Engine Manual - Clark

Operation and Maintenance
Instructions Manual
JU/JW/JX MODELS
ELECTRONIC 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 TELE: +1.513.771.2200 Ext. 427
FAX: +44(0)1236 427274 FAX: +1.513.771.5375
www.clarkefire.com
C132678
6/15
RevX
CONTENTS
SUBJECT PAGE
1.0 INTRODUCTION 6
1.1 IDENTIFICATION/NAMEPLATE 6
1.2 SAFETY/CAUTION/WARNINGS 7
1.3 PRECAUTIONS FOR WELDING 11
2.0 INSTALLATION/OPERATION 11
2.1 TYPICAL INSTALLATION 11
2.2 ENGINE STORAGE 12
2.2.1 Storage Less than 1 year 12
2.2.2 Extended Storage Maintenance Procedure 12
2.3 INSTALLATION INSTRUCTIONS 12
2.4 SPECIFIC FLYWHEEL COUPLING ALIGNMENT INSTRUCTIONS 14
2.4.1 Driveshaft 14
2.4.2 Falk “Steelflex” Coupling 16
2.5 WEEKLY TEST 16
2.6 STARTING/STOPPING THE ENGINE 16
2.6.1 To Start Engine 16
2.6.2 To Stop Engine 16
2.6.3 Describing Engine Gauge Panel 19
2.6.3.1 ECM Selector Switch and Primary/Alternate Electronic Control Modules (ECM’s) 19
2.6.3.2 Dual ECM Automatic Switching 19
2.6.3.3 Using PowerView Gauge 20
3.0 ENGINE SYSTEMS 29
3.1 FUEL SYSTEM 29
3.1.1 Bleeding the Fuel System 29
3.1.1.1 JU4/6 Engine Series 30
3.1.1.2 JW6H Engine Series 30
3.1.1.3 JX6H Engine Series 30
3.1.2 Changing Fuel Filter Cartridge 31
3.1.2.1 JU4/6 Engine Series 31
3.1.2.2 JW6 Engine Series 32
3.1.2.3 JX6 Engine Series 33
3.1.3 Restarting Engine which has run out of Fuel 34
3.1.4 Fuel Tanks 37
3.2 AIR/EXHAUST SYSTEM 37
3.2.1 Ambient Conditions 37
3.2.2 Ventilation 37
3.2.3 Standard Air Filter 37
3.2.4 Crankcase Ventilation 38
3.2.5 Exhaust System 39
Page 2 of 65
3.3 LUBRICATION SYSTEM 40
3.3.1 Checking Sump Oil 40
3.3.2 Changing Engine Oil 40
3.3.3 Changing Oil Filter Cartridge 40
3.3.4 Oil Specification 41
3.3.5 Oil Capacities 41
3.4 COOLING SYSTEM 41
3.4.1 Intended Engine Operating Temperature 41
3.4.2 Engine Coolant 41
3.4.3 Water 41
3.4.4 Coolant Capacities 42
3.4.5 Coolant Inhibitors 42
3.4.6 Procedure for Filling Engine 42
3.4.7 Providing Raw Water Supply to the Engine Heat Exchanger 43
3.4.7.1 Raw Water Supply 43
3.4.7.2 Cooling Loop 43
3.4.7.3 Setting Raw Water Flow Rate 44
3.4.7.4 Raw Water Outlet 45
3.4.7.5 Raw Water Quality Strainers, Deterioration of Heat Exchanger (CAC) 45
3.4.7.6 Backflow Preventers 45
3.4.7.7 Raw Water Outlet Temperature 45
3.4.8 Flow Paths of Engine Cooling System 46
3.4.9 Important Service Notice 46
3.4.9.1 Water Pump Cavitation 47
3.5 ELECTRICAL SYSTEM 47
3.5.1 Wiring Diagrams 47
3.5.2 Checking Drive Belt Tension and Adjustment 47
3.5.3 Engine Overspeed 48
3.5.4 Field Simulation of Pump Controller Alarms 48
3.5.5 Battery Requirements 48
3.6 ENGINE SPEED ADJUSTMENT 48
4.0 MAINTENANCE SCHEDULE 49
4.1 ROUTINE MAINTENANCE 49
5.0 TROUBLE SHOOTING 49
5.1 DIAGNOSTIC TROUBLE CODES 50
6.0 PARTS INFORMATION 51
6.1 SPARE PARTS 51
6.2 ENGINE MAINTENANCE PARTS LIST 51
7.0 OWNER ASSISTANCE 52
8.0 WARRANTY 52
8.1 GENERAL WARRANTY STATEMENT 52
Page 3 of 65
8.2 CLARKE WARRANTY 52
8.3 JOHN DEERE WARRANTY 52
9.0 INSTALLATION & OPERATION DATA (See Page 5) 55
10.0 WIRING DIAGRAMS (See Page 5) 55
11.0 PARTS ILLUSTRATION & DRAWINGS (See Page 5) 55
12.0 KEYWORD INDEX 56
13.0 APPENDIX “A” 57
Check factory availability for a manual in one of the following languages:
Spanish German French Italian
NOTE
The information contained in this book is intended to assist operating personnel by providing information
on the characteristics of the purchased equipment. It does not relieve the user of their responsibility of
using accepted practices in the installation, operation, and maintenance of the equipment.
NOTE: CLARKE FPPG Reserves the right to update the contents of this publication without notice.
Page 4 of 65
Technical Catalog Discontinuation Notice
Effective January 2015,
Clarke has done away with the Technical Catalogs. The Technical Catalogs consisted of the
following technical documents:
o Model Specific Installation and Operations Data (I&O)
o NFPA20 Cooling Loop C13977
o NFPA20 Lead Acid Battery Specifications C131885
o NFPA20 Exhaust Piping C06918
o NFPA20 Fuel Line Plumbing C132026
o DC Jacket Water Heater Wiring Diagrams
o AC Wiring Diagrams
o Parts Illustration
o Language Translation Pages
All the above can be located on www.clarkefire.com as follows:
 For all documents listed above, use the following steps to get to the document pages that
you are looking for:
Page 5 of 65
1.0 INTRODUCTION There are two identification plates attached to each
engine. Clarke Identification Plate: Engine Model,
The following paragraphs summarize the “Scope of Serial Number, Rating and Date of Manufacture are
Supply” of the Engine: shown on this identification plate. The JU Series
identification plate is mounted on the flywheel
 The CLARKE Engine supplied has been housing at the rear of the engine. The JW Series
designed for the sole purpose of driving a identification plate is mounted on right rear engine
stationary Emergency Fire Pump. It must mount. The JX Series identification plate is
not be used for any other purpose. mounted on the flywheel housing at the rear of the
engine.
 Shall not be subjected to Horsepower Note that there are two types of Clarke identification
requirements greater than the certified plates, dependent on whether the engine is a “Non-
nameplate rating (for UL/cUL/FM only). Listed” or “Listed/Approved” Model. These are
typical examples. (See Figure #1)
 Engines must be sized to cover fully the
maximum power absorbed by any particular Clarke Identification Plates
driven equipment together with a safety USA Non Listed USA
factor on no less than 10%. (For Non-listed Listed/Approved
only).
 Derates for elevation ambient and

temperature need to be considered for
maximum pump power.
 Fuel delivery settings are factory set and

must not be tampered with or adjusted.
Minor RPM adjustments to meet pump
requirements are permissible.
 The engine shall be installed and maintained

in accordance with the guidelines stated in Figure #1
this manual.
Clarke model number reflects the base engine type,
 Periodic running checks to ensure number of cylinders, cooling system, approval
functionality should be kept to a maximum listing and a power rating code.
of ½ hour per week. Example: JX6H-UFAD50
1.1 IDENTIFICATION/NAMEPLATE  J = John Deere base engine

 X = base engine series (12.5 liter)
 Throughout this manual, the terms “Engine”  6 = number of cylinders
and “Machine” are used.  H = Heat Exchanger cooled (R = Radiator)
 UF = Underwriters Laboratories Listed/
 The term “Engine” refers solely to the diesel Factory Mutual Approved, (NL = Non-
engine driver as supplied by CLARKE. Listed)
 A = Manufacture Location
 The term “Machine” refers to any piece of  D = Tier 3, A = Non-Emissionized
equipment with which the engine might  50 = A power rating code
interface.
John Deere Identification Plate: The second
This manual provides all the information necessary identification plate contains the John Deere Model
to operate your newly acquired engine safely and Number and Serial Number. On the JW Series, the
efficiently, and perform routine servicing correctly. John Deere Serial identification plate is located on
Please read it carefully. the left-hand side of the engine between the intake
MODEL NUMBERING & IDENTIFICATION
Page 6 of 65
manifold and starting motor. On the JU Series, the JU6H-UFADP0 1902
John Deere identification plate is located on the right JU6H-UFADQ0 1902
side of the cylinder block behind the fuel filter. On JU6H-UFADR0 1902
the JX Series, the John Deere Serial identification JU6H-UFADS0 1902
plate is located on the left-hand side of the engine JU6H-UFAD98 1902
between the intake manifold and starting motor. JU6H-UFADR8 1902
JU6H-UFADS8 1902
1.2 SAFETY/CAUTION/WARNINGS JU6H-UFADW8 1902
JU6H-UFADX8 1902
ATTENTION: This engine has components and JW6H-UFAD80 2094
fluids that reach very high operating temperatures
JW6H-UFADB0 2094
and is provided with moving pulleys and belts.
JW6H-UFADD0 2094
Approach with caution. It is the responsibility of the
JW6H-UFADF0 2094
builder of the machine using a Clarke engine to
JW6H-UFADJ0 2094
optimize the application in terms of maximum end
user safety. JW6H-UFAD70 2094
*JW6H-UFAA60 2094
BASIC RULES *JW6H-UFAAM8 2094
*JW6H-UFAA80 2094
The following recommendations are given to reduce JX6H-UFADF0 3315
the risk to persons and property when an engine is in JX6H-UFAD60 3315
service or out of service. JX6H-UFADK0 3315
JX6H-UFADN0 3315
Engines must not be used for applications other than JX6H-UFADP0 3315
those declared under “Scope of Supply”. JX6H-UFAD88 3315
Figure #2
Incorrect handling, modifications and use of non-
original parts may affect safety. When lifting the * Non-Emissionized
engine, take care to use suitable equipment to be
applied to the points specially provided as shown on Figure #3 shows the typical lifting arrangement of a
the appropriate Engine Installation Drawing. Engine bare engine. Note the lifting points on the engine
weights are shown in figure #2 are for lifting the engine only. Caution, when lifting,
lift point should always be over the equipment
ENGINE MODEL WEIGHT lbs (kg) Center of Gravity.
JU4H-UFAD4G 1490
JU4H-UFAD5G 1490
JU4H-UFAD58 1490
JU4H-UFADJG 1490
JU4H-UFADP0 1490
JU4H-UFADR0 1490
JU4H-UFADW8 1490
JU4H-UFADY8 1490
JU4H-UFAD98 1490
JU6H-UFADK0 1747
JU6H-UFADN0 1747
JU6H-UFAD58 1747 Figure #3
JU6H-UFADNG 1747
JU6H-UFADP8 1747 Figure #4 shows the typical lifting arrangement of a
JU6H-UFAD88 1747 base mounted engine and pump set when the base
JU6H-UFADM8 1747 (or module) is furnished with lifting holes.
JU6H-UFADMG 1747
JU6H-UFADT0 1902
Page 7 of 65
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 65
3133 East Kemper Road • Cincinnati, Ohio • 45241 • USA
Tel: +1 (513) 771-2200 • Fax: +1 (513) 771-0726
DECLARATION OF INCORPORATION
We hereby declare that the engine is intended to be incorporated into other machinery and must not be put
into service until the relevant machinery, into which the engine is to be incorporated, has been declared in
conformity with the essential health and safety requirements of the machinery Directive 2006/42/EC and
consequently the conditions required for the CE Mark.
We declare that the engine is manufactured in accordance with the following Standards and
Directives:
Directive 2006/42/EC, 2004/108/EC, 2006/95/ECEC
Standards EN ISO 12100:2010, EN 60204-1:2006
1) Description – Diesel Engines

Manufacturer – Clarke Fire Protection Products, USA
Model Number –
Serial Number –
Year of Manufacture –
Contract Number –
Customer Order Number –
2) The 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.
3) The engine produces harmful gases, noise and vibration and it is necessary to
take suitable precautionary measures when moving, installing and operating the
engine to reduce risk associated with the characteristics stated above.
4) The engine must be installed in accordance with local laws and regulations. The
engine must not be started and operated before the machinery into which it is to
be incorporated and/or its overall installation has been made to comply with local
laws and regulations. The engine must only be used in accordance with the scope
of supply and the intended applications.
Signed ___________________________________ Date: _______________

Ken Wauligman – Engineering Manager
C13944_rev. E 16July12
Figure #5
Page 9 of 65
WHAT TO DO IN AN EMERGENCY CAUSTIC BURNS
Any user of the Engine who follows the instructions 1) Caustic burns to the skin are caused by acid
set out in this manual, and complies with the escaping from the batteries:
instructions on the labels affixed to the engine are  remove the clothes
working in safe conditions.  wash with running water, being
careful not to affect injury-free areas
If operating mistakes cause accidents call for help 2) Caustic burns to the eyes are caused by
If operating mistakes cause accidents call for help battery acid, lubricating oil and diesel fuel.
immediately from the EMERGENCY SERVICES.  Wash the eye with running water for
In the event of an emergency, and while awaiting the at least 20 minutes, keeping the
arrival of the EMERGENCY SERVICES, the eyelids open so that the water runs
following general advice is given for the provision of over the eyeball and moving the eye
first aid. in all directions.
FIRE ELECTROCUTION
Put out the fire using extinguishers recommended by Electrocution can be caused by:
the manufacturer of the machine or the installation.
1) The engine’s electrical system (24VDC)
BURNS
1) Put out the flames on the clothing of the 2) The coolant pre-heating system 120/240 Volt
burns victim by means of: AC (if supplied).
 drenching with water
 use of powder extinguisher, making In the first case, the low voltage does not involve
sure not to direct the jets onto the high current flows through the human body;
face however, if there is a short circuit, caused by a metal
 blankets or rolling the victim on the tool, sparks and burns may occur.
ground In the second case, the high voltage causes strong
2) Do not pull off strips of clothing that are currents, which can be dangerous.
sticking to the skin. If this happens, break the current by operating the
3) In the case of scalding with liquids, remove switch before touching the injured person.
the soaked clothing quickly but carefully.
4) Cover the burn with a special anti-burn If this is not possible, bear in mind that any other
packet or with a sterile bandage. attempt is highly dangerous also for the person
assisting; therefore, any attempt to help the victim
CARBON MONOXIDE POISONING (CO) must be carried out without fail using means that are
insulating.
Carbon monoxide contained in engine exhaust gases
is odorless and dangerous because it is poisonous and WOUNDS AND FRACTURES
with air, it forms an explosive mixture.
The wide range of possible injuries and the specific
Carbon monoxide is very dangerous in enclosed nature of the help needed means that the medical
premises because it can reach a critical concentration services must be called.
in a short time. If the person is bleeding, compress the wound
externally until help arrives.
When attending a person suffering from CO
poisoning in enclosed premises, ventilate the In the case of fracture do not move the part of the
premises immediately to reduce the gas body affected by the fracture. When moving an
concentration. injured person permission from that person must be
When accessing the premises, the person providing received until you can help him. Unless the injury is
the aid must hold his breath, not light flames, turn on life threatening, move the injured person with
lights or activate electric bells or telephones so as to extreme care and then only if strictly necessary.
avoid explosions.
Take the victim to a ventilated area or into the open
air, placing him on his side if he is unconscious.
Page 10 of 65
WARNING LABELS Jacket Water Heater Voltage
Warning labels, in picture form, are applied to the
engine. Their meanings are given below.
Important Note: Labels that show an exclamation

mark indicate that there is a possibility of danger.
Heat Exchanger Maximum Working Pressure
Air Filter Installation
Coolant Mixture
1.3 PRECAUTIONS FOR WELDING
IMPORTANT: ALWAYS disconnect electronic

Control Module (ECM) connectors before welding.
High currents or electrostatic discharge in electronic
components from welding may cause permanent
Lifting Point damage. Connect the welder ground close to the
welding point and be sure ECM or other electronic
components are not in ground path.
Automatic Start
2.0 INSTALLATION/OPERATION
2.1 TYPICAL INSTALLATION

Rotating Parts
A typical Fire Pump installation is shown in Figure
#6.
1. Pump/Engine set
2. Main Pump Controller
3. Pump discharge
4. Air louver
5. Entrance door with air louver
6. Exhaust silencer
7. Exhaust system supports
Page 11 of 65
8. Exhaust outlet pipe 8) Start and run the engine at a slow speed for
9. Concrete base 1-2 minutes being careful not to exceed the
10. Exhaust flexible connection joint/pipe 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:
Figure #6 To restore the normal operation running conditions of
Typical Installation the engine, carry out the following:
1) Fill the engine sump with the normal
2.2 ENGINE STORAGE recommended oil, to the required level.
2) Remove the protective plugs used for
2.2.1 Storage less than 1 year shipping and storage.
3) Refill cooling water to proper level.
Storing engines requires special attention. Clarke 4) Remove the card “ENGINE WITHOUT OIL,
engines, as prepared for shipment, may be stored for DO NOT OPERATE”.
a minimum of one year. During this period, they 5) Follow all steps of the Installation
should be stored indoors in a dry environment. Instructions when the engine will be put into
Protective coverings are recommended provided they service.
are arranged to allow for air circulation. The stored
engine should be inspected periodically for obvious 2.3 INSTALLATION INSTRUCTIONS
conditions such as standing water, part theft, excess
dirt buildup or any other condition that may be The correct installation of the engine is very
detrimental to the engine or components. important to achieving optimum performance and
Any such conditions found must be corrected extended engine life.
immediately.
In this respect, the engine has certain installation
2.2.2 Extended Storage Maintenance Procedure requirements, which are critical to how it performs.
These requirements are generally associated with the
After a one year storage period or if the engine is cooling, exhaust, induction air, and fuel systems.
being taken out of service for more than 6 months,
additional preservation service must be performed as This section of the manual should be read in
follows: conjunction with the relevant Installation and
1) Drain the engine oil and change the oil filter. Operation Data Sheets. If there is any doubt about an
2) Refill the engine crankcase with MIL-L- installation, contact should be made with Clarke
21260 preservative oil. Customer Support giving exact details of the
3) Change the fuel filter. problem.
4) Install the coolant plugs and install coolant in
the normal mix percentage of 50% coolant, All installations should be clean, free of any debris
50% water, premixed. and dry. Care should be taken to ensure that there is
5) Remove the protection from the intake and easy access to the engine for maintenance and repair.
exhaust openings. The safety of personnel who may be in the area of the
6) Prepare a container as a fuel source using a engine when it is running is of paramount importance
mixture of Mobilarma or Sta-Bil with ONLY when designing the installation layout.
Diesel #2 fuel or “Red” diesel fuel (ASTM
D-975) or BS2869 Class A2. 1) Secure pump set to foundation and complete
7) Disconnect the coupling or drive shaft from installation in accordance with pump
the pump. manufacturer’s instructions. Perform engine-
Page 12 of 65
to-pump coupling alignment. Lubricate Falk and maximum allowable fuel head
coupling with supplied grease or driveshaft requirements. Fill supply tank with #2 diesel
universal joints with NLGI grade #1 or #2 fuel (ASTM D-975) or BS 2869 Class A2
grease at the (3) Zerk fittings. (Refer to “Red” diesel fuel, bleed supply system of air
section 2.4 for specific alignment and check for leaks.
instructions). CAUTION: Biodiesel fuel is not
2) Install the heat exchanger discharge pipe. recommended for stand-by equipment
The discharge pipe should be no smaller than that can have minimal fuel consumption
the outlet connection on the heat exchanger. (such as standby generators, fire
Discharge water piping should be installed in protection, etc.). For standby applications,
accordance with applicable codes. All use only petroleum based diesel fuel with
plumbing connecting to the heat exchanger John Deere approved fuel conditioners/
must be secured to minimize movement by additives. For fuel conditioners/additives,
the engine. Cooling loop water pressure to check with your local John Deere dealer
the heat exchanger must not exceed the limit or Clarke. Fuel supply level must meet
that is stated on the heat exchanger supplied applicable code requirements. Do not use a
with the engine. copper based or galvanized material for any
3) Install all engine cooling system draincocks component of a diesel fuel system. The fuel
and plugs. Close all drain cocks at (DAVE will chemically react with the zinc resulting
TO IDENTIFY)….. in clogged fuel filters and injector systems.
Engine 7) Remove protective covering on air filter
Qty Description Location Model element.
1 1/8” Water Heater JU4H / 8) Connect jacket water heater (if supplied) to
draincock inlet tube JU6H AC power source. For JU6 Series the
1 1/8” Coolant heater JW6H electrical supply requirements are indicated
draincock inlet tube on the heater body. Connect the supplied
1 Plug Oil Cooler JU4H / heater connection wire directly to a customer
RE46686 JU6H supplied electrical junction box. For
1 3/8” pipe plug Heat exchanger JW6H JW6/JX6 Series the electrical supply
1 Electrode Bottom of heat JU4H / requirements are indicated on the connection
plug exchanger JU6H box. Connect to the heater directly to the
1 1/8” Water Heater JX6H junction box at the end of the heater only.
draincock inlet Supply wiring should never be routed
1 Electrode Bottom of heat JX6H through the engine gauge panel. Severe
plug exchanger damage to critical engine control components
1/4” Water Pump JX6H could result. Energize heater only after step
1 draincock Inlet Hose #4 is completed.
9) Connect exhaust system to flexible
4) Fill engine cooling system with premixed connection on the engine. The exhaust
50% water / 50% coolant solution. Use only system plumbing must be supported by the
coolants meeting ASTM-D6210 building structure and not the engine. The
specifications for heavy-duty diesel engines. exhaust flexible connection is provided only
Never use light-duty or automotive coolants for the purpose of thermal expansion and
in the engine that are stated as ASTM-D3306 vibration isolation, not for misalignment or
only. (Refer to Figure #18 of Instruction directional change.
Manual in Section 3.4.3 for cooling system 10) Make electrical DC connections between the
capacity.) Fill expansion tank per figure engine gauge panel terminal strip (if
#19A, Section 3.4.5 of Instruction Manual. supplied) and the controller per the controller
5) Engine is shipped with oil installed. For manufacturer’s instructions.
make-up oil specifications refer to section 11) Fill batteries with electrolyte per battery
3.3 Lubrication System. manufacturer’s instructions. Connect cables
6) Connect fuel supply and return line to fuel between engine and batteries only after
supply tank plumbing. Reference the Fuel electrolyte is installed. Refer to the wiring
System section of the Installation and diagram inside the engine gauge panel cover
Operation Data in (see Page 5), for piping (if supplied), or appropriate wiring diagram
size, maximum allowable fuel pump suction, (see Page 5), for correct positive and
Page 13 of 65
negative connections. Connect negative JU4H-UFAD98
cables directly to the engine block. Connect JU6H-UFADP8
JU6H-UFADP0
each positive cable to the large outer post of JU6H-UFADT0
the manual starting contactors. JU6H-UFADS0
12) Note: Clarke Operation and Maintenance JU6H-UFAD88
Instructions Manual, C132679, are located JU6H-UFAD98
JU6H-UFADR8
inside the engine gauge panel. JU6H-UFADS8 7/16-20
13) Note: During commissioning of the engine, 50 – 55
JU6H-UFADS0 CDS50-SC Grade 8
the final speed setting must be performed on (68 - 75)
JU6H-UFADW8 (Hi-
(see note #2)
both the Primary and Alternate ECM’s. JU6H-UFADX8 Tensile)
Refer to section 3.6 Speed Adjustment. JU6H-UFADM8
JU6H-UFADMG
14) IMPORTANT! In order to obtain prompt JW6H-UFAD80
Warranty Service and to comply with JW6H-UFADB0
Emissions Regulations, this engine must be JW6H-UFADD0
registered to the final installation name and JW6H-UFADP0
JW6H-UFADJ0
address. To register this engine, go to JW6H-UFAD70
www.clarkefire.com and select Warranty
JX6H-UFADF0
Registration. JX6H-UFAD60 M16,
JX6H-UFADK0 Class 10.9 100 - 105
2.4 SPECIFIC FLYWHEEL COUPLING JX6H-UFADN0 SC2160A (Metric) (135 - 142)
ALIGNMENT INSTRUCTIONS JX6H-UFADP0 (Hi- (see note #2)
JX6H-UFAD88 Tensile)
2.4.1 Driveshaft
Note 1 – It is recommended that a medium strength
To check the alignment of the pump shaft and threadlocker (i.e. Loctite – blue #64040) be used in
engine crankshaft centerlines for proper Parallel the assembly and torquing of all hardware. This may
be purchased as part number 23509536.
Offset and Angular tolerance, the drive shaft
must be installed between the flywheel and the Note 2 – 4 of the hi-tensile bolts and/or nuts, that are
flanged hub on the pump shaft. used to connect the driveshaft to the drive disc and
that connect the driveshaft to the pump companion
Before beginning the alignment checks and making flange, will require a “crow’s foot” wrench attached
any necessary corrections, install the driveshaft and to a standard torque wrench in order to apply the
re-torque all driveshaft connection bolts to the values required tightening torque. A standard socket will
given in the following table: not work due to close proximity of the bolts and/or
nuts with the driveshaft yoke. The tightening torque
TIGHTEN- values listed for these bolts and/or nuts have been
DRIVE BOLT ING
MODELS SHAFT SIZE TORQUE corrected for using a “crow’s foot” adapter which
/MATERIA ft-lbs extends the standard torque wrench’s length.
L GRADE (N-m)
1/2-20 Before removing the drive shaft guard, disconnect the
Grade 8 75 - 82
JU4H-UFAD4G CDS20-SC
(Hi- (102 – 112)
negative battery cable from both batteries.
Tensile)
JU4H-UFAD5G The following steps describe the proper way to check
JU4H-UFAD58 3/8-24 30 - 35 alignment. A small pocket scale or ruler with
JU4H-UFADJG Grade 8 (41 - 48) millimeter markings is recommended to make all
JU4H-UFADP0 (Hi- (see note #2)
JU4H-UFADR0
CDS30-S1
Tensile)
measurements.
JU4H-UFADW8
JU4H-UFADY8 A) To check the Horizontal Parallel Offset, the drive
shaft must be in the proper orientation.
1. Rotate the shaft so the reference “AB” on the

flywheel adaptor disc is in the 12 O’clock
position as shown below.
2. Measure from the face of the flywheel drive
disc to point “E” as shown in below. (Point
Page 14 of 65
“E” is to the furthermost point on the bearing CDS30-S1/SC61LA 86.5+ 1mm
bore diameter) This measurement must be: CDS50-SC /SC81A 112.5 + 1mm
SC2160A 126.5 + 1mm
Driveshaft Model Measurements SC2390 145.5 + 1.5mm
CDS10-SC /SC41A 58 + 1mm
CDS20-SC /SC55A 68 + 1.5mm
CDS20-S1/SC55L-A 68 + 1.5mm
CDS30-S1/SC61LA 84 + 1.5mm
CDS50-SC /SC81A 109 + 2mm
SC2160A 123.5 + 1.5mm
SC2390 142.5 + 1.5mm
D) With the driveshaft in the same orientation as the

previous step (Step C), check the Vertical
B) With the drive shaft in the same orientation as the Angular Alignment of the shaft.
previous step (Step A), check the Horizontal
Angular Alignment of the shaft.
1. Measure the face of the pump shaft
flange to point “J” as shown below.
1. Measure from the face of the pump shaft flange to
(Point “J” is the same as point “G”, with
point “G” as shown below. (Point “G” is to the
the driveshaft rotated 90º). This
furthermost point on the bearing bore diameter). This
measurement must be equal to the
measurement must be equal to the measurement at
measurement at point “H” + 1 mm.
point “E” + 0.5mm.
C) To check the Vertical Parallel Offset, the

driveshaft must be re-orientated.
1. Rotate the shaft 90º so the reference
“CD” on the flywheel adaptor disc is in
the 12 O’clock position as shown below. Reinstall all guards and grease fittings before
2. Measure from the flywheel adaptor disc reconnecting the battery cables.
to point “H” as shown below. (Point “H”
is the furthermost point on the bearing DRIVESHAFT MAINTENANCE
bore diameter) This measurement must
be: 1. To service the driveshaft disconnect the
negative battery cables, remove the top of
Driveshaft Model Measurements guard and set aside.
CDS10-SC /SC41A 60 + 1mm 2. Rotate engine shaft manually so the u-joint
CDS20-SC /SC55A 70.5 + 1mm grease fittings are accessible.
CDS20-S1/SC55L-A 70.5+ 1mm
Page 15 of 65
3. Using a hand held grease gun with N.L.G.I. 3) All the guards are in position and, if not, for
grade 1 or 2 grease position on grease fitting. whatever reason, any rotating parts will be
Pump with grease until grease is visible at all free and clear without restriction.
four cap seals. 4) Battery covers are in place and there is
4. Verify all driveshaft connecting bolts remain nothing on top of or touching the engine,
tight. Re-torque per 2.4.1 if necessary. which is not part of the original supply
5. Reinstall top of guard and connect negative specification.
battery cables. 5) The raw water supply for cooling is available
without restriction. Typically restriction
2.4.2 Falk “Steelflex” Coupling occurs from a plugged cooling loop strainer.
JX engines are offered with an optional FALK When engine is running make sure that the coolant
“Steelflex” drive hub. temperature, oil pressure and raw cooling water flow
are within the limits specified on the relevant
If your engine includes this type of coupling, please Installation & Operation Data Sheet (see Page 5).
refer to Appendix “A” for installation, alignment and
maintenance information. To achieve final If the coolant temperature is excessive, check:
installation alignment Limits (see Table 2 of a) Cooling loop strainers
appendix), shims are provided with the engine. Shim b) Proper functioning of thermostat
as required under the engine feet to achieve proper c) Condition of heat exchanger tube bundle
alignment
2.6 STARTING/STOPPING THE ENGINE
2.6.1 To Start Engine
Use main pump controller for starting. Follow

instructions provided by controller manufacturer.
On UL/FM engines, use main pump controller for

starting and stopping the engine. Should the main
pump controller become inoperable, the engine can
be manually started and stopped from the engine
gauge panel. For manual starting and stopping of an
engine with a gauge panel: Position MODE
SELECTOR to MANUAL RUN. (Refer to Figure
#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
2.5 WEEKLY TEST #2 and repeat step. If RAW COOLING WATER is
not flowing or engine COOLANT
An experienced operator should be present during the TEMPERATURE is too HIGH, open cooling
weekly test. system manual by-pass valves.
Note: On JW/JX Engines you can also start engines
NOTE: This engine is designed to operate at rated using manual starting contactors.
load conditions. For testing purposes the engine can
be run at lower load (lower flow) conditions. IMPORTANT: Main pump controller selector
Running times in any one period should not exceed should be in the OFF position when starting from
30 minutes maximum. engine gauge panel. Be sure to return selector on
Before starting the engine make sure of the main pump controller and engine gauge panel to
following: AUTOMATIC after completing manual run.
1) The operator has free access to stop the 2.6.2 To Stop Engine
engine in an emergency.
2) The plant room ventilation ducts are open If engine is started from main pump controller use
and the engine has good access for air. main pump controller to stop the engine.
Page 16 of 65
If engine is started from engine gauge panel: Lift and
hold MANUAL STOP SWITCH, until engine stops.
Close cooling system manual by-pass valve if
opened.
Note: Lift and hold this switch to prevent engine
from starting during the cycle-crank testing.
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).
Page 17 of 65
Figure #9
1 - PowerView Gauge 6 - Manual Mode Indicator Warning Light

2 – Momentary Display On Switch 7 - Alternate ECM Indicator Warning Light
3 – Voltmeter/Battery Selector Switch 8 - Manual Stop Switch
4 - Automatic/Manual Mode Selector Switch 9 - Manual Crank Switch – Battery #1
5 - ECM Selector Switch 10 - Manual Crank Switch – Battery #2
Page 18 of 65
2.6.3 Describing Engine Gauge Panel  Secondary heartbeat failure only: LED
Flashes at 1 ½ Hz or 15 times in 10 seconds.
2.6.3.1 ECM Selector Switch and Primary/Alternate
ECM
Clarke UL/FM Engines come equipped with dual

ECMs and an ECM Selector Switch on engine
gauge panel. (Item #6). Default position of
ECM selector switch is to the Primary ECM. In
BASE &
the event of a failure of the Primary ECM, green status
where-by the engine shuts down or will not start, LED
it will become necessary to manually switch to
the Alternate ECM position. When the ECM
Selector Switch is positioned to the Alternate Interior view of instrument control panel door -
ECM position a warning light will illuminate at BASE dual ECM auto-switching device and
the engine gauge panel. Also, the main controller green LED
will display a warning light and an audible alarm.
The engine should then be re-started manually. If the currently selected ECM experiences a
(See section 2.6.1). Contact a Clarke Authorized failure detected by the BASE unit, an ECM
Service Dealer immediately when this situation warning alarm will be sent to the fire pump
occurs to troubleshoot. (See section 7.0). controller via interconnect terminal 303, and will
automatically switch to the other functional
Information displayed on the PowerView ECM. If the automatic switching devices
diagnostic gauge will come from either the switches to alternate ECM, a visual indication
Primary or Alternate ECM depending upon the light will illuminate on the engine control panel,
position of the ECM Selector Switch. and an alternate ECM alarm will be sent to the
fire pump controller via interconnect terminal
If a fault code(s) is displayed and comes from the 301. Upon failure of the second ECM, the
Primary ECM, and then the ECM selector switch automatic switching device will alarm an ECM
is moved to the Alternate ECM position, it may failure alarm to the fire pump controller via
be necessary to “crank” the engine in order for interconnect terminal 304. Additionally, the
the Alternate ECM to pick-up the same fault BASE status LED will flash at rate of 2 ½ Hz or
code(s). 25 times in 10 seconds.
2.6.3.2 Dual ECM Automatic Switching If an ECM failure occurs during engine
operation, the automatic switching device will
Engine models utilizing dual ECMs are equipped control engine shutdown and will prevent starter
with a BASE unit (Board for Auto-Switching motor re-engagement while the engine is shutting
ECMs) that can detect failure on either primary down. After the engine safely comes to a stop
or alternate ECM. The BASE monitors two the automatic switching device will switch to the
separate heartbeat signals from each of the other functional ECM and will then allow starter
ECMs. If the BASE fails to detect BOTH of motor re-engagement control from the fire pump
these signals, the BASE will recognize this as an controller.
ECM failure and initiate the automatic ECM
switching process. If the BASE fails to detected The automatic ECM switching process will not
only one of these signals, the automatic ECM initiate upon failure of any primary, alternate, or
switching process will not initiate however an non-critical engine sensors as per UL/FM.
indication will be made by a green status LED on
the BASE. After ECM repair, activate the ECM Failure reset
 Normal Operation: LED Flashes at 1/10 Hz switch to the down position for 3 seconds and
or 1 time in 10 seconds release. This will de-activate the ECM Warning
and Failure alarms to the fire pump controller at
 Primary heartbeat failure only: Led Flashes at interconnect terminals 303 and 304.
½ Hz or 5 times in 10 seconds.
Page 19 of 65
The hand operated ECM selector switch allows NOTE:
for manual selection of either primary or alternate  Red indicator light (E) indicates a serious
ECM. condition. Correct problem before
restarting.
In the event of failure of the BASE unit while the  Amber indicator light (F) indicates an
ECMs are functional, a Diagnostic Trouble Code abnormal condition. It is not necessary
of SPN 2145 FMI 9 will be displayed on the to shutdown engine immediately but
diagnostic gauge. problem should be corrected as soon as
possible.
2.6.3.3 Using the PowerView Gauge
The PowerView gauge (reference Figure #9A)

allows the operator to view operating conditions
and diagnostic trouble codes (DTC’s).
Press the menu key (B) to access the various

engine functions in sequence. The displays can
be selected as either customary English or metric
units.
The following menu of engine parameters can be

displayed on the power view (refer to Figure
#9A).
1. Engine rpm*
2. Coolant temperature*
3. Oil pressure*
4. Machine hours*
5. System voltage (rectified voltage of
battery #1 & #2) Figure #9A
6. Percent engine load at the current rpm
7. Throttle position Setup the 1-Up Display
8. Intake manifold temperature
9. Current fuel consumption
10. Active service (diagnostic) codes
11. Store service (diagnostic) codes from the
engine
12. Set the units for display
13. View the engine configuration
parameters
Note: Not recommended for Clarke Engines. 1-Up
* These four parameters are fixed for the power-
display should be used for diagnostic needs only.
up display.
Main Menu Navigation
The PowerView gauge includes a liquid crystal
display (LCD) screen. The display can show
NOTE: The engine does not need to be running to
either a single parameter or a quadrant display
navigate the diagnostic gauge screens. It will display
showing four parameters simultaneously. The
information when the batteries are connected. If
diagnostic gauge uses two arrow keys (C) for
engine start up is desired see: Starting The Engine.
scrolling through the engine parameter list and
All of the engine values illustrated in this example on
viewing the menu list and an enter key (D) for
the diagnostic gauge indicate the engine is running.
selecting highlighted items. The red (E) and
amber (F) lights are used to signal active trouble
1. Starting at the four engine parameter display,
codes received by the diagnostic gauge.
press the “Menu” key.
Page 20 of 65
2. The first seven items of the “Main Menu”
will be displayed.
5. Use the arrow keys to scroll to the desired

menu item or press the “Menu Button” to
exit the main menu and return to the engine
parameter display.
3. Pressing the “Arrow” keys will scroll

through the menu selections.
Engine Configuration Data
NOTE: The engine configuration data is a read only

function. All engine configuration parameters are
4. Pressing the right arrow key will scroll down pre-set by Clarke.
to reveal the last items of “Main Menu”
screen, highlighting the next item down. 1. Starting at the four engine parameter display,
Page 21 of 65
2. The main menu will be displayed. Use the
“Arrow” keys to scroll through the menu
until “Engine Config” is highlighted.
6. Press the “Menu” key to exit the main menu

and return to the engine parameter display.
3. Once “Engine Config” menu item has been

highlighted, press the “Enter” key to view the
engine configuration.
Accessing Stored Trouble Codes

4. Use the “Arrow” keys to scroll through the

engine configuration data.

until “Stored Codes” is highlighted.
5. Press the “Menu” key to return to the main

menu.
Page 22 of 65
3. Once the “Stored Codes” menu item has been 6. Press the “Menu” key to exit the main menu
highlighted press the “Enter” key to view the and return to the engine parameter display.
stored codes.
Accessing Active Trouble Codes
For description of trouble codes, see chart in

Troubleshooting Section.
4. If the word “Next” appears above the
“Arrow” keys, there are more stored codes 1. During normal operation the four parameter
that may be viewed. Use the “Arrow” key to screen will be displayed.
scroll to the next stored code.
2. When the diagnostic gauge receives a trouble

code from an engine control unit. The single
or four parameter screen will be replaced
with the “Warning” message. The SPN and
5. Press the “Menu” key to return to the main FMI number will be displayed along with a
menu. description of the problem and the corrective
action needed.
Page 23 of 65
6. Pressing the “Enter” key once again will hide
the trouble code and return the screen to the
single or four parameter display.
IMPORTANT: Ignoring active trouble codes can

result in severe engine damage.
3. If the word “Next” appears above the arrow

keys, there are more trouble codes that can be
viewed by using the arrow keys to scroll to
the next trouble code.
7. The single or four parameter screen will

display the warning icon until the trouble
code condition is corrected.
4. To acknowledge and hide the code and return

to the single of four parameter display, press
the “Enter” Key.
Engine Shutdown Codes
Note: For Clarke Engine models the only shutdown

will be due to an overspeed condition.
1. During the normal operation the four

parameter screen will be displayed.
5. The display will return to the single of four

parameter display, but the display will
contain the warning icon. Pressing the
“Enter” key will redisplay the hidden trouble
code.
Page 24 of 65
2. When the diagnostic gauge receives a severe 5. Pressing the “Enter” key once again will hide
trouble code from an ECM, the four the trouble code and return the screen to the
parameter screen will be replaced with the four parameter display.
“Shutdown” message, The SPN and FMI
number will be displayed along with a
description of the problem and the corrective
action needed.
6. The four parameter screen will display the

shutdown icon until the trouble code
condition is corrected.
If the word “Next” appears above the arrow key,

there are more trouble codes that can be viewed by
using the arrow keys to scroll to the next trouble
code.
3. To acknowledge and hide the trouble code

and return to the four parameter display, pres
the “Enter” key.
Adjusting Backlighting

4. The display will return to the four parameter

display, but the display will contain the 2. The main menu will be displayed. Use the
“Shutdown” icon. Pressing the “Enter” key
will redisplay the hidden code.
until “Adjust Backlight” is highlighted.
Page 25 of 65
3. Once the “Adjust Backlight” menu item has

been highlighted, press the “Enter” key to
activate the “Adjust Backlight” function.
Adjusting Contrast
1. Starting at the single or four engine

parameter display press the “Menu” Key.
4. Use the “Arrow” keys to select the desired

backlight intensity.

until “Adjust Contrast” is highlighted.

menu.
3. Once the “Adjust Contrast” menu item has

been highlighted, press the “Enter” key to
activate the “Adjust Contrast” function.
Page 26 of 65
Selecting Units of Measurement
1. Starting at the four engine parameter display

4. Use the “Arrow” keys to select the desired press the “Menu” Key.
contrast intensity.

until “Select Units” is highlighted.

menu.
3. Once the “Select Units” menu item has been

highlighted, press the “Enter” key to activate
the “Select Units” function.

Page 27 of 65
4. There are three choices for units of 6. Press the “Menu” key to return to the main
measurements, English, Metric kPa or Metric menu.
Bar.
English is for Imperial units, with pressures displayed

in PSI and temperatures in °F.
Metric kPa and Metric bar are the IS units, with

pressures displayed in kPa and bar respectively, and
temperatures in °C.
Use the “Arrow” keys to highlight the desired units

of measurements.
7. Press the “Menu” key to return to the engine

parameter display.
5. Press the “Enter” key to select the

highlighted units. Displaying Diagnostic Gauge Software
NOTE: The following steps can be used to display

the software version of the diagnostic gauge if
needed by your dealer for troubleshooting. This is a
read only function.

Page 28 of 65
“Arrow” key to scroll through the menu until
“Utilities” is highlighted.
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.
3. Once “Utilities” is highlighted, press “Enter” Use a piece of cardboard or paper to search for
to activate the utilities function. 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
4. Scroll to the “Software Version”. Press

“Enter” to view the software version. Press
the menu button twice to return to the main
menu.
Figure #10
IMPORTANT: Fuel filter must be replaced

according to maintenance schedule (See Section 4.0)
or when trouble code indicates plugged filter (fuel
supply pressure moderately/extremely low).
Page 29 of 65
3.1.1.1 JU4/6 Engine Series: At High Common Pressure Rail:
1) Loosen the air bleed vent screw (A) two full 1) Slightly loosen injector fuel line above
turns by hand on fuel filter base. Ref. Figure shuttle valve (A) in high common pressure
#11 rail. Ref figure #13
2) Operate supply pump primer lever (B) until 2) Operate fuel supply pump primer lever until
fuel flow is free from air bubbles. Ref. fuel, without air bubbles, flows from fuel
Figure #12. return line connection.
3) Tighten bleed plug securely; continue 3) Tighten return line connector at 30N-m (22
operating hand primer until pump action is lb-ft).
not felt. Push hand primer inward (toward 4) Leave hand primer in the inward position
engine) as far as it will go. toward cylinder block. Ref. Figure #14.
4) Start engine and check for leaks.
A
A
Figure # 13
Figure #11
Figure #14
B 3.1.1.2 JW6 Engine Series:
Note: Under normal conditions, fuel system bleeding

Figure # 12 is not required. The JW6 engines have an electric
fuel pump. To prime or bleed the fuel system, the
If engine will not start, it may be necessary to bleed electric pump will automatically turn on to maintain a
air from fuel system at fuel injection pump or correct downstream pressure
injection nozzles as explained next.
3.1.1.3 JX6 Engine Series
Note: Under normal conditions, fuel system bleeding

is not required. Priming system with hand primer (B)
is normally sufficient. If necessary to bleed the
Page 30 of 65
system, use the following procedure (Refer to Figure 3.1.2.1 JU4/6 Engine Series
10A).
1) Drain water and contaminants from water Each engine has two fuel filters, a primary filter (B)
separator sediment by opening drain valve and a secondary filter (F). For the purpose of
(C) and operating primer (B) until fuel is identity, the primary filter incorporates the
clear of water. transparent water separator.
2) Attach an open line to diagnostic port (A)
and place end of line in suitable container for 1) Close fuel shut-off valve, if equipped
diesel fuel. 2) Thoroughly clean fuel filter assembly and
3) Pump hand primer (B) until a steady flow of surrounded area.
fuel (without bubbles) comes out of line. 3) Disconnect water-in-fuel sensor
4) Disconnect line from diagnostic port. 4) Loosen drain plug (C) from both filters and
5) Start engine and run for five minutes. drain fuel into a suitable container. Ref
figure#21
Note: Lifting up on retaining ring and rotate it helps

to get past raised locators.
5) Firmly grasp the retaining rings (A) and

rotate it counterclockwise ¼ turn. Remove
ring with filter element (B). Ref figure#21
6) Inspect filter mounting bases for cleanliness.
Clean as required.
Note: Raised locators on fuel filter canister must be

indexed properly with slots in mounting base for
correct installation.
7) Install new filter elements onto mounting

base. Be sure element is properly indexed
Figure #10A and firmly seated on base. It may be
necessary to rotate filter for correct
Whenever the fuel system has been opened up for alignment.
service (lines disconnected or filters removed), it will
be necessary to bleed air from the system. If equipped with water separator, remove filter
element from water separator bowl. Drain and clean
3.1.2 Changing the Fuel Filter Cartridges separator bowl. Dry with compressed air. Install
water separator bowl onto new element. Tighten
Changing the cartridges and bleed any air from the securely.
fuel system as per instructions given in section 3.1.1.
Fuel filter changes should take place as per 8) Align keys on filter element with slots in
recommendations and only using approved filters. It filter base.
may also be necessary to change filters out with the 9) Install retaining ring onto mounting base
recommendations in the event of: making certain dust seal is in place on filter
base. Hand tighten ring (about 1/3 turn) until
1) The engine has had an overhaul. it “snaps” into the detent. DO NOT over
2) The quality of the fuel is questionable. tighten retaining ring.
3) The engine has been subjected to temporary
adverse conditions outwith it normal Note: The proper installation is indicated when a
operating parameters. “click” is heard and a release of the retaining ring is
4) The fuel tank condensation trap has not been felt.
drained in line with manufacturer’s
recommendations. A plug is provided with the new element for plugging
the used element.
Page 31 of 65
10) Open fuel shut-off valve and bleed the fuel 6) Once filter canister is removed, pull filter
system. Tighten bleed plug (D). Reference element (E) down to remove from filter
Figure #2. header (A).
7) Inspect filter header and filter canister sealing
D surfaces. Clean as required.
8) Place new packing on filter canister.
9) Place thin film of fuel on filter packing.
A
10) Place filter in canister with tangs on bottom
going into canister.
B 11) Install fuel filter onto fuel filter header.
Tighten until fuel filter snugly mates with
fuel filter header.
F 12) Turn filter additional ¾ turn after seal contact
with header.
13) Connect water-in-fuel sensor connector.
C Replacing Secondary Fuel Filter Element

Figure #21 – JU6 models only
1) Close fuel shut-off valve at bottom of fuel
tank, if equipped.
2) Loosen drain plug (B) and drain fuel into a
D suitable container. Ref figure#22
A 3) . Turn filter (K) counter-clockwise (CCW) to
remove.
4) Inspect filter header surface. Clean as
required.
5) Install new filter drain valve and tighten to
F B 30-35 lb-in (3.4-4 Nm)
6) Place new filter packing (L) on filter
7) Place thin film of fuel on packing.
8) Install fuel filter onto fuel filter header.
C Tighten until fuel filter snugly mates with
Figure #21 – JU4 models only fuel filter header (I).
9) Turn filter additional ¾ turn after seal contact
3.1.2.2 JW6 Engine Series with header.
Each engine has two fuel filters. For the purpose of

identity, the primary filter incorporates the
transparent water separator. Both primary and
secondary filters must be replaced at the same time.
Replacing Primary Fuel Filter/Water Separator
1) Close fuel shut-off valve at bottom of fuel

tank, if equipped.
2) Thoroughly clean filter header (A) and
surrounding area to keep from getting dirt
and debris into fuel system. Ref to figure#22.
3) Loosen drain plug (B) and drain fuel into a
suitable container. Ref to figure#22.
4) Disconnect water-in-fuel sensor
5) Turn filter canister (D) counter-clockwise
(CCW) to remove.
Page 32 of 65
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.
IMPORTANT: Fuel filter must be replaced

according to maintenance schedule (See Section
4.0) or when trouble code indicates plugged filter
(fuel supply pressure moderately/extremely low).
CAUTION: If engine has been running, engine

and fuel filter housing may be hot.
1) Close fuel shut-off valve (if equipped).

2) Clean entire area surrounding fuel filter
assembly to keep debris from entering fuel
system.
3) Remove cap from fuel filter housing.
4) Relieve vacuum in filter housing by
operating hand primer until fuel filter “pops-
up”.
5) Lift filter element up in housing until seal
clears inlet tube inside housing. Continue to
hold filter suspended straight up in top of
housing to drain fuel from filter.
6) Allow fuel to drain completely from filter
into housing. Carefully begin rotating filter
from housing as shown until completely
upside down to ensure minimum leakage
from fuel filter. (Refer to Figure #10D)
7) Place filter in container suitable for diesel
fuel.
IMPORTANT: Reusing fuel filter once removed

Figure #22 – JW6 models only from housing may result in trapped air in the filter.
This may cause fuel to overflow from the filter
3.1.2.3 JX6 Engine Series housing during insertion of filter element, and/or
cause the engine to stall and not restart without
Replacing Fuel Filter and cleaning the Water additional system purging.
Separator Bowl
CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious 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.
Page 33 of 65
Install New Fuel Filter Element
1) Check to ensure that the fuel level in the
filter housing is between the MIN (B) and
MAX (A) fuel levels indicated on the outside
of the housing and on the corresponding
marks on the center tube. If the fuel is below
the MIN level, then carefully open the fuel
supply shut-off valve a small amount (if
equipped) to add fuel. (Refer to Figure #10F)
Operate the hand primer to add more fuel if
required or if the unit is not equipped with a fuel
supply shut-off valve.
IMPORTANT: Fuel level below the MIN

Figure #10D indication may result in trapped air in the filter
causing the engine to stall and not restart without
Removing and cleaning the Water Separator Bowl additional system purging. Fuel level above the
MAX indication may cause fuel to overflow from
1) Disconnect wiring connector from water-in- the filter housing during insertion of filter
fuel sensor. element.
2) Drain fuel from separator bowl. 2) Insert new (dry) fuel filter element into filter
3) Position a strap wrench (A) as close as housing.
possible to top edge of separator bowl. 3) Reinstall fuel filter cap and tighten to
While applying pressure with strap wrench, “hand tight” condition.
grip bowl and twist with other hand as shown 4) Open the fuel supply shut-off valve (if
to remove bowl. (See Figure #10E) equipped).
4) Clean separator bowl and dry it. 5) Restart engine and allow to run
5) Install separator bowl and tighten by hand for five minutes minimum.
until seal makes contact. Hand tighten to the
following specification:
Water Separator Bowl-To-Filter
Housing ---Torque…..…….5 N·m (44 lb-in)
6) Connect wiring to water-in-fuel sensor.
Figure #10F
3.1.3 Restarting Engine Which Has Run

Out Of Fuel
NOTE: The procedures provided here pertain

Figure #10E to normal initial start-up, not to the “hard
starting” problem that may be associated with
initial starting of engines
Page 34 of 65
Note: This procedure assumes the Supply and Return a) Power View Gauge in 4-Up Display
lines from the fuel tank are already connected to the Mode:
Supply and Return Flex Fuel Hoses on the engine.
1) You will need to obtain Clarke JX “Fuel

Priming Assist Kit” p/n C02602 (See Figure
1).
A) Kit includes the following:
i. Quick Connect Coupling
and clear plastic hose
assembly (Air Bleed Tool)
ii. 37° flare Cap for plugging
fuel return line at JIC
connection on flex fuel
return line hose and ½” npt
plug for plugging fuel
return line at fuel adapter
fitting.
4-Up Display
b) Push the Menu Key, B, to display Menu.
c) Using the Arrow Keys, C, scroll down
until “Set-Up 1-Up Display” is
highlighted. Then push the Enter Key,
D.
d) Using the Arrow Keys, C, scroll until
“Custom Set-Up” is highlighted. Then
press the Enter Key, D.
Figure 1 e) Using the Arrow Keys, C, scroll until
“Fuel Pressure” is highlighted. Then
2) Change 4-up Display on Power View press the Enter Key, D.
Display to 1-up Display in order to display f) The Power View Gauge will now display
fuel pressure as follows: “Fuel Pressure” only.
3) Close fuel supply valve at fuel tank.
4) Quick-connect the Air Bleed Tool from
Priming Assist Kit to the Diagnostic Port
located at left rear side of fuel filter cartridge
(See Figure 2). Place the clear plastic hose
outlet of the Air Bleed Tool into a 5 gallon
(19 liters) bucket.
Page 35 of 65
Note: Fuel Return Line must be plugged by the
JIC Cap from “Priming Assist Kit” (or ½” npt
plug) in order to build up fuel pressure!
10) If engine does not start, reconnect Air Bleed

Tool to Diagnostic Port on engine (same as
step 4 above).
11) Pump the hand primer (same as step 7)
approximately another 200 times.
12) Repeat steps 8 and 9.
Note: In order for engine to start, it requires that

the engine fuel pressure stay above 60 psi for at
least 15 – 20 seconds!
13) If engine does not start, wait 1 – 2 minutes

for the electric starter motor on the engine to
cool and then crank for additional 20 – 30
seconds. Observe fuel pressure - it needs to
be greater than 60 psi for the engine to start.
When engine starts, the fuel pressure will
jump to roughly 90 – 95 psi.
Figure 2 Note: When engine finally starts, do not run for

more than 15 to 20 seconds with the Fuel Return
5) Disconnect flex fuel return line hose at Line capped off. Also remember to always wait 1
swivel end and install the JIC Cap from to 2 minutes between each cranking cycle in
Priming Assist Kit to plug off the fuel return order to keep starter from over-heating.
line. (Alternately, remove the steel adapter
fitting attached to fuel line and screw back 14) Shut down the engine
onto flex return line hose and then install 15) Shut off the fuel supply valve on the fuel
1/2” npt plug from Priming Assist Kit to plug tank.
off fuel return line.) 16) Remove JIC cap (or 1/2” npt plug) and then
6) Open fuel supply valve on fuel tank and let reconnect the flex fuel hose to the fuel return
fuel flow into the engine fuel piping system. line
7) After approximately 1 minute of gravity 17) Re-open the fuel supply valve at the fuel
filling, pump the hand primer located on the tank.
front left hand side of the fuel filter cartridge 18) Return Power View Display to normal 4-up
roughly 200 times. Display as follows:
a) Refer to figure 2a.
Note: As you continue to pump you should see b) Push the Menu Key, B, to display menu.
fuel with entrained air come out of the Air Bleed c) Using the Arrow Keys, C, scroll until
Tool outlet. As you continue to pump, the “Set-Up 4-Up Display” is highlighted. Then
amount of entrained air will be significantly push the Enter Key, D.
reduced. d) Using the Arrow Keys, C, scroll until
8) Once all the air appears to have been purged “Use Defaults” is highlighted. Then push the
from the engine fuel piping system, quick- Enter Key, D.
disconnect the Air Bleed Tool. e) The Power View Gauge will now display
9) Proceed to then crank the engine for 20 to 30 the normal 4-Up Display.
seconds while observing the fuel pressure. 19) Engine is now primed and ready to run
Fuel pressure should gradually climb to
roughly 65 psi.
Page 36 of 65
3.1.4 Fuel Tanks JU4H-UFADJG
JU4H-UFADP0
Keep the fuel tank filled to reduce condensation to a
JU4H-UFADR0
minimum. Open drain at the bottom of the fuel tank
once a week to drain off any possible water and/or JU4H-UFADW8
sediment. Fill tank after each test run. JU4H-UFADY8
JU4H-UFAD98
Note: Per NFPA 25 standards, the fuel tank level
must never be less than 67% of its capacity. Air filter
restriction
Maximum Allowable Fuel Head above Fuel pump, Engine model
(inches of water)
Supply or Return.
JU6H-UFADK0
Engine model feet meters
JU6H-UFADN0
JU4, JU6, JW6 6.6 2.0
JU6H-UFAD58
JX6 10.7 3.3
JU6H-UFADNG
10
JU6H-UFADP8
3.2 AIR/EXHAUST SYSTEM JU6H-UFAD88
JU6H-UFADM8
3.2.1 Ambient Conditions
JU6H-UFADMG
Clarke engines are tested in accordance with SAE JU6H-UFADT0
J1349 (Clarke USA) or ISO 3046 (Clarke UK). In JU6H-UFADP0
this capacity they may be derated to meet certain site JU6H-UFADQ0 14
conditions, failure to do so can seriously impede the JU6H-UFADR0
performance of the engine and could lead to
premature failure. JU6H-UFADS0
JU6H-UFAD98
3.2.2 Ventilation JU6H-UFADR8
JU6H-UFADS8 14
The engine must be provided with adequate
JU6H-UFADW8
ventilation to satisfy the requirements of the
combustion system, radiator cooling systems where JU6H-UFADX8
fitted, and allow adequate dissipation of radiated heat JW6H-UFAD80
and crankcase emissions. For all this data refer to JW6H-UFADB0
Installation & Operation Data (see Page 5). This data
JW6H-UFADF0
can be used for proper sizing of inlet and outlet
louvers. JW6H-UFADJ0
14
JW6H-UFAD70
3.2.3 Standard Air Filter JW6H-UFAA60
JW6H-UFAAM8
The standard air filter is a reusable type. Should a
situation occur where the air filter becomes plugged JW6H-UFAA80
with dirt (starving the engine of air), loss of power JW6H-UFADD0 14
and heavy black smoke will result; the air filter JX6H-UFADF0
should be serviced immediately. See figure #21 for JX6H-UFAD60
air filter part numbers by Clarke Engine Model.
JX6H-UFADK0
Air filter 26
JX6H-UFADN0
restriction
JX6H-UFADP0
Engine model (inches of water)
JU4H-UFAD4G JX6H-UFAD88
JU4H-UFAD5G 12
JU4H-UFAD58
Page 37 of 65
CAUTION: Do not attempt to remove the air filter
while an engine is running nor run the engine while
the air filter 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 filter 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 #11 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 #11
Figure #11 Cont’d
Note: Intake Air Shutoff Valve - Engine may

include an intake air shutoff valve as an optional
feature that is activated by an overspeed event
and provides a positive shutoff of combustion air
to the engine. The optional air intake shutoff
valve has not been evaluated by UL as part of a
UL Listed fire pump driver.
3.2.4 Crankcase Ventilation
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 are expelled
through a vent pipe attached to the rocker cover
breather element. Ref. Figure #12.
Page 38 of 65
JU4H-UFADW8
JU4H-UFADY8
JU4H-UFAD98
JU6H-UFADK0
JU6H-UFADN0
JU6H-UFAD58
JU6H-UFADNG
30
JU6H-UFADP8
JU6H-UFAD88
JU6H-UFADM8
JU6H-UFADMG
Exhaust
Engine model backpressure limit
(inches of water)
JU6H-UFADT0
JU6H-UFADP0
JU6H-UFADQ0 30
JU6H-UFADR0
JU6H-UFADS0
JU6H-UFAD98
JU6H-UFADR8
JU6H-UFADS8 30
Figure #12 JU6H-UFADW8
JU6H-UFADX8
JW6H-UFAD80
3.2.5 Exhaust System
JW6H-UFADB0
Excessive back pressures to the engine exhaust can JW6H-UFADF0
considerably reduce both engine performance and JW6H-UFADJ0
life. It is therefore important that exhaust systems 30
JW6H-UFAD70
should be the proper diameter and be as short as
JW6H-UFAA60
possible within the minimum amount of bends. Refer
to Installation & Operating Data (see Page 5) for JW6H-UFAAM8
exhaust data. Also refer to the table below for JW6H-UFAA80
maximum exhaust restrictions. JW6H-UFADD0 30
JX6H-UFADF0
Exhaust JX6H-UFAD60
backpressure limit JX6H-UFADK0
Engine model (inches of water) 40
JX6H-UFADN0
JU4H-UFAD4G
JX6H-UFADP0
JU4H-UFAD5G
JX6H-UFAD88
JU4H-UFAD58
30
JU4H-UFADJG
JU4H-UFADP0
JU4H-UFADR0
Page 39 of 65
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.
JX
1) Blue Smoke – Possible engine oil Figure #13
consumption.
2) White Smoke – Possibility of water in This level must always be between the dipstick marks
cylinders, water in fuel or internal engine Min. and Max. with the engine not running.
problem.
3.3.2 Changing Engine Oil
3.3 LUBRICATION SYSTEM
1) Operate the engine until it is warm.
3.3.1 Checking Sump Oil 2) Stop the engine. Remove the sump drain
plug and drain the lubricating oil from the
Check the sump oil level using the dipstick on the sump. Fit the drain plug and tighten the plug
engine as shown in Figure #13. to 34 Nm (25lb-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) Dispose used oil properly.
3.3.3 Changing Oil Filter Cartridge
1) Put a tray under the filter to retain spilt

lubricating oil.
2) Remove the filter with a strap wrench or
similar tool. Then dispose of the filter
properly.
3) Clean the filter head.
JU 4) Add clean engine lubricating oil to the new
filter. Allow the oil enough time to pass
through the filter element.
5) Lubricate the top of the filter seal with clean
engine lubricating oil.
6) Fit the new filter and tighten it by hand only.
Do not use a strap wrench.
7) 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.
8) Operate the engine and check for leakage
from the filter. When the engine has cooled,
check the oil level on the dipstick and put
JW
more oil into the sump, if necessary.
Page 40 of 65
9) Return the unit back into service by returning coolant temperature within recommended operating
the main pump controller selector to guidelines.
“automatic” position and the manual
operating lever to AUTO-OFF position. The JU4H, JU6H, and JW6H have an intended
engine operating temperature of 175º F (79ºC) to
3.3.4 Oil Specification 195º F (91º C). A high coolant temperature sensor
monitors coolant temperature and will set an alarm at
Diesel Engine Oil 230º F (110º C).
This engine is factory-filled with John Deere 3.4.2 Engine Coolant

Engine Break-in Oil.
The following information is provided as a guide for
Important: Do not add makeup oil until the oil John Deere Engine users in the selection of a suitable
level is BELOW the add mark on dipstick. John coolant.
Deere Engine Break-In Oil (TY22041) should be
used to make up any oil consumed during the The water/ethylene glycol/inhibitor coolant mixture
break-in period. Break-in period is 1 year from used in John Deere engines must meet the following
engine start-up. 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.
Figure #15
Note: CF-4, CG-4, and CH-4 are also acceptable WARNING
A water and anti-freeze solution is required for
3.3.5 Oil Capacities (Including Filter) pump installations. Premixing this solution prior
ENGINE OIL CAPACITY to installing is required. This prevents possible
MODEL QUARTS (LITERS) pure anti-freeze chemical reactions to block
JU4 – All Models 15.5 (14.7) heater elements which can burnout the element.
JU6 – All Models Please see the I&O section (see Page 5) for proper
(Except JU6H-PTP 21.1 (20) cooling system capacities of each model.
models listed below)
JU6 – PTP 3.4.3 Water
(JU6H-UFAD98,
ADP0, ADQ0, ADR0, 34.3 (32.5) Water can produce a corrosive environment in the
ADR8, ADS0, ADS8, cooling system, and the mineral content may permit
ADT0, ADW8, ADX8) scale deposits to form on internal cooling surfaces.
JW6 – All Models 30.1 (28.5) Therefore, inhibitors must be added to control
JX6H – All Models 44.7 (42.3) corrosion, cavitation, and scale deposits.
Figure #16
Chlorides, sulfates, magnesium and calcium are
3.4 COOLING SYSTEM among the materials which make up dissolved solids
that may cause scale deposits, sludge deposits,
3.4.1 Intended Engine Operating Temperature corrosion or a combination of these. Chlorides
and/or sulfates tend to accelerate corrosion, while
The JU, JW, and JX engines are provided with either hardness (percentage of magnesium and calcium salts
a heat exchanger or radiator to maintain the engine broadly classified as carbonates) causes deposits of
scale. Water within the limits specified in figure #17
Page 41 of 65
is satisfactory as an engine coolant when properly corrosion protection, cavitation suppression, pH
inhibited. Use of distilled water is preferred. controls and prevents scale. These inhibitors are
available in various forms, such as liquid packages or
Grains integral parts of anti-freeze.
Parts per per It is imperative that supplemental inhibitors be added
Materials Million Gallon to all John Deere engine systems. A pre-charge
Chloride (Max.) 40 2.5 dosage must be used at the initial fill and the
Sulfates (Max.) 100 5.8 maintenance dosage used at each service interval.
Total Dissolves Solids Serious damage will occur unless inhibitors are used.
(Max.) 340 20 Some of the more common corrosion inhibitors are
Total Hardness (Max.) borates, nitrates and silicates.
170 10
Figure #17 Inhibitors become depleted through normal
operation; additional inhibitors must be added to the
3.4.4 Coolant Capacities coolant as required to maintain original strength
levels. Refer Figure #19 for proper concentrations of
Use an ethylene glycol coolant (low silicate inhibitors.
formulation) that meets the standard of either the GM Min. Max
6038-N formulation (GM1899-M performance) or PPM PPM
ASTM D6210 requirements. Boron (B) 1000 1500
Nitrite (NO2) 800 2400
A 50% coolant water solution is recommended. A Nitrates (NO3) 1000 2000
concentration over 70% is not recommended because Silicon (Si) 50 250
of poor heat transfer capability, adverse freeze Phosphorous (P) 300 500
protection and possible silicate dropout. PH 8.5 10.5
Concentrations below 30% offer little freeze, boil Figure #19
over or corrosion protection.
Do not use soluble oils or chromate inhibitors in John
IMPORTANT Deere engines. Detrimental effects will occur.
Never use automotive-type coolants (such as those
meeting only ASTM D3306 or ASTM D4656). To properly check inhibitor concentrations it may be
These coolants do not contain the correct additives necessary to contact your local Service/Dealer for
to protect heavy-duty diesel engines. They often assistance. Refer to Parts Information Section to
contain a high concentration of silicates and may obtain the part number for the factory Coolant
damage the engine or cooling system. Analysis Kit. This kit can be purchased for a
ENGINE COOLANT nominal fee for analyzing the conditions of the
MODEL CAPACITY engine’s coolant.
QUARTS (LITERS)
JU4H-All Models 15 (14.2) 3.4.6 Procedure for Filling Engine
JU6H-All Models 20 (19)
JW6-All Models 23 (22) During filling of the cooling system, air pockets may
JX6H-All Models 29.6 (28) form. The system must be purged of air prior to
Figure #18 being put in service. This is best accomplished by
filling with a pre-mix solution. Refer to Figure #19A
3.4.5 Coolant Inhibitor for proper fill level.
The importance of a properly inhibited coolant Caution: Do not overfill cooling system.
cannot be over-emphasized. A coolant which has A pressurized system needs space for heat
insufficient or no inhibitors at all, invites the expansion without overflowing.
formation of rust, scale, sludge and mineral deposits.
These deposits can greatly reduce the cooling Install the pressure cap, start and run engine for
systems efficiency and protection capabilities. approximately 5 minutes in order to purge the air
Recommended supplemental coolant inhibitors are a from the engine cavities.
combination of chemical compounds which provide
Page 42 of 65
When verifying that the coolant is at a safe operating 3.4.7.2 Cooling Loop
level, it is best to wait until the engine temperature
drops to approximately 120ºF (49ºC), or lower, Note: Engine may include a cooling loop as an
before removing the pressure cap. optional feature and has not been evaluated by UL as
part of a UL Listed fire pump driver.
Remove the pressure cap and refill to the proper fill Clarke cooling loops are FM Approved to meet
level. To continue the deaeration process start and standard sizing conditions of 50% blocked wye
run engine until the temperature stabilizes at strainers, 100degF (38degC) raw water inlet
approximately 160°-200° (71°-93° C) or run engine temperature, 80 psi inlet pressure, and 10 psi
for 25 minutes, whichever is longer. During this available at the engine outlet.
warming process, you may see coolant coming from
the overflow tube attached at the pressure cap Figure #26 shows the standard NFPA 20 cooling
location. Allow engine to cool, then remove the loop piping arrangement. The cooling loop consists
pressure cap and refill to the proper fill level. of an Automatic flow line with a 12v or 24v solenoid
valve (HSC and ES pump applications only) that is
Caution: Do not remove pressure cap while coolant energized to open anytime the engine is called upon
is at normal operating temperatures. Possible to run from either the fire pump controller or from
personal injury could result from the expulsion of hot the engine instrument panel.
coolant.
NOTE: VT type pump applications do not require a
solenoid valve in the Automatic flow line.
NOTE: With the Mechanical Engine and Alarm
Control Board, See section 3.5.5, the solenoid valve
will open 15 seconds after engine shutdown and will
stay open for 60 seconds. This allows for raw water
to flow through the heat exchanger and reduce the
heat soak rise caused in the engine.
The second flow line is called the Manual by-pass

line and it can be opened at any time if for any reason
the engine shows signs of overheating. Each line has
two (quarter turn) shutoff values installed and the
normal position of the shutoff valve is to remain open
in the Automatic flow line and remain closed in the
Manual by-pass flow line.
Figure 19A NOTE: Opening up both lines to flow is never a

problem should there be some concern of engine
3.4.7 Providing adequate Raw Water Supply to the overheat, especially if there is an emergency
Engine Heat Exchanger situation. The Manual by-pass line can only be
opened by an operator in the pump room.
3.4.7.1 Raw Water Supply
The shutoff valves are all identified to show which
Most Clarke diesel engine fire pump drivers are heat are Normally Open (Automatic flow line) and which
exchanger cooled and some engines also have a are Normally Closed (Manual by-pass flow line).
charge air cooler (CAC) that uses raw water to cool The shutoff valves are also used to isolate water
the air before entering the intake manifold. If you pressure in the event of maintenance to pressure
have a radiator cooled Clarke engine, you can regulators, strainers and solenoid valve. Shut off
disregard this section. Heat exchanger cooled diesel valves in the Automatic flow line are provided with
engine drivers require a clean source of pressurized lockable handles for cooling loops that have been
water from the discharge side of the fire pump in tested to FM requirements.
order to keep the engine from overheating by
providing a specified minimum amount of raw water In each flow line there is also a pressure regulator.
flow. Each pressure regulator protects the downstream
Page 43 of 65
piping from over-pressurization which includes the Note: See section 3.4.7.5 regarding strainer
tube side of the engine shell & tube heat exchanger maintenance.
(and/or CAC) and to control raw water flow rate.
The pressure regulators are set to limit downstream
pressure to 60 psi (4 bar). There is a 0-60 psi (0-4
bar) pressure gauge installed at the cooling loop
outlet, and prior to the engine heat exchanger (or
CAC).
Wye strainers are used to remove debris from the raw

water supply. One strainer is in the Automatic flow
line and the other is in the Manual by-pass flow line.

Figure #26
3.4.7.3 Setting Raw Water Flow Rate raw water flow. With the fire pump flowing 150% of
rated flow, and the Automatic flow line open; verify
The proper amount of raw water flow thru the engine sufficient raw water flow rate is achieved and that the
is of the utmost importance, and the pressure gauge reading of the cooling loop pressure gauge does not
value does little to indicate if there is sufficient flow. exceed 60 psi (4 bar). You will need to capture the
When the engine is exercised weekly, the amount of flow for a specific amount of time coming out of the
raw water flow exiting the engine should always be heat exchanger and going to a floor drain in order to
checked to verify it does not appear to have establish a reasonably accurate flow rate value. Using
diminished. a container or bucket of known volume, record the
time required to fill the container and compare to the
During initial commissioning of the engine, it is gpm or L/min value provided on the I&O datasheet.
important to correctly set the raw flow rate going thru THIS IS CRITICAL FOR PROPER ENGINE
the cooling loop. Each Clarke engine model has an COOLING AT MAXIMUM PUMP LOAD!!
Installation and Operation (I&O) Datasheet that If proper cooling water flow rate is established then
provides basic operating conditions of the engine and no fire pump controller alarm will be triggered to
most values are given based upon engine speed. You indicate clogged raw water strainer (low raw water
will find this datasheet in the documentation bag that flow).
is shipped with the engine for your specific Clarke After verifying raw water flow rate in the Automatic
model. This datasheet must be available during flowline, open the Manual by-pass line shut-off
commissioning in order to set the proper minimum valves, and then close the Automatic flowline shut-
Page 44 of 65
off valves and repeat the above process in order to failure. When this occurs you have no fire
verify the flowrate going thru the Manual by-pass protection! Clarke recommends that after the initial
line. Note, with Automatic flowline closed the engine commissioning and also prior to each weekly
controller low raw water flow alarm may be present , exercise of the engine / fire pump set, both strainers
this is normal. Once this is completed; close the be removed and cleaned and then re-installed before
Manual by-pass shut-off valves and open the starting the engine.
Automatic flowline shut-off valves to restore
conditions back to normal. Clarke engines are equipped with an alarm that is
meant to signal diminished raw water flow rate
3.4.7.4 Raw Water Outlet (terminal 311), possibly due to clogged raw water
strainers in the cooling loop. Refer to Figures 26 and
NOTE: NFPA 20 does allow for the heat exchanger 26A1 for location of sensors. A circuit board located
outlet flow to be returned to a suction reservoir. This near the front of the cooling loop monitors
makes it very difficult to measure the flowrate. differential pressure between the two sensors and will
When discharging to a suction reservoir, NFPA send an alarm to the controller if a low water flow
provides additional requirements: condition exists.
1) A visual flow indicator and temperature Additionally, a raw water temperature switch will
indicator are installed in the discharge (waste send an alarm (terminal 310) when temperature of the
outlet) piping. water exceeds 105°F (41° C). Refer to Figures 26
2) When waste outlet piping is longer than 15ft and 26A1 for location of switch. If either of these
(4.6m) and / or the outlet discharges are more alarms are active, it indicates that the cooling
than 4ft (1.2M) higher than the heat system’s capability may be compromised.
exchanger, the pipe size increased by at least
one size.
3) Verify that when the correct flow rate is
achieved that the inlet pressure to the heat
exchanger (or CAC) does not exceed 60psi
(4bar)
If you have such an installation, it is recommended

that you run the engine for a period of time at
firepump 150% flow and confirm the visual flow
indicator is showing water flow, the temperature rise
is not excessive (usually no more than 40F (4.5C)
over ambient raw water temperature) and the engine
is showing no signs of overheating.

Figure #26A1
3.4.7.5 Raw Water Quality, Strainers and
Deterioration of Heat Exchanger (or CAC) 3.4.7.6 Backflow Preventers
Over time, as the heat exchanger (or CAC) begins to NFPA20 allows for the use of backflow preventers in
plug and foul, this pressure will rise and the flow will the Automatic and Manual flow line of the cooling
diminish which could mean that the heat exchanger loop as required by local code. For specific
(or CAC) may have to be replaced. application information contact factory.
It can be not stressed enough how important it is to
keep the wye strainers within the cooling loop clean: 3.4.7.7 Raw Water Outlet Temperature
Most engine failures occur due to plugged cooling
loop strainers! If the raw water supply has debris in Certain local codes may not allow you to discharge
it (leaves, stones, etc) as the strainer accumulates the waste water outlet from the engine heat
more debris (that will not pass thru it), the flowrate exchanger either due to its temperature or it now
will continue to diminish which will eventually starve being considered hazardous waste. It is
the engine of adequate cooling water flow which will recommended you always check local codes
lead to engine overheat and catastrophic engine regarding waste water discharge.
Page 45 of 65
3.4.8 Flow Paths of Engine Cooling System On heat exchanger equipped engines raw cooling
water flows through the tube side of the charge air
The engine coolant flows through the shell side of the cooler, if equipped, and the tube side of the heat
heat exchanger (or radiator), engine coolant pump, oil exchanger.
cooler, engine block and cylinder head, jacket water
heater, thermostat, expansion tank, and coolant Refer to Figures #35E for heat exchanger cooled
recovery tank (if equipped). engines and #35F for radiator cooled engines for
cooling system flow path diagrams.
Figure 35E – Heat Exchanger cooled engines
Figure 35F- radiator cooled engines
3.4.9 IMPORTANT SERVICE NOTICE overheat must be determined and the cause corrected
to prevent a recurring overheat event.. Additionally,
Any time an engine experiences a high coolant if an event of a restricted flow, collapsed hose,
temperature alarm condition the primary cause of the insufficient coolant level or failed pressure cap is
Page 46 of 65
experienced, further investigation of the cooling UFADR0, UFADS0,
system is required. C071368 UFAD98, UFADR8,
UFADS8, UFADW8,
1) The coolant shoud be drained (after de- UFADX8
energizing the coolant heater Engine Harness
2) Replace the engine thermostat(s) JW6H-UFAD80,
3) Remove the engine water pump and C071369 UFADB0, UFADF0,
inspect the impeller and seal for damage, replace as UFADJ0, UFAD70
necessary. Reassemble and refill coolant according JW6H-UFAAM8,80
to the Installation and Operations Instruction Manual. Engine Harness
4) Run the engine to verify normal operating JW6H-UFADD0
temperature. C071370 Engine Harness
JX6H-UFADF0,
3.4.9.1 Water Pump Cavitation UFAD60, UFADK0,
C071371 UFADN0, UFADP0,
Cavitation is a condition that occurs when bubbles UFAD88
form in the coolant flow in the low pressure areas of Engine Harness
the cooling system and implode as they pass to the
higher pressure areas of the system. This can result in Drawing No. Description (AC Reference
damage to cooling system components, particularly Voltage) Document
the water pump impeller and cylinder liners. C07651 Jacket Water Heater
Cavitation in an engine can be caused by: (JW/JX) (NL Models
 Improper coolant C07591 Optional)
 Restricted coolant flow caused by collapsed (JU)
hose or plugged system Figure #20
 Coolant fill cap is loose or unable to retain
the required pressure 3.5.2 Checking Drive Belt Tension and Adjustment
 Insufficient fluid level
 Failure to de-aerate All drive belts must be adequately tightened to secure
 Overheat that both the engine water pump and battery charging
alternator (when fitted) are operating efficiently.
3.5 ELECTRICAL SYSTEM Refer to Figure #37.
B
3.5.1 Wiring Diagrams (Only with Engine Gauge B
Panel)
Drawing No. Description Reference

(DC Voltage) Document A
C072200 Instrument Panel
C071361 ECM Harness
JU4H-UFAD4G,
UFAD5G, UFAD58,
C071367 UFADJG, UFADP0,
UFADR0, A
UFADW8, Figure #37

UFADY8, UFAD98 To adjust Belt Tension:
JU6H-UFADK0, Check belt tension:
UFADN0, UFAD58, - Give at arrow must be .4” - .6” (10-15mm).
UFADNG,UFADP8 To increase tension of the water pump driving belts:
UFAD88, UFADM8, - Loosen alternator or belt tensioner mounting
UFADMG bolts A and B.
Engine Harness - Adjust to proper belt tension.
JU6H-UFADT0, - Tighten mounting bolts A and B.
UFADP0, UFADQ0,
Page 47 of 65
JX units equipped with automatic tensioner. No belt  Alarm 3: High Engine Coolant Temperature:
adjustment is required. With the engine running, lift high water
temperature switch.
3.5.3 Engine Overspeed (Note: There is no engine mounted High
B Coolant Temperature switch to jumper
In the event of an engine overspeed, the ECM signals across).
the main pump controller and also affects an engine  Alarm 4: Overcrank:
shutdown. Should an overspeed condition occur, Lift and hold the MANUAL STOP SWITCH
investigate the cause and make necessary corrections to prevent the engine from starting during the
before placing engine back in service. The overspeed cycle-crank testing. NEVER shut off the fuel
reset switch must be manually lifted for 30 seconds to supply to the engine to prevent it from
reset. starting. Shutting off the fuel supply will
cause an air lock condition in the fuel system
OVERSPEED VERIFICATION and possibly cause fuel system component
damage.
Hold the OVERSPEED VERIFICATION switch in  Alarm 5: Low Engine Coolant Temperature:
the “up” position. This will provide the main pump With engine at rest, lift low coolant
controller with an overspeed signal and engine temperature switch for 25 seconds.
shutdown at 30 RPM’s below the rated RPM.  Alarm 6: ECM Warning: Lift the Manual
Stop switch for 2 minutes with engine not
Start the engine via the main pump controller; the running to verify ECM Warning Alarm; note
speed switch will generate an overspeed signal and engine will automatically switch to alternate
shutdown protecting both the engine and pump. ECM.
 Alarm 7: ECM Failure: After ECM Warning
EXAMPLE Alarm has been tested, continue lifting
Rated Speed: 1760 RPM Manual Stop Switch for additional 2 minutes
Overspeed Shutdown: 2112 RPM (120% of with engine not running to verify ECM
1760 RPM) Failure Alarm.
Verification Shutdown: 1730 1. After activation of both ECM
CAUTION-after verification of overspeed, lift the Warning and Failure Alarms,
OVERSPEED RESET switch and reset the main activate the ECM Failure Reset
pump controller to re-instate normal operation of the Switch inside the engine control
engine and speed switch. panel.
The over speed shut down set point is factory set, 3.5.5 BATTERY REQUIREMENTS
programmed into the ECM, and not field adjustable.
All Clarke engine models require 8D batteries, as
Caution: Do not attempt to overspeed the engine to sized per SAE J537 and NFPA20. The battery
verify overspeed shutdown. should meet the following criteria:
Cold Cranking Amps (CCA @ 0°F): 1400
3.5.4 Field Simulation of Pump Controller Alarms Reserve Capacity (minutes): 430
Refer to Clarke drawing C131885 (see Page 5)
Field simulation of pump controller alarms – Refer for additional information on Clarke supplied
to supplemental document C134335 for additional batteries.
information.
3.6 ENGINE SPEED ADJUSTMENT
 Alarm 1: Over speed Shutdown: Follow
over speed verification steps above. All governor and speed control functions are
programmed into each ECM at the factory. During
 Alarm 2: Low Oil Pressure: With the engine Start-Up Inspection, some minor speed adjustment
running, lift the low oil pressure switch. may be required.
(Note: There is no engine mounted Low Oil
Pressure switch to jumper across).
Page 48 of 65
To adjust the speed of the engine: Governor Run-Stop Control

A. Start the engine by following the “To Start  Jacket Water Heater
Engine” Procedure in this manual.  Lubrication Oil Level
B. Let the engine warm-up. Open engine gauge  Operating Gauges
panel.  Remove Water from Fuel Filter
C. While observing the tachometer, lift and hold  Run Engine
the speed change enable switch. Toggle  Warning Light
speed adjustment switch up or down to EVERY 6 MONTHS
increase or reduce speed. (Refer to Figure #  Batteries
20A below).  Battery Charging Alternator
D. Stop engine by following “To Stop Engine”  Belts
Procedure in this manual.  Cooling Water Strainers
E. Switch to Alternate ECM and repeat steps A  Driveshaft U-Joints
through D.  Fuel Lines
F. Stop engine by following “To Stop Engine” EVERY 1 YEAR
Procedure in this manual.  Air Filter
G. Switch back to Primary ECM.  Fuel Lift Pump Strainer
H. Close panel door, replace door retaining  Coolant Inhibitor
screws.  Crankcase Vent System
o Driveshaft U-Joints
 Fuel & Oil Filters
 Heat Exchanger Electrode
 Lubricating Oil
 Mounting Isolators
 Wiring System
EVERY 2 YEARS
 Air Filter
 Batteries
 Belts
Figure #20A  Coolant Hoses
 Coolant
4.0 MAINTENANCE SCHEDULE  Thermostat
4.1 ROUTINE MAINTENANCE IMPORTANT: Set main pump controller to “OFF”

while servicing engine. Before turning the main
NOTE: The following Routine Maintenance schedule pump controller to the "OFF" position, check with
is based on an engine usage rate not exceeding 2 the maintenance and security supervisors to verify
hours per month. For UL/FM engine models, also that all the departments concerned will be alerted of
refer to NFPA25. the temporary interruption of their fire protection
LEGEND: equipment for normal maintenance or testing. Also,
 Check
alert the local fire department in the event that the
 Clean main pump controller is connected by silent alarm to
 Replace headquarters. When servicing is complete, return
o Lubricate main pump controller selector to "Automatic"
WEEKLY position and the mode selector on the engine to
 Air Filter
“Automatic” position. Advise the appropriate
 Battery
personnel the engine has been returned to the
 Coolant Hoses
“Automatic”.
 Coolant Levels
 Cooling Water Solenoid Valve 5.0 TROUBLE SHOOTING
 Exhaust System
 Fuel Tank General Troubleshooting Information
 General Inspection
Page 49 of 65
Troubleshooting engine problems can be difficult. above normal. Combining the SPN 000110
with FMI 03 yields engine coolant temperature
The engine control unit (ECM) has the ability to input voltage too high.
detect problems internally and in the electronic Always contact your Clarke service dealer for
control system. This includes determining if any of help in correcting diagnostic trouble codes
the sensor input voltages are too high or too low, if which are displayed for your engine.
the camshaft and crankshaft position sensor inputs
are valid, and if the unit injector solenoids are Listing of Diagnostic Trouble Codes (DTCs)
responding properly. The Diagnostic Trouble Codes (DTCs) are output on
If the ECM detects a problem with the electronic the diagnostic gauge according to J1939 standard as a
control system a diagnostic trouble code (DTC) two-part code. The first part is a two to four-digit
specific to the failed system will be stored in the Suspect Parameter Number (SPN) followed by a one
ECM’s memory. or two-digit Failure Mode Identifier (FMI) code.
5.1 DIAGNOSTIC TROUBLE CODES (DTC’s) Following is a list of SPN’s, FMI’s and a description
of the diagnostic trouble codes that can occur in the
There are two types of DTC’s various engine systems. Not all of these codes will
 Active be present in all engine applications.
 Inactive (stored)
When trouble codes appear on the PowerView
Active DTCs indicate that the failure is occurring. diagnostic gauge, see your engine dealer for repairs
These type of failures are sometimes called “hard” as soon as possible.
failures. They can be accessed on the diagnostic Listing of Diagnostic Trouble Codes
gauge (A) on the instrument panel. SPN FMI Description
28 03 Throttle #3 Input High
Inactive DTCs indicate that a failure has occurred in 28 04 Throttle #3 Input Low
the past, but is not currently occurring. This type of 29 03 Throttle #2 Input High
“stored” DTC can be caused by an “intermittently” 29 04 Throttle #2 Input Low
failure. These could be problems such as a bad 91 03 Throttle #1 Input High
connection or a wire intermittently shoring out. 91 04 Throttle #1 Input Low
91 08 PWM Throttle Abnormal Pulse Width
If a sensor or wiring fails and a DTC is active for the 91 09 Throttle Invalid
sensor, the ECM will use a substitute “limp home” 91 14 Throttle Voltage Out of Range
value in its calculation to continue engine operation. 94 01 Fuel Supply Pressure Extremely Low
Displaying of Diagnostic Trouble Codes (DTCs) 94 03 Fuel Supply Pressure Input Voltage
SPN/FMI CODES High
94 04 Fuel Supply Pressure Input Voltage
Stored and active diagnostic trouble codes Low
are output on the PowerView Gauge 94 16/31 Fuel Supply Pressure Moderately High
according to the J1939 standard as a two- 94 18 Fuel Supply Pressure Moderately Low
part code as shown on the table on the
97 00 Water in Fuel – Continuously Detected
following pages.
97 03 Water in Fuel Signal – Voltage High
The first part is a Suspect Parameter Number
97 04 Water in Fuel Signal – Voltage Low
(SPN) followed by a Failure Mode Identifier
(FMI) code. In order to determine the exact 97 16 Water in Fuel Detected
failure, both (SPN and FMI) of the code are 100 01 Engine Oil Pressure Extremely Low
needed. 100 03 Engine Oil Pressure Input Voltage
High
The SPN identifies the system or the 100 04 Engine Oil Pressure Input Voltage Low
component that has the failure; for example 100 18 Engine Oil Pressure Moderately Low
SPN 000110 indicates a failure in the engine 102 03 Manifold Air Pressure Input Voltage
coolant temperature circuit. High
The FMI identifies the type of failure that has 102 04 Manifold Air Temperature Input
occurred; for example FMI03 indicates value Voltage Low
Page 50 of 65
105 03 Manifold Air Temperature Input 1569 31 Fuel Derate
Voltage High 2000 13 Security Violation
Listing of Diagnostic Trouble Codes
105 04 Manifold Air Temperature Input NOTE: The PowerView diagnostic gauge can have
Voltage Low communication problems that result in Error Codes
105 16 Manifold Air Temperature Input being shown on its LCD display window. The
Voltage High following Error Codes all indicate that there is a
110 00 Engine Coolant Temperature Diagnostic Gauge communication error with the
Extremely High ECM. Contact your servicing dealer for help in
110 03 Engine Coolant Temperature Input correcting these codes:
Voltage High
110 04 Engine Coolant Temperature Input EE – Error XXXXX – EP
Voltage Low No Data
110 16 Engine Coolant Temperature
Moderately High ACP – Err XXXXX - BO
111 01 Engine Coolant Level Low No Addr No Data
158 17 ECM Power Down Error
174 03 Fuel Temperature Input Voltage High ACP – Err XXXXX - BR
174 04 Fuel Temperature Input Voltage Low BUS – EP No Data
611 03 Injector Wiring Shorted to Power
Source NOTE: Refer to wiring diagnostic earlier in this
section as a guide to connections and wires.
611 04 Injector Wiring Shorted to Ground
620 03 Sensor Supply Voltage High
6.0 PARTS INFORMATION
620 04 Sensor Supply Voltage Low
627 01 Injector Supply Voltage Problem
6.1 SPARE PARTS
629 12/13 ECM Error
636 02 Cam Position Input Noise To ensure best operation and efficiency of all engine
636 08 Cam Position Input Missing components, always use genuine Clarke spare parts.
636 10 Cam Position Input Pattern Error Orders should specify:
637 02 Cam Position Input Noise  Engine Model Number - See Engine General
637 08 Cam Position Input Missing  Engine Serial Number - Specification
637 07 Crank Position/Cam Position Out of  Part Number(s) Refer to Engine Maintenance
Sync Parts List section 6.2 or Parts Illustration (see
637 10 Crank Position Input Pattern Error Page 5).
651 05 Cylinder #1 EUI Circuit Open
651 06 Cylinder #1 EUI Circuit Shorted Contact numbers for spare parts:
652 05 Cylinder #2 EUI Circuit Open • www.clarkefire.com
652 06 Cylinder #2 EUI Circuit Shorted • Phone USA: (513) 771-2200 Ext. 427 (calling
653 06 Cylinder #3 EUI Circuit Open within USA)
653 05 Cylinder #3 EUI Circuit Shorted • Phone UK: (44) 1236 429946 (calling outside USA)
654 06 Cylinder #4 EUI Circuit Open • Fax USA: (513) 771-5375 (calling within USA)
654 05 Cylinder #4 EUI Circuit Shorted • Fax UK: (44) 1236 427274 (calling outside USA)
655 06 Cylinder #5 EUI Circuit Open • E-Mail USA: parts@clarkefire.com
655 05 Cylinder #5 EUI Circuit Shorted • E-Mail UK: dmurray@clarkefire.com
656 05 Cylinder #6 EUI Circuit Open
656 06 Cylinder #6 EUI Circuit Shorted 6.2 ENGINE MAINTENANCE PARTS LIST
970 02 Auxiliary Engine Shutdown Switch
Signal Invalid Refer to Appendix “A” at the end of this manual.
970 31 Auxiliary Engine Shutdown Switch
Active
971 31 External Fuel Derate Switch Active
1109 31 Engine Shutdown Warning
1110 31 Engine Shutdown
Page 51 of 65
7.0 OWNER ASSISTANCE as part of a product manufactured by a company
other than John Deere or its affiliates:
Consult Clarke Service Dealer or Factory. Service • 12 months, unlimited hours of use, or
Dealers can be located by going to our website: • 24 months and prior to the accumulation of 2000
www.clarkefire.com. hours of use;
and on each John Deere engine used in an off-
8.0 WARRANTY highway repower application:
•12 months, unlimited hours of use.
8.1 GENERAL WARRANTY STATEMENT Note: In the absence of a functional hourmeter,
hours of use will be determined on the basis of 12
The satisfactory performance of Clarke engines and hours of use per calendar day.
the goodwill of owners / operators of Clarke engines
are of primary concern to the Engine Manufacturer, (*John Deere” means Deere Power Systems Group
the Engine Service Dealer and Clarke. All provide with respect to users in the United States, John Deere
support of these products after final installation of the Limited with respect to users in Canada, and Deere &
complete fire pump and sprinkler system. Company or its subsidiary responsible for marketing
Warranty responsibility involves both Clarke and the John Deere equipment in other counties where the
John Deere service organizations worldwide. user is located)
The Engine Manufacturer (John Deere) provides 8.3.2 Warranty Coverage

Warranty for the basic engine components and Clarke
provides warranty on the accessories added to meet This warranty applies to the engine and to integral
the NFPA-20 specifications and FM/UL certification components and accessories sold by John Deere.
requirements.
All John Deere-warranted parts and components of
8.2 CLARKE WARRANTY John Deere engines which, as delivered to the
purchaser, are defective in materials and/or
All Clarke warranted components have warranty workmanship will be repaired or replaced, as John
duration of 24 months beginning at the Start-up date Deere elects, without charge for parts or engine repair
of the fire pump system. The warranty coverage labor, including reasonable costs of labor to remove
includes replacement of the part and reasonable cost and reinstall non engine parts or components of the
of labor for installation. Components failed due to equipment in which the engine is installed, and, when
improper engine installation, transportation damage, required, reasonable costs of labor for engine
or misuse is not covered under this warranty. removal and reinstallation, if such defect appears
For additional warranty details, see the specific within the warranty period as measured from the date
warranty statement “John Deere New Engine of delivery to the first retail purchaser, if the delivery
Warranty” on the below. Also contact Clarke direct if is reported to John Deere within 30 days of the
you have any questions or require additional delivery.
information.
8.3.3 Emissions System Warranty (Non-Road
Clarke is not responsible for incidental or Diesel)
consequential costs, damage or expenses which the
owner may incur as a result of a malfunction or EMISSIONS CONTROL SYSTEM
failure covered by this warranty. CERTIFICATION LABEL
8.3 JOHN DEERE WARRANTY WARNING: Statutes providing severe penalties for
tampering with emissions controls may apply at the
8.3.1 Warranty Duration user’s location.
Unless otherwise provided in writing, John Deere* The emissions warranty described below applies only
makes the following warranty to the first retail to those engines marketed by John Deere that have
purchaser and each subsequent purchaser (if purchase been certified by the United States Environmental
is made prior to expiration of applicable warranty) of Protection Agency (EPA) and/or California Air
each John Deere new off-highway engine marketed Resources Board (CARB); and used in the United
Page 52 of 65
States in equipment. The presence of an emissions COVERED EMISSIONS SYSTEMS AND
label like the one shown signifies that the engine has COMPONENTS
been certified with the EPA and/or CARB. The EPA System Sample Sub-Systems and Components
and CARB warranties only apply to new engines Air induction system o Air filter housing
o Air mass sensor assembly
having the certification label affixed to the engine o Controlled hot air intake system
and sold as stated above in the geographic areas o Heat riser
governed by the regulation agencies. o Intake manifold
o Intercooler
o Turbocharger
o Wastegate control assembly valve
Fuel metering o Aneroid

system (fuel system) o Carburetor
o Choke mechanism
o Electronic injection unit
o Fuel injection assembly
o Fuel injection nozzle assembly
o Fuel injection injector
o Fuel injector nozzle
o Fuel injection valve assembly
o Fuel line
o Gas pressure regulator
o Pressure relief valve/assembly
o Air restriction sensor
o Air temperature sensor
o Coolant temperature sensor
o Fuel temperature sensor
Note: The hp/kW rating on the engine emissions o Mass flow module sensor
certification label specifies the gross engine hp/kW, o UEGO sensor
Throttle
which is flywheel power without fan. In most
Ignition control o Distributor assembly
applications this will not be the same rating as the system o Engine control module
advertised vehicle hp/kW rating. o Glow plugs
o Ignition coil
Stationary engines under the NSPS provisions are o Ignition control module
o Ignition sensor
also covered, including stationary fire pump ratings. o Ignition wires
Fire pump ratings labeled under the 40 CFR part 60 o Spark plugs
(NSPS). EGR system o EGR cooler
o EGR valve body
U.S. EMISSIONS CONTROL WARRANTY Advanced Oxides of o Lean NOx catalysts
Nitrogen (NOx o Nox absorbers
STATEMENT (UNITED STATES ONLY) controls) o Reductant (urea/fuel)
containers/dispensing systems
Emissions control-related parts and components are Catalyst or thermal o Catalytic converter
warranted by John Deere for five years or 3000 hours reactor system o Double wall portion of exhaust
of operation, whichever occurs first. John Deere system
o Exhaust manifold
further warrants that the engine covered by this o Exhaust gas recirculation valve
warranty was designed, built, and equipped so as to Particulate Controls o Control device enclosure and
conform at the time of sale with all U.S. emissions manifolding
standards at the time of manufacture, and that it is o Regenerators
o Oxidizers
free of defects in materials and workmanship which
o Traps
would cause it not to meet these standards within the o Filters
period of five years or 3000 hours of operation, o Precipitators
whichever occurs first. o Manifold absolute pressure (MAP)
sensor
PCV system o Oil filler cap
Warranties stated in this manual refer only to o PCV solenoid
emissions-related parts and components of your o PCV valve
engine. For complete engine warranty, less o Crankcase ventilation filter
emissions related parts and components, ref to 8.3.1. o Crankcase ventilation valve
Page 53 of 65
Miscellaneous items o Electronic control sensors when so documented by the pump manufacturer’s
used in the above o Electronic control units (ECUs) approved service outlet.
systems o ECU software
o Pump/valve controllers
o Wiring harness 8.3.6 Purchaser’s Responsibilities
o Coolant temperature sensor
o Emissions labels The cost of normal maintenance and depreciation.
o Sealing gaskets
o Thermocouples
Consequences of negligence, misuse, or accident
o Thermostats involving the engine, or improper application,
o Vacuum-sensitive valve/switches installation, or storage of the engine, or improper
application, installation, or storage of the engine.
8.3.4 Obtaining Warranty Service
Consequences of service performed by someone
Warranty service must be requested of the nearest other than a party authorized to perform warranty
authorized John Deere engine service outlet before service, if such service, in John Deere’s judgment,
the expiration of the warranty. An authorized service has adversely affected the performance or reliability
outlet is a John Deere engine distributor, a John of the engine.
Deere engine service dealer, or a John Deere
equipment dealer selling and servicing equipment Consequences of any modification or alteration of the
with an engine of the type covered by this warranty. engine not approved by John Deere, including, but
not limited to, tampering with fuel and air delivery
Authorized service outlets will use only new or systems.
remanufactured parts or components furnished or
approved by John Deere. The effects of cooling system neglect as manifested
in cylinder liner or block cavitation (“pitting”,
Authorized service locations and the name of the “erosion”, “electrolysis”).
John Deere division or subsidiary making this Any premium for overtime labor requested by the
warranty are listed in the Parts and Service Directory purchaser.
for John Deere Engines.
At the time of requesting warranty service, the Costs of transporting the engine or the equipment in
purchaser must be prepared to present evidence of the which it is installed to and from the location at which
date of delivery of the engine. the warranty service is performed, if such costs are in
excess of the maximum amount payable to the
John Deere reimburses authorized service outlets for service location were the warranty service performed
limited travel expenses incurred in making warranty at the engine’s location.
service repairs in non-John Deere applications when Costs incurred in gaining access to the engine; i.e.,
travel is actually per formed. The limit, as of the date overcoming physical barriers such as walls, fences,
of publication of this statement, is US $300.00 or floors, decks or similar structures impeding access to
equivalent. If distances and travel times are greater the engine, rental of cranes or similar, or construction
than reimbursed by John Deere, the service outlet of ramps or lifts or protective structures for engine
may charge the purchaser for the difference. removal and reinstallation.
Incidental travel costs including tolls, meals, lodging,
8.3.5 Warranty Exclusions and similar.
John Deere’s obligations shall not apply to fuel Service outlet costs incurred in solving or attempting
injection pump and nozzles during the pump and to solve non-warrantable problems.
nozzle manufacturer’s warranty period on the pump
and nozzles, components and accessories which are Services performed by a party other than an
not furnished or installed by John Deere, nor to authorized John Deere engine service dealer, unless
failures caused by such items. When the pump required by law.
manufacturer’s warranty is less than the engine
warranty, John Deere will reimburse pump repair Charges by dealers for initial engine start-up and
costs for warrantable-type failures during the inspection, deemed unnecessary by John Deere when
remainder of the original engine warranty period, operation and maintenance instructions supplied with
the engine are followed.
Page 54 of 65
Costs of interpreting or translating services. equipment dealers, nor any other person or entity, has
any authority to make any representation or promise
8.3.7 No Representations or Implied Warranty on behalf of John Deere or to modify the terms or
limitations of this warranty in any way.
Where permitted by law, neither John Deere nor any
company affiliated with it makes any guaranties, 8.3.10 Additional Information
warranties, conditions, representations or promises,
express or implied, oral or written, as to the For additional information concerning the John Deere
nonoccurrence of any defect or the quality or New Off-Highway Engine Warranty, see booklet
performance of its engines other than those set forth Engine Owner’s Warranty – Worldwide.
herein, and DOES NOT MAKE ANY IMPLIED
WARRANTY OR CONDITIONS OF 9.0 INSTALLATION & OPERATION DATA
MERCHANTABILITY OR FITNESS otherwise (See Page 5)
provided for in the Uniform Commercial Code or
required by any Sale of Goods Act or any other 10.0 WIRING DIAGRAMS
statute. This exclusion includes fundamental terms. (See Page 5)
In no event will a John Deere engine distributor or
engine service dealer, John Deere equipment dealer, 11.0 PARTS ILLUSTRATION DRAWING
or John Deere or any company affiliated with John (See Page 5)
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.
8.3.8 Remedy Limitation
The remedies set forth in this warranty are the

purchaser’s 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 purchaser’s performance problems caused by
defects in workmanship and/or materials, purchaser’s
exclusive remedy shall be limited to payment by John
Deere of actual damages in an amount not to exceed
the cost of the engine.
8.3.9 No Seller’s 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
Page 55 of 65
12.0 KEYWORD INDEX
Subject Page Subject Page

(A) (H)
Air Filter 2,9,11,35,36,47,51 Heater, Engine 9,11,39,43,44,45,47
Alternator 45,47 (I)
(B) Installation Data *
Battery Cables 12,14 Installation Instructions 10
Battery Recommendations 12, 46 (L)
Belt Adjustment 45 Lubricating Oil Volume 39
(C) Lubricating System 38
Capacities 11,35,39,40 (M)
Coolant Recommendations 39 Maintenance Schedule 47
Cooling System Manual Operation 15
Anti-Freeze Solutions 39 Model Number Identification 4
Cooling System Capacity 40 (N)
Cooling Water Supply (Loop)…11,14,41,42,43 Name Plate (Engine) 4
Cooling Water Flow Requirements * (O)
Filling Procedure 40 Oil Filter 10,38,47
Heat Exchanger 5,9,11,14,39,41,42,43,44,47 Oil Pressure *
Inhibitors 39,40,41 Oil Specifications/Recommendations 38
Maintenance 43 Operation Data *
Water 39 Out Of Fuel 32
Crankcase Ventilation 36 Overspeed Reset 45,46
(D) Overspeed Verification 46
Diagnostic Trouble Codes 18,21,23,47,48 (P)
Dipstick, Oil Level 38 Parts Illustrations *
Driveshaft alignment 12,13,14 Parts Information 49,50,51,52
Driveshaft Maintenance 14 Powerview Gauge 16,17,18,48,49
(E) Pump:
ECM – Engine Control Module Fuel Injection Pump 28
9,12,16,17,18,23,45,46,47,48,49 Fuel Lift Pump 47
Electrical System 45 (S)
Engine Gauge Panel 11,12,15,17,41,45,46,48 Serial Number 4,5,7,49
Engine Models 4 Shutdown Systems 17,18,22,23,41,45,46,49
Engine Out of Fuel 32 Speed Adjustment 46
Engine Protective Systems (overspeed) 22,36,45,46 Storage 10,52
Exhaust System 8,10,11,35,37,47 (T)
(F) Technical Data *
Falk “Steelflex” Coupling 10,11,12,14,33 (W)
Fuel Filter 5,10,11,27,28,29,30,31,32,33,34,47 Warranty 12,49
Fuel Specifications 11 Wiring Diagram:
Fuel System Operation 27 DC System ,*
Bleeding 27,28 AC Heater Systems ,*
Hand Primer Pump 28,29,31,32,34
* See Page 5
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Appendix “A”
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JU4/JU6H MODELS
JU4H‐UFADW8,
JU6H‐UFADN0,
JU4H‐UFADY8,
JU6H‐UFAD88, JU6H‐UFAD98,
JU4H‐UFAD98,
JU6H‐UFAD58, JU6H‐UFADR8, JU6H‐UFADT0*,
JU4H‐UFAD4G,
JU6H‐UFADNG, JU6H‐UFADS8, JU6H‐UFADP0*,
JU4H‐UFAD5G,
Clarke Engine Models JU6H‐UFADP8, JU6H‐ JU6H‐UFADR0*,
JU4H‐UFAD58,
JU6H‐UFADM8, UFADW8, JU6H‐UFADQ0*
JU4H‐UFADP0,
JU6H‐UFADMG, JU6H‐UFADX8
JU4H‐UFADR0,
JU6H‐UFADK0*
JU4H‐UFADJG*
* Includes ‐D, ‐S, and ‐DS models
Part Description Part Number (standard items only, optional items not shown)
Oil Filter C04521
Fuel Filter (Primary) C02775
Fuel Filter (Secondary) C02776
Air Filter C03396 C03244
Alternator C071363 (12V) or C071365 (24V)
Fuel Pump, High Pressure C02778 C02777 C02778
Heat Exchanger C051386
Starter Motor (12V)
RIGHT SIDE‐
C071588 and RIGHT SIDE – C071946 and LEFT SIDE – C071944 or
LEFT SIDE‐ RIGHT SIDE ‐ C071071 and LEFT SIDE ‐ C071072
C071587
Starter Motor (24V) RIGHT SIDE‐ C071073 and LEFT SIDE‐ C071074
Engine Control Module C071948 C071947
C061522 (12V) C061524 (12V)
Turbocharger C061521 C061523 (24V) C061525 (24V)
Thermostat C071950 C071951 (1) and C071952 (2)
Nozzle, Injector C02779 C02780
Page 63 of 65
JW6H MODELS
JW6H‐UFAD80,
JW6H‐UFADB0,
JW6H‐UFADF0,
JW6H‐UFADD0*
Clarke Engine Models JW6H‐UFADJ0,
JW6H‐UFAD70,
JW6H‐UFAD80
Part Description Part Number (standard items only,
optional items not shown)
Oil Filter C04593
Fuel Filter (Primary) C02773 (INCLUDES PRIMARY AND
Fuel Filter (Secondary) SECONDARY)
Air Filter C03244
Alternator C071363 (12V) or C071365 (24V)
Fuel Pump, High Pressure C02774
Heat Exchanger C051387 R.B
Starter Motor (12V) C071944 or C071072
Starter Motor (24V) C071937 or C071074
Engine Control Module C071942
C061519 (12V)
Turbocharger C061518 C061520 (24V)
Thermostat C072147 (2)
Nozzle, Injector C02772
Page 64 of 65
JX6H MODELS
JX6H‐UFAD88,
JX6H‐UFADP0,
JX6H‐UFADNO,
Clarke Engine Models JX6H‐UFAD60,
JX6H‐UFADF0,
JX6H‐UFADK0*
Part Description Part Number (standard items only, optional items not shown)
Oil Filter C04592
Fuel Filter (Primary) C02770
Air Filter C03595
Alternator (24V) C071365
Heat Exchanger C051433
Starter Motor (24V)
C071937 OR C071938
Engine Control Module C071939
Turbocharger C061517
Thermostat C071940 (1) C071941 (2)
Nozzle, Injector C02771
Page 65 of 65

Engine Manual - Clark

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What are the main components of the engine discussed in the manual?

What are the main components of the engine discussed in the manual?

What maintenance tasks are described for the engine?

What maintenance tasks are described for the engine?

Operation and Maintenance

This manual covers John Deere Engines

Clarke UK, Ltd. Clarke Fire Protection Products, Inc.

 Derates for elevation ambient and

 Fuel delivery settings are factory set and

 The engine shall be installed and maintained

1.1 IDENTIFICATION/NAMEPLATE  J = John Deere base engine

When Clarke furnishes the base (or module) for the

Note: The engine produces a noise level exceeding

CLARKE UK provides the machine manufacturer

Tel: +1 (513) 771-2200 • Fax: +1 (513) 771-0726

1) Description – Diesel Engines

Signed ___________________________________ Date: _______________

Important Note: Labels that show an exclamation

Heat Exchanger Maximum Working Pressure

Air Filter Installation

1.3 PRECAUTIONS FOR WELDING

IMPORTANT: ALWAYS disconnect electronic

2.1 TYPICAL INSTALLATION

IMPORTANT: THIS TREATMENT MUST BE

1. Rotate the shaft so the reference “AB” on the

D) With the driveshaft in the same orientation as the

C) To check the Vertical Parallel Offset, the

2.6.1 To Start Engine

Use main pump controller for starting. Follow

On UL/FM engines, use main pump controller for

1 - PowerView Gauge 6 - Manual Mode Indicator Warning Light

Clarke UL/FM Engines come equipped with dual

The PowerView gauge (reference Figure #9A)

Press the menu key (B) to access the various

The following menu of engine parameters can be

5. Use the arrow keys to scroll to the desired

3. Pressing the “Arrow” keys will scroll

Engine Configuration Data

NOTE: The engine configuration data is a read only

6. Press the “Menu” key to exit the main menu

3. Once “Engine Config” menu item has been

Accessing Stored Trouble Codes

1. Starting at the four engine parameter display,

4. Use the “Arrow” keys to scroll through the

2. The main menu will be displayed. Use the

5. Press the “Menu” key to return to the main

Accessing Active Trouble Codes

For description of trouble codes, see chart in

2. When the diagnostic gauge receives a trouble

IMPORTANT: Ignoring active trouble codes can

3. If the word “Next” appears above the arrow

7. The single or four parameter screen will

4. To acknowledge and hide the code and return

Engine Shutdown Codes

Note: For Clarke Engine models the only shutdown

1. During the normal operation the four

5. The display will return to the single of four

6. The four parameter screen will display the

Signed _____________________ Date: _