MAINTENANCE SCHEDULE

MAINTENANCE SCHEDULE
RESOURCES

The following routine maintenance schedule

is based on an engine usage rate not
exceeding 2 hours per month. The Operation
and Maintenance Instructions Manual,
provided with the engine, outlines the
maintenance requirements.

For UL/FM engine models also refer to NFPA

25 for further maintenance requirements.

MAINTENANCE SCHEDULE
 MAINTENANCE SCHEDULE
CHECKLIST

The Maintenance Schedule Checklist is an

optional document to record Clarke Fire
specific maintenance items.

The PDF document can be downloaded from

ClarkeFire.com

clarkefire.com/home/service/service-providers/maintenance-checklist
MAINTENANCE SCHEDULE
WEEKLY
MAINTENANCE

Weekly Maintenance Items are routine tasks

based on an engine usage rate not exceeding
2 hours per month. For UL/FM engine
models, also refer to NFPA 25.

Static Checks are tasks that are to be

completed before starting the engine.

MAINTENANCE SCHEDULE
WEEKLY
MAINTENANCE

Check the Air Filter for rips, crushed

elements or extreme dirt.

A dirty filter can make it more difficult for

the engine to draw in air and effect the
power output.

MAINTENANCE SCHEDULE
WEEKLY
MAINTENANCE

Check the Battery electrolyte level and cable

connections.

To maintain battery performance and

reliability, it’s very important to check the
water levels in the battery on a routine
basis. The level of the water should be
enough so that the cell plates are
submerged. If the batteries require fluid
while in service, add water, never add acid.

MAINTENANCE SCHEDULE
WEEKLY
MAINTENANCE

Check the Coolant

Hoses for rips,
splitting, collapses
or bulges.

Heat Jacket-Water
Exchanger Heater
MAINTENANCE
SCHEDULE
WEEKLY
MAINTENANCE

Check the Coolant Level.

During filling of the cooling system, air

pockets may form. The system must be
purged of air prior to being put in service.

Caution: Do not overfill cooling system. A

pressurized system needs space for heat
expansion without overflowing.

MAINTENANCE SCHEDULE
WEEKLY
MAINTENANCE

Check the Coolant

Level.

MAINTENANCE
SCHEDULE
WEEKLY
MAINTENANCE

Check the Fuel Tank for leaks and minimum

two-thirds full.

Inspect the outside of the container for signs of

deterioration or leaks. This visual inspection is
intended to be a routine walk-around and
includes the tank’s piped connections, supports
and foundations.

MAINTENANCE SCHEDULE
WEEKLY
MAINTENANCE

Check the governor run-stop solenoid.

On mechanical engines make sure the speed

adjustment jam nuts are tight and the Manual
Stop is in the Automatic Run position, if
equipped.

MAINTENANCE SCHEDULE
WEEKLY
MAINTENANCE

Check the Jacket Water Heater.

The heater should be warm to the touch.

Confirm there is no discoloration to the outside

of the heater assembly.

MAINTENANCE SCHEDULE
WEEKLY
MAINTENANCE

Check the Lubrication Oil Level.

The level must always be between the

dipstick marks Min. and Max. with the
engine not running.

MAINTENANCE SCHEDULE
WEEKLY
MAINTENANCE

Remove water from the fuel filter by

opening the valve under the filter and let
water and sediment flow until fuel comes
out.

MAINTENANCE SCHEDULE
WEEKLY
MAINTENANCE

Check the Not In Auto Warning Light.

Ensure the warning bulb is functional by

changing the mode selector switch to the
manual mode position.

MAINTENANCE SCHEDULE
WEEKLY
MAINTENANCE

Check the Manual Valves on the cooling

loop. The bypass line manual valves should
be normally closed, and the automatic line
manual valves should be normally open.

MAINTENANCE SCHEDULE
WEEKLY
MAINTENANCE

Check and Clean the Y-strainer screens.

With the engine off, close the manual valves

to restrict flow to the cooling loop. Remove
the endcaps on the y-strainer assembly and
pull the screens. Clean the screens and
ensure there is no containments or
restrictions inside the y-strainer. Replace the
screens, install the endcaps and return the
manual valves to the normal position.

MAINTENANCE SCHEDULE
WEEKLY
MAINTENANCE

Run the engine for no more than 30 minutes

per week.

Starting Method: From the Fire Pump

Controller using test feature or actual
pressure drop.

MAINTENANCE SCHEDULE
WEEKLY
MAINTENANCE

Run the engine

The engine is designed to operate at rated

load conditions. For testing purposes, the
engine can run at lower load (lower flow)
conditions. Running times in any one period
should not exceed 30 minutes maximum.

MAINTENANCE SCHEDULE
WEEKLY
MAINTENANCE

Before starting the engine make sure of the

following:

• The operator has free access to the stop the engine in

an emergency.
• The ventilation ducts are open, and the engine has good
access for air
• All guards are in position
• Battery covers are in place and nothing on top of or
touching the engine.
• The raw water supply for cooling is available without
restriction.

MAINTENANCE SCHEDULE
WEEKLY
MAINTENANCE

Run the engine

When the engine is running make sure that

the coolant temperature, oil pressure and
raw water flow are within limits specified on
the relevant Installation & Operation Data
Sheet.

MAINTENANCE SCHEDULE
WEEKLY
MAINTENANCE

Check the Operating Gauges on the engine

instrument panel.

MAINTENANCE SCHEDULE
WEEKLY
MAINTENANCE

Check the Cooling Loop Raw Water Solenoid

for operation while the engine is running.

The Solenoid is closed when de-energized. A

start signal from the pump controller or
changing the engine instrument panel mode
selector to manual mode will energize the
solenoid, allowing raw water to flow to the
heat exchanger.

MAINTENANCE SCHEDULE
WEEKLY
MAINTENANCE

Check the Heat Exchanger Discharge for free

flow of water.

Raw water flow is crucial for cooling the

engine. The engine’s heat exchanger
transfers heat from the engine coolant to the
raw water.

MAINTENANCE SCHEDULE
WEEKLY
MAINTENANCE

Check the Exhaust System for leaks, proper

support and operational rain cap.

Unsupported exhaust systems will vibrate

excessively and lead to broken pipe
connections or welds.

Exhaust rain-protection is crucial to

preventing water from entering the engine.

MAINTENANCE SCHEDULE
WEEKLY
MAINTENANCE

General Inspection for excessive noise,

adequate ventilation, missing items, fluid
leaks or anything broken.

MAINTENANCE SCHEDULE
6 MONTH
MAINTENANCE

6 MONTH Maintenance Items are routine

tasks to be completed twice a year in
addition to the Weekly Maintenance items.

MAINTENANCE SCHEDULE
6 MONTH
MAINTENANCE

Clean the Battery posts and cable

connectors.

Use baking soda and water or battery

cleaner to clean the terminals and battery
surfaces.

Use terminal spray or Vaseline on the

terminals to minimize corrosion.

MAINTENANCE SCHEDULE
6 MONTH
MAINTENANCE

Check the Battery Charging Alternator for

proper operation.

• Disable the pump controller battery chargers.

• Read the battery voltage with the engine off. (ex:
12 vdc or 24 vdc)
• Read the battery voltage with the engine running.
(ex: 14-15 vdc or 27-29 vdc)
• Compare the readings to determine if the
alternator is charging.
• Enable the battery chargers.

MAINTENANCE SCHEDULE
6 MONTH
MAINTENANCE

Check the Belt for proper tension,

alignment, signs of fraying or cracks.

All belts must be adequately tightened so

that both the engine water pump and
battery charging alternator are operating
efficiently.

MAINTENANCE SCHEDULE
6 MONTH
MAINTENANCE

Check and Clean the Y-strainer screens.

• With the engine off, close the manual valves to

restrict flow to the cooling loop.
• Remove the endcaps on the y-strainer assembly
and pull the screens.
• Clean the screens and ensure there is no
containments or restrictions inside the y-strainer.
• Install the screens, install the endcaps and return
the manual valves to the normal position.

MAINTENANCE SCHEDULE
6 MONTH
MAINTENANCE

Check the Driveshaft U-joints or Coupling.

Visual inspection to ensure they are not
loose and check the set screws.

Disable the pump controller battery charger

and disconnect negative battery cable before
removing the driveshaft guard and
inspecting the driveshaft.

MAINTENANCE SCHEDULE
6 MONTH
MAINTENANCE

Check the Fuel Lines for leaks, breaks, bends

or inconsistencies.

MAINTENANCE SCHEDULE
1 YEAR
MAINTENANCE

1 YEAR Maintenance Items are routine tasks

to be completed once a year in addition to
the Weekly and 6 Month Maintenance
items.

MAINTENANCE SCHEDULE
1 YEAR
MAINTENANCE

Clean or Replace the Air Filter.

MAINTENANCE SCHEDULE
1 YEAR
MAINTENANCE

Clean the Fuel Lift Pump Strainer.

DP and DQ engine models only.

MAINTENANCE SCHEDULE
1 YEAR
MAINTENANCE

Check the Crank Case Vent System to make

sure it is open and not kinked.

MAINTENANCE SCHEDULE
1 YEAR
MAINTENANCE

Lubricate the Driveshaft U-Joints and check

alignment according to the operation
manual instructions.

Use a handheld grease gun with NLGI grade

1 or 2 grease. Pump the driveshaft grease
fittings until grease is visible at all four cap
seals.

MAINTENANCE SCHEDULE
1 YEAR
MAINTENANCE

Replace the Fuel and Oil Filters with OEM or

Clarke branded filters.

MAINTENANCE SCHEDULE
1 YEAR
MAINTENANCE

Check the Heat Exchanger Electrode. If the

length is less than one inch, replace the
electrode.

The heat exchanger plug, known as the Zinc

Electrode or heat exchanger anode, is a 3/8”
NPT zinc electrode element. The Zinc
Electrode is a sacrificial element to help
protect the cooling system from galvanic
corrosion which eats away metal.

MAINTENANCE SCHEDULE
1 YEAR
MAINTENANCE

Test the Fuel for degradation.

Testing shall comply with ASTM D975 and

D6751.

If diesel fuel is found to be deficient the fuel

shall be reconditioned or replaced.

MAINTENANCE SCHEDULE
1 YEAR
MAINTENANCE

Replace the Lubricating Oil. Refer to the

Operations Manual for oil weight and
capacity.

MAINTENANCE SCHEDULE
1 YEAR
MAINTENANCE

Replace the Coolant.

The coolant is a water and ethylene glycol,

50-50%.

Use Clarke part number 0C054129 Clarke

Coolant. The only acceptable replacement is
COOL-GARD II, part number TY26575.

MAINTENANCE SCHEDULE
1 YEAR
MAINTENANCE

Check the Mounting Isolators and

foundation nuts. (If applicable.)

MAINTENANCE SCHEDULE
1 YEAR
MAINTENANCE

Check the Wiring System connections,

tighten if necessary.

MAINTENANCE SCHEDULE
2 YEAR
MAINTENANCE

2 YEAR Maintenance Items are routine tasks

to be completed once every two years in
addition to the Weekly, 6 Month and 1 Year
Maintenance items.

MAINTENANCE SCHEDULE
2 YEAR
MAINTENANCE

Replace the Air Filter.

MAINTENANCE SCHEDULE
2 YEAR
MAINTENANCE

Replace the Batteries.

Batteries are under a constant charge and

only exercised once a week. Replace all
batteries at the same time. An older battery
will drain power from a new battery,
reducing the total amount of battery power
available.

Refer to the Installation and Operations data

for battery sizing requirements.
MAINTENANCE SCHEDULE
2 YEAR
MAINTENANCE

Replace the Belt.

MAINTENANCE SCHEDULE
2 YEAR
MAINTENANCE

Replace the coolant

hoses.

Heat Jacket-Water
Exchanger Heater
MAINTENANCE
SCHEDULE
2 YEAR
MAINTENANCE

Replace the engine Thermostats.

Thermostat Kits can be purchased from

Clarke Fire Protection Products that include
all required thermostats, gaskets and seals.

MAINTENANCE SCHEDULE
2 YEAR
MAINTENANCE

Check the Water Pump Impeller and Seal.

On JU4 and JU6 engine models remove the

water pump to inspect the impeller and seal.
Any over-heating occurrence or use of
incorrect type of coolant can cause
cavitation to the water pump impeller. A
total loss of the impeller would prevent the
engine from cooling in any capacity. Routine
inspection of the impeller can prevent this
situation.
MAINTENANCE SCHEDULE
5 YEAR
MAINTENANCE

Replace the Torsional Coupling.

MAINTENANCE SCHEDULE
PLD
MAINTENANCE

Maintenance Items for –P1 PLD engines.

Inspect the throttle linkage weekly.

MAINTENANCE SCHEDULE
PLD
MAINTENANCE

Maintenance Items for –P1 PLD engines.

Inspect the Damper Fluid weekly.

Refill damper fluid reservoir with Dot 5

Brake Fluid if the fluid level drops.

Minimum 0.50” fluid level

Maximum 0.75” fluid level

MAINTENANCE SCHEDULE
PLD
MAINTENANCE

Maintenance Items for –P1 PLD engines.

Inspect the PLD strainers every 6 months.

May require more frequent inspections

depending up on the quality of the sprinkler
system water supply.

MAINTENANCE SCHEDULE