary
jurisdiction for implementing and enforcing
the ATCM. Actual test data in the field or
other information established by the local air
districts or CARB that show actual emissions
from an engine supplied by Clarke in excess
of the ATCM limitations could indicate a
violation of the ATCM and subject the seller,
owner and operator of the engine to penalties
under California law. Although Clarke
believes that the engines supplied by Clarke
comply with the ATCM based on the
available data and methodology accepted by
CARB, for the foregoing reasons, Clarke
cannot, and does not, guarantee that its
engines will comply with the ATCM
emission regulations.
4. CLARKE MAKES NO WARRANTIES OR
GUARANTIES, EXPRESS OR IMPLIED,
INCLUDING ANY WARRANTY OF
MERCHANTABILITY, FITNESS FOR A
PARTICULAR PURPOSE OR
OTHERWISE, THAT THE ENGINES
SUPPLIED BY CLARKE WILL COMPLY
WITH THE ATCM. CLARKE ALSO
EXPRESSLY DISCLAIMS THAT THE
ENGINES SUPPLIED BY CLARKE WILL,
IN FACT, COMPLY WITH THE ATCM.
IN NO EVENT SHALL CLARKE BE
LIABLE FOR SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES ARISING
OUT OF OR IN CONNECTION WITH
THESE TERMS AND CONDITIONS OR
THE ENGINES SUPPLIED BY CLARKE
OR FOR INDEMNIFICATION OF BUYER
ON ACCOUNT OF ANY CLAIM
ASSERTED AGAINST BUYER, OR FOR
ANY OTHER DAMAGE OF ANY KIND,
WHETHER DIRECT OR INDIRECT, IF
THE ENGINES SUPPLIED BY CLARKE
DO NOT COMPLY WITH THE ATCM.
5. If Buyer resells any of the goods sold under
this Agreement, Buyer shall include
language in an enforceable agreement with
its buyer that makes the language in this
Agreement, including Clarkes disclaimer of
warranties and remedies in paragraph 5,
binding on its buyer. Buyer shall defend,
indemnify and hold Clarke harmless from
any claims, causes of action, damages, losses
or expenses (including reasonable attorneys
fees) that Clarke incurs by reason of Buyers
failure to comply with this paragraph.
6. Each Clarke ATCM Compliant Fire Pump
Driver will be affixed with the following
ATCM Tier 2 Label:

7. Each Clarke ATCM Compliant Fire
Pump Driver will be stamped with new
fuel injection pump timing alignment
marks. Refer to figure #___. Original
factory timing marks will be X out.
10.0 INSTALLATION & OPERATION DATA
(See Technical Catalog C13965)

11.0 WIRING DIAGRAMS
(See Technical Catalog C13965)

12.0 PARTS ILLUSTRATION DRAWING
(See Technical Catalog C13965)

13.0 APPENDIX (Alpha Index)


























Page 38 of 38
13.0 APPENDIX (Alpha Index)

Subject Page

A
ACTM Compliant Engines 35
Air Cleaner 23,31
Alternator 29,30

B
Battery Cables 12
Battery Recommendations 12,31
Belt Adjustment 29

C
Capacities 27,28
Coolant Recommendations 27,28
Cooling System
Anti-Freeze Solutions 27,28
Cooling System Capacity 27
Cooling Water Supply (Loop) 11,14
Cooling Water Flow Requirements *
Filling Procedure 28
Heat Exchanger 11,14,31
Inhibitors 27,28,31
Maintenance 31,32
Radiator 11,14,23,31
Water 25
Crankcase Ventilation 24

D
Dipstick, Oil Level 25,26
Driveshaft alignment 11
Driveshaft Maintenance 13,31

E
Electrical System 29
Engine Models 5
Engine Out of Fuel 11
Engine Protective Systems (overspeed) 30
Engine Start-Up Service 14
Exhaust System 23

F
Filters:
Air Cleaner 23,31
Fuel 17,31
Lubricating Oil 8,6,31
Fuel Specifications 10,11
Fuel System Operation 17
Bleeding 17
Pump, Injection 4,8,22,23
Pump, Lift 14
Service 13 to 19

G
Governor Speed Adjustment 30,31

H
Heaters, Engine 11

I
Installation Data *
Installation Instructions 10


Subject Page

L
Lube Oil Recommendations 27
Lubricating Oil Volume 27
Lubricating System 25

M
Magnetic Pickup 30
Maintenance Schedule 31
Manual Operation 14
Model Number Identification 4

N
Name Plate (Engine) 4

O
Oil Filter 26
Oil Level Dipstick 25
Oil Pressure *
Oil Specifications/Recommendations 27
Operation Data *
Out Of Fuel Procedures 11
Overspeed Reset 30
Overspeed Verification 30

P
Parts Illustrations *
Parts Information 31
Preventive Maintenance Schedule 31
Pump:
Fuel Injection Pump 4,18,22,23
Fuel Lift Pump 14

S
Serial Number 4
Shutdown Systems 30
Specifications:
Fuel 11
Lubrication Oil 27
Speed Switch 30
Storage 10


T
Technical Data *

W
Warranty 32
Wiring Diagram:
DC System 29*
AC Heater Systems 29*










* See Technical Catalog C13965