Operation And Maintenance Instructions Manual
Operation and MaintenanceInstructions ManualJU/JW MODEL ENGINESFORFIRE PUMP APPLICATIONSThis manual covers John Deere Enginesprepared by Clarkefor fire pump serviceClarke UK, Ltd.Unit 1, Grange WorksLomond RoadCoatbridgeML5 2NNUnited KingdomTELE: 44(0)1236 429946FAX: 44(0)1236 427274Clarke Fire Protection Products, Inc.3133 E. Kemper RoadCincinnati, OH 45241U.S.A.TELE: 1.513.771.2200FAX: 1.513.771.0726www.clarkefire.comMP-7 12/06C13960 rev G
CONTENTSSUBJECTPAGE1.0 INTRODUCTION41.1 IDENTIFICATION/NAMEPLATE41.2 SAFETY/CAUTION/WARNINGS592.0 INSTALLATION/OPERATION92.1 TYPICAL INSTALLATION102.2 ENGINE STORAGE3.02.2.1 Storage Less than 1 year102.2.2 Extended Storage Maintenance Procedure102.3 INSTALLATION INSTRUCTIONS102.4 SPECIFIC FLYWHEEL COUPLING ALIGNMENT INSTRUCTIONS122.4.1 Driveshaft122.4.2 Other Coupling Types132.5 WEEKLY TEST142.6 STARTING/STOPPING THE ENGINE142.6.1 Special Notes to Equipment Installer of an LPCB Approved (LPS1239) Engine Model142.6.2 To Start Engine142.6.3 To Stop Engine1717ENGINE SYSTEMS173.1 FUEL SYSTEM3.1.1 Bleeding the Fuel System173.1.1.1 JU4/6 UF, NL173.1.1.2 JU4/6 LP183.1.1.3 JW6 UF, NL183.1.2 Draining the Condensate from the Fuel Filter203.1.3 Changing Fuel Filter Cartridge203.1.3.1 JU4/6 UF, NL203.1.3.2 JU4/6 LP213.1.3.3 JW6 UF, NL213.1.4 Fuel Tanks223.1.5 JU Fuel Injection Pump Components223.1.6 JW Fuel Injection Pump Components23233.2 AIR/EXHAUST SYSTEM3.2.1 Ambient Conditions233.2.2 Ventilation233.2.3 Standard Air Cleaner233.2.4 Crankcase Ventilation243.2.4.1 Open Crankcase Ventilation243.2.4.2 Crankcase Ventilation System24Page 2 of 38
3.2.5 Exhaust System25253.3 LUBRICATION SYSTEM3.3.1 Checking Sump Oil253.3.2 Changing Engine Oil263.3.3 Changing Oil Filter Cartridge263.3.4 Oil Specification263.3.5 Oil Capacities27273.4 COOLING SYSTEM3.4.1 Engine Coolant273.4.2 Water273.4.3 Coolant Capacities273.4.4 Coolant Inhibitors273.4.5 Procedure for Filling Engine283.4.5.1 Engines without Coolant Recovery Tank283.4.5.2 Engines with Coolant Recovery Tank29303.5 ELECTRICAL SYSTEM3.5.1 Wiring Diagrams303.5.2 Checking Drive Belt Tension and Adjustment303.5.3 Speed Switch303.5.4 Magnetic Pick-Up31313.6 ENGINE SPEED ADJUSTMENT4.031MAINTENANCE SCHEDULE314.1 ROUTINE MAINTENANCE5.0TROUBLE SHOOTING326.0PARTS INFORMATION326.1 SPARES326.2 ENGINE MAINTENANCE PARTS LIST327.0OWNER ASSISTANCE338.0WARRANTY338.1 GENERAL WARRANTY STATEMENT338.2 CLARKE WARRANTY338.3 JOHN DEERE WARRANTY339.0ATCM CALIFORNIA EMISSION REGULATIONS FOR STATIONARY ENGINES3510.0INSTALLATION & OPERATION DATA (See Technical Catalog C13965)3611.0WIRING DIAGRAMS (See Technical Catalog C13965)3612.0PARTS ILLLUSTRATION (See Technical Catalog C13965)3613.0APPENIX (Alpha Index)37Page 3 of 38
Check factory availability for a manual in one of the following -7C13961C13962C13963C13964NOTEThe information contained in this book is intended to assist operating personnel by providinginformation 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 withoutnotice.Page 4 of 38
efficiently, and perform routine servicing correctly.Please read it carefully.1.0 INTRODUCTIONSCOPE OF SUPPLYMODEL NUMBERING & IDENTIFICATIONThe following paragraphs summarize the “Scope ofSupply” of the Engine: The CLARKE Engine supplied has beendesigned for the sole purpose of driving astationary Emergency Fire Pump. It must notbe used for any other purpose. Shall not be subjected to Horsepowerrequirements greater than the certifiednameplate rating (for UL/cUL/FM/LPCBonly). Engines must be sized to cover fully themaximum power absorbed by any particulardriven equipment together with a safetyfactor on no less than 10%. (For Non-listedonly). Derates for elevation and temperature need tobe considered for maximum pump power. Fuel delivery settings are factory set with-inthe injection pump and must not be tamperedwith or adjusted. Minor RPM adjustments tomeet pump requirements are permissible. The engine shall be installed and maintainedin accordance with the guidelines stated inthis manual and technical catalog (C13965). There are two identification plates attached to eachengine. Clarke Identification Plate: Engine Model,Serial Number, Rating and Date of Manufacture areshown on this identification plate. The JU Seriesidentification plate is mounted on the flywheelhousing at the rear of the engine. The JW Seriesidentification plate is mounted on right rear enginemount.Note that there are five types of identification plates,dependent on whether the engine is a “Non-Listed”or “Listed/Approved” Model. These are typicalexamples. (See Figure #1).Clarke Identification PlatesUSA Non ListedUSA Listed/ApprovedUK Non-ListedUK Listed/ApprovedPeriodic running checks to ensurefunctionality should be kept to a maximum of½ hour per week.1.1 IDENTIFICATION/NAMEPLATE Throughout this manual, the terms “Engine”and “Machine” are used. The term “Engine” refers solely to the dieselengine driver as supplied by CLARKE. The term “Machine” refers to any piece ofequipment with which the engine mightinterface.Figure #1This manual provides all the information necessary tooperate your newly acquired engine safely andPage 5 of 38
BASIC RULESUK Listed/ApprovedThe following recommendations are given to reducethe risk to persons and property when an engine is inservice or out of service.Engines must not be used for applications other thanthose declared under “Scope of Supply”.Figure #1 cont’dClarke model numbers reflects the base engine type,number of cylinders, cooling system, approval listingand a power rating code.Example: JU6H-UF50 J John Deere base engine prepared byCLARKE U base engine series (4.5 liter 4 cylinder or6.8 liter 6 cylinder) 6 number of cylinders H Heat Exchanger cooled (R Radiator) UF Underwriters Laboratories Listed/Factory Mutual Approved, (LP LPCB LossPrevention Council Board Approved, NL Non-Listed) 50 A power rating codeJohn Deere Identification Plate: The secondidentification plate contains the John Deere ModelNumber and Serial Number. On the JW Series, theJohn Deere Serial identification plate is located onthe left-hand side of the engine between the intakemanifold and starting motor. On the JU Series, theJohn Deere identification plate is located on the rightside of the cylinder block behind the fuel filter.1.2 SAFETY/CAUTION/WARNINGSIncorrect handling, modifications and use of nonoriginal parts may affect safety. When lifting theengine, take care to use suitable equipment to beapplied to the points specially provided as shown onthe appropriate Engine Installation Drawing. Engineweights are shown in figure #2ENGINE MODELJU4H-UF10, 12, 20, 22JU4H-NL20, 22JU4H-LP20,24JU4H-UF30, 32, 40, 42, 50, 52,8H, H0, H2, 58JU4H-NL30, 32, 40, 42JU4H-LP50,54JU4H-LP84WEIGHT lbs (kg)910 (413)JU4R-UF09, UF11,13,19,21,23JU4R-UF40, 49, 51, 53JU6H-UF30, 32, 50, 52D0, D2, G8, M8, M0, M2, 58JU6H-NL30, 32, 50, 52JU6H-LP50,54JU6H-UF60, 62, 68JU6H-LP60,84JW6H-UF30 (JDFP-06WA), 38JW6H-NL30JW6H-UF40 (JDFP-06WR), 48JW6H-NL40JW6H-UF50, 60, 58JW6H-NL50, 60935 (424)1085 (492)956 (434)982 (445)1657 (750)1693 (766)2012 (910)2003 (906)2053 (929)Figure #2Figure #3 shows the typical lifting arrangement of abare engine. Note the lifting points on the engine arefor lifting the engine only. Caution, when lifting, liftpoint should always be over the equipment Center ofGravity.ATTENTION:This engine has components andfluids that reach very high operating temperaturesand is provided with moving pulleys and belts.Approach with caution. It is the responsibility of thebuilder of the machine using a Clarke engine tooptimize the application in terms of maximum enduser safety.Page 6 of 38
When Clarke furnishes the base (or module) for theengine and pump set, the combined weight of theengine and base (or module) will be indicated on theunit. Caution, when lifting, lift point shouldalways be over the equipment Center of Gravity.Note: The engine produces a noise level exceeding70 dB(a). When performing the weekly functionaltest, it is recommended that hearing protection beworn by operating personnel.CLARKE UK provides the machine manufacturerwith a “Declaration of Incorporation”for the Engine, when required, a copy of which isenclosed in the manual. This document clearly statesthe machine manufacturers’ duties andresponsibilities with respect to health and safety.Refer to Figure #5.Figure #3Figure #4 shows the typical lifting arrangement of abase mounted engine and pump set when the base (ormodule) is furnished with lifting holes.Figure #4Page 7 of 38
GRANGE WORKS, LOMOND ROAD, COATBRIDGE, UNITED KINGDOM, ML5 2NNTEL: 0044 1236 429946FAX: 0044 1236 427274DECLARATION OF INCORPORATIONWe hereby declare that the following engine is intended to be incorporated into other machinery and must not be put into service untilthe relevant machinery, into which it is to be incorporated has been declared in conformity with the essential health and safetyrequirements of the Machinery Directive 89/392/EEC.Description: -DIESEL ENGINESModel: 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 anelectrical 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 SPECIFICATIONSSigned:Date:REGISTERED IN SCOTLAND NO: 81670C13896, Rev C, 3 Jan 2003Figure #5following general advice is given for the provision offirst aid.WHAT TO DO IN AN EMERGENCYAny user of the Engine who follows the instructionsset out in this manual, and complies with theFIREinstructions on the labels affixed to the engine areworking in safe conditions.Put out the fire using extinguishers recommended bythe manufacturer of the machine or the installation.If operating mistakes cause accidents call for helpIf operating mistakes cause accidents call for helpimmediately from the EMERGENCY SERVICES.In the event of an emergency, and while awaiting thearrival of the EMERGENCY SERVICES, theBURNS1) Put out the flames on the clothing of theburns victim by means of: drenching with waterPage 8 of 38
use of powder extinguisher, makingsure not to direct the jets onto theface blankets or rolling the victim on theground2) Do not pull off strips of clothing that aresticking to the skin.3) In the case of scalding with liquids, removethe soaked clothing quickly but carefully.4) Cover the burn with a special anti-burnpacket or with a sterile bandage.CARBON MONOXIDE POISONING (CO)Carbon monoxide contained in engine exhaust gasesis odorless and dangerous because it is poisonous andwith air, it forms an explosive mixture.Carbon monoxide is very dangerous in enclosedpremises because it can reach a critical concentrationin a short time.When attending a person suffering from COpoisoning in enclosed premises, ventilate thepremises immediately to reduce the gasconcentration.When accessing the premises, the person providingthe aid must hold his breath, not light flames, turn onlights or activate electric bells or telephones so as toavoid explosions.Take the victim to a ventilated area or into the openair, placing him on his side if he is unconscious.CAUSTIC BURNS1) Caustic burns to the skin are caused by acidescaping from the batteries: remove the clothes wash with running water, beingcareful not to affect injury-free areas2) Caustic burns to the eyes are caused bybattery acid, lubricating oil and diesel fuel. Wash the eye with running water forat least 20 minutes, keeping theeyelids open so that the water runsover the eyeball and moving the eyein all directions.ELECTROCUTIONElectrocution can be caused by:1) The engine’s electrical system (12/24VDC)2) The electrical coolant pre-heating system120/240 Volt AC (if supplied) AC current.In the first case, the low voltage does not involvehigh current flows through the human body;however, if there is a short circuit, caused by a metaltool, sparks and burns may occur.In the second case, the high voltage causes strongcurrents, which can be dangerous.If this happens, break the current by operating theswitch before touching the injured person.If this is not possible, bear in mind that any otherattempt is highly dangerous also for the personassisting; therefore, any attempt to help the victimmust be carried out without fail using means that areinsulating.WOUNDS AND FRACTURESThe wide range of possible injuries and the specificnature of the help needed means that the medicalservices must be called.If the person is bleeding, compress the woundexternally until help arrives.In the case of fracture do not move the part of thebody affected by the fracture. When moving aninjured person permission from that person must bereceived until you can help him. Unless the injury islife threatening, move the injured person withextreme care and then only if strictly necessary.WARNING LABELSWarning labels, in picture form, are applied to theengine. Their meanings are given below.Important Note: Labels that show an exclamationmark indicate that there is a possibility of danger.Page 9 of 38
Heat Exchanger Maximum Working PressureCoolant MixtureLifting PointJacket Water Heater VoltageAir Filter Installation2.0 INSTALLATION/OPERATION2.1 TYPICAL INSTALLATIONAutomatic StartA typical Fire Pump installation is shown in Figure#6 & 6A.1. Pump/Engine set2. Main Pump Controller3. Pump discharge4. Air louver5. Entrance door with air louver6. Exhaust silencer7. Exhaust system supports8. Exhaust outlet pipe9. Concrete base10. Exhaust flexible connection joint/pipe11. Air Discharge Duct from RadiatorRotating PartsFigure #6Typical InstallationHeat Exchanger Cooled EnginePage 10 of 38
8) Start and run the engine at a slow speed for1-2 minutes being careful not to exceed thenormal operating temperature.9) Drain the oil and coolant.10) Replace the protective plugs that were usedfor shipping and storage.11) Attach to the engine a visible card, specifying“ENGINE WITHOUT OIL” DO NOTOPERATE”.11Figure #6ATypical InstallationRadiator Cooled EngineIMPORTANT: THIS TREATMENT MUST BEREPEATED EVERY 6 MONTHS************************PUTTING ENGINE INTO SERVICE AFTERADDITIONAL PRESERVATION SERVICE:To restore the normal operation running conditions ofthe engine, carry out the following:2.2 ENGINE STORAGE2.2.1 Storage less than 1 yearStoring engines requires special attention. Clarkeengines, as prepared for shipment, may be stored fora minimum of one year. During this period, theyshould be stored indoors in a dry environment.Protective coverings are recommended provided theyare arranged to allow for air circulation. The storedengine should be inspected periodically for obviousconditions such as standing water, part theft, excessdirt buildup or any other condition that may bedetrimental to the engine or components.Any such conditions found must be correctedimmediately.2.2.2 Extended Storage Maintenance ProcedureAfter a one year storage period or if the engine isbeing taken out of service for more than 6 months,additional preservation service must be performed asfollows:1) Drain the engine oil and change the oil filter.2) Refill the engine crankcase with MIL-L21260 preservative oil.3) Change the fuel filter.4) Install the coolant plugs and install coolant inthe normal mix percentage of 50% coolant,50% water, premixed.5) Remove the protection from the intake andexhaust openings.6) Prepare a container as a fuel source using amixture 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 fromthe pump.1) Fill the engine sump with the normalrecommended oil, to the required level.2) Remove the protective plugs used forshipping 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 InstallationInstructions when the engine will be put intoservice.2.3 INSTALLATION INSTRUCTIONSThe correct installation of the engine is veryimportant to achieving optimum performance andextended engine life.In this respect, the engine has certain installationrequirements, which are critical to how it performs.These requirements are generally associated with thecooling, exhaust, induction air, and fuel systems.This section of the manual should be read inconjunction with the relevant Installation andOperation Data Sheets. If there is any doubt about aninstallation, contact should be made with ClarkeCustomer Support giving exact details of theproblem.All installations should be clean, free of any debrisand dry. Care should be taken to ensure that there iseasy access to the engine for maintenance and repair.The safety of personnel who may be in the area of thePage 11 of 38
engine when it is running is of paramount importancewhen designing the installation layout.1) Secure pump set to foundation and completeinstallation in accordance with pumpmanufacturer’s instructions. Perform engineto-pump coupling alignment. Lubricate Falkcoupling with supplied grease or driveshaftuniversal joints with NLGI grade #1 or #2grease at the (3) Zerk fittings. (Refer tosection 2.4 for specific alignmentinstructions).2a) Engine with Heat Exchanger Cooling:Install the heat exchanger discharge pipe.The discharge pipe should be no smaller thanthe outlet connection on the heat exchanger.Discharge water piping should be installed inaccordance with applicable codes. Allplumbing connecting to the heat exchangermust be secured to minimize movement bythe engine. Cooling loop water pressure tothe heat exchanger must not exceed the limitthat is stated on the heat exchanger suppliedwith the engine.2b) EnginewithRadiatorCooling:Connect radiator air discharge ducting toradiator duct flange. Discharge ductingshould be installed in accordance withapplicable codes. A flexible duct sectionshould be provided to isolate engine frombuilding.3) Install all engine cooling system draincocksand r HeaterJU4/6H,draincockinlet tubeJU4/6R11/8”Coolant heaterJDFP,draincockinlet tubeJW61PlugOil CoolerJU4/6H,RE46686JU4/6R13/8” pipe plug Heat exchangerJDFP,JW61ElectrodeBottom of heatJU4/6Hplugexchanger4) Fill engine cooling system with premixed50% water / 50% coolant solution. Use onlycoolantsmeetingASTM-D4985specifications for heavy-duty diesel engines.Never use light-duty or automotive coolantsin the engine that are stated as ASTM-D3306only. Refer to Figure #34 in section 3.4.3Page 12 of 385)6)7)8)9)10)for cooling system capacity. Refer to section3.4.5 for filling procedure.Engine is shipped with oil installed. Formake-up oil specification refer to section 3.3Lubrication System.Connect fuel supply and return line to fuelsupply tank plumbing. Reference the FuelSystem section of the Installation andOperation Data in the Technical Catalog, forpiping size, maximum allowable fuel pumpsuction, and maximum allowable fuel headrequirements. Fill supply tank with #2 dieselfuel (ASTM D-975) or BS 2869 Class A2“Red” diesel fuel, bleed supply system of airand check for leaks. Fuel supply level mustmeet applicable code requirements. Do notuse a copper based or galvanized material forany component of a diesel fuel system. Thefuel will chemically react with the zincresulting in clogged fuel filters and injectorsystems.Remove protective covering on air cleanerelement.Connect jacket water heater (if supplied) toAC power source. For JU4/6 S
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
Operation and Maintenance Manual Excerpt. SEBU8019-05 October 2010 Operation and Maintenance Manual 246C, 256C, 262C and 272C Skid Steer Loaders JAY1-Up (246C) DWS1-Up (256C) MST1-Up (262C) RED1-Up (272C) SAFETY.CAT.COM. 130 SEBU8019-05 Maintenance Section Maintenance Interval Schedule i04112615
The Bobcat Filter Reference Guide is subject to change. Consult your Operation & Maintenance Manual for maintenance intervals and additional maintenance items. . Consult your Operation & Maintenance Manual for maintenance intervals and additional maintenance items. Skid-Steer Loader: Air Filter (Inner) . 843B: 6598362 6598492: 6659329 .
The following stormwater facility maintenance table (See ODOT Maintenance Guide) should be used to maintain the facility outlined in this Operation and Maintenance Manual or follow the Maintenance requirements outlined in Appendix C when proprietary structure is selected below: Table 1 (general maintenance) Table 2 (stormwater ponds)
INTRODUCTION This manual provides safe and reliable instructions for the installation, operation and maintenance of your Ingersoll-Rand air compressor. Carefully read this manual before attempting to operate or perform any maintenance. If you are uncertain about any of the instructions or procedures provided in this manual, contact Ingersoll-Rand.
Installation, Operation, and Service Instructions Installation, Operation and Maintenance Instructions for your Cryo-Torr vacuum pump provides easily accessible information. All personnel with installation, operation, and servicing responsibilities should become familiar with the contents of these instructions to ensure safe, reliable
Operating & Maintenance Manual Safety 12 Book: 46490694 (02-2011) Rev B Safety Precautions General Ensure that the operator reads and underst ands the decals and consults the manuals before maintenance or operation. Ensure that the Operation and Maintenance manual, and manual holder if equipped, are not removed permanently from the machine.
the Operation and Maintenance Manual except for the interval and the maintenance items in that interval. Major repairs should only be carried out by . and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in serious injury or death. Illustration 1 g01154807
the Operation and Maintenance Manual except for the interval and the maintenance items in that interval. Major repairs should only be carried out by . and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in serious injury or death. i02328435
