Operation and Maintenance Instructions Manual

1 Operation and MaintenanceInstructions ManualPDFP SERIES ENGINESFORFIRE PUMP APPLICATIONSThis Manual covers Perkins 1000 Series enginesprepared by Clarke DD-Afor fire pump servicePrinted in 1/98 LISTEDAPPROVEDLISTEDC13196 FMABBREVIATIONSACA lternating CurrentAECA utomatic Engine ControllerAPIA merican Petroleum InstituteCDD-AClarke Detroit Diesel-AllisonDCDirect CurrentDDCD etroit Diesel CorporationPDFPP erkins Diesel Engines approved for Fire Pump Serviceas certified by FM/UL/ULC for Clarke Detroit Diesel-AllisonFMFactory Mutual ResearchIDIdentificationIPInstrument PanelY1000 Series, Perkins EngineNNaturally AspiratedNANaturally AspiratedNFPAN ational Fire Protection AssociationP/NPart NumberPSIP ounds Per Square InchPTOP ower Take OffRPMR evolutions Per MinuteSAES ociety of Automotive EngineersS/NSerial NumberTTurbochargedWTurbocharged and IntercooledULUnderwriters Laboratories Laboratories of CanadaLISTEDAPPROVEDLISTEDFMSUBJECTPA G ETABLE OF Inside Front CoverDESCRIPTION Section 1 Principles of Diesel Engine Operation .

2 1 General Description ..2 Introduction ..2 Model and Serial Number Identifications ..2FM/UL/ULC Certification Nameplate ..3 Standard Engine Equipment ..5 GENERAL Instructions Section 2 Engine Storage ..6 Preparing New Engine For Running ..7 Normal Maintenance Checks ..8 Fuel System ..8 Drive Belts ..8 Battery ..8 Oil Pressure ..8 Coolant Temperature & Level ..8 Crankcase ..8 Running Inspection ..8 Preventative Maintenance Schedule ..9 ENGINE SYSTEMS Section 3 Fuel System Section .. 10 Diesel Fuel Recommendations .. 11 Maintenance Procedures .. 12 Service Procedures .. 13 Fuel System Priming .. 15 Air Intake and Exhaust System Section .. 17 Air System Operation .. 17 Air Cleaner .. 17 Crankcase Ventilation .. 19 Exhaust 19 Maintenance & Service Procedures.

3 20 Lubrication System Section .. 21 Lubricating System Schematics .. 22 Oil Cooler .. 23 Lube Oil Fill .. 23 Oil Level Dipstick .. 23 Lube Oil Filter .. 23 Lubricating Oil Requirements .. 24 Changing The Lubricating Oil .. 24 Lubricating Oil Analysis .. 25 Changing The Lubricating Oil Filter .. 26 Maintenance Procedures .. 26 TABLE OF CONTENTSSUBJECTPA G ECooling System Section .. 27 Engine Coolant .. 28 Water .. 28 Antifreeze .. 28 Coolant Inhibitor .. 28 Procedure For Filling Engine .. 29 Pressure Cap .. 29 Thermostat .. 30 Engine Coolant Heater .. 30 Heat Exchanger Cooling .. 31 Raw Water System (Cooling Loop) .. 31 Zinc Electrode .. 32 Maintenance & Service Procedures .. 32 Electrical System Section.

4 33 Engine Operating System .. 33 Manual Starting Instructions .. 33 Fuel Injection Pump Solenoid .. 34 Instrumentation And Controls .. 34 Speed Switch .. 35 Battery Charging Alternator .. 36 Starters .. 36 Alarms .. 36 Batteries .. 36 Battery Cables .. 36DC Wiring Diagram .. 37 Engine Heater AC Wiring Diagram .. 38 Maintenance & Service Procedures .. 39 Falk Drive Coupling Instructions Section ..40-45 Installation Procedures ..40-45 ENGINE TUNE-UP Section 4 Tune Up .. 46 Speed Adjustments .. 47 TECHNICAL DATA Section 5 .. 48PA RTS INFORMATION Section 6 Basic Engine Parts .. 49 Option Parts .. 50 OWNER ASSISTANCE Section 7 .. 51 WARRANTY Section 8 ..53-54 ALPHABETICAL INDEX Section 9 ..55-56 PDFPSECTION 1 PRINCIPLES OF DIESEL ENGINE OPERATIONFig.

5 1 - The Four Stroke Cycle4 CYCLEA reciprocating engine is an internal combustion power unit,in which the heat of burning fuel is converted into work inthe cylinder of the engine. In the diesel engine, air is com-pressed in the cylinder; then, after the air has been com-pressed, a charge of fuel is sprayed into the cylinder andignition is accomplished by the heat of compression. Theresulting expanding gas provides the force to turn the FOUR CYCLE PRINCIPLEThe four piston strokes of the cycle occur in the followingorder: Intake, Compression, Power and Stroke:During the intake stroke, the piston travels downward, theintake valve is open, and the exhaust valve is downstroke of the piston permits air from outside toenter the cylinder through the open intake valve port.

6 Theturbocharger (when fitted) increases air pressure in theengine intake manifold and forces it into the cylinder. Theintake of air is never restricted by carburetion or mixingvalves such as those used on spark-ignited, automotive-typeEXHAUSTPOWERCOMPRESSIONIN TAKE gasoline intake charge consists of air only with no fuel Stroke:At the end of the intake stroke, the intake valve closes andthe piston starts upward on the compression stroke. Theexhaust valve remains the end of the compression stroke, the air in the combus-tion chamber has been compressed by the piston to occupya space about one-sixteenth in volume as it occupied at thebeginning of the stroke. Thus, the compression ratio is 16 the air into a small space causes the tempera-ture of that air to rise.

7 Near the end of the compressionstroke, the pressure of the air above the piston is approxi-mately 470 to 585 psi (3240 to 4034 kPa) and the tempera-ture of that air is approximately 1000 F (538 C).During the last part of the compression stroke and the earlypart of the power stroke, a small metered charge of fuel isinjected in the combustion 1 PDFPSECTION 1 Exhaust Stroke:During the exhaust stroke, the intake valve is closed, theexhaust valve is open, and the piston is on its gases are forced out of the combustion chamberthrough the open exhaust valve port by the upward travel ofthe the preceding description of the Diesel Cycle, it isapparent that the proper Operation of the engine dependsupon the two separate functions - first compression for igni-tion, and, second, that fuel be measured and injected into thecompressed air in the cylinder in the proper quantity and atthe proper immediately after the fuel charge is injected into thecombustion chamber, the fuel is ignited by the hot air andstarts to the time the piston reaches the end of the compressionstroke.

8 The burning fuel causes a further increase in the pres-sure above the piston. As the more fuel is added and burnsthe gases get hotter, the pressure increases, pushing the pis-ton downward and adds impetus to crankshaft Stroke:During the power stroke, the piston travels downward andtorque power is translated to the rotating crankshaft thruconnecting rods. Both intake and exhaust valves are 20 states "The compression ignition diesel engine hasproven to be the most dependable of the internal combustionengines for driving fire pumps." The diesel engine will oper-ate under emergency power conditions where loss of utilityor stand-by electric power renders electric motor drivenpumps useless. The diesel driven fire pump system is pre-ferred by most insurance Manual covers Perkins diesel engines as marketed thruDetroit Diesel Corporation.

9 These engines have been manu-factured with specific options to function integrally with anautomatic engine controller for stand-by fire protection ser-vice and to meet NFPA-20 requirements. These systems aredesigned to function under emergency conditions and toassist in holding fire damage to a minimum. Complete under-standing of the Operation and Maintenance of this fire protec-tion system is essential to achieve this separate Manual covers the Operation and Maintenance ofthe Automatic Engine Controller (AEC).The four-cycle engines covered in this Manual are of thefour and six cylinder inline arrangement. The engines areeither naturally aspirated (N) or turbocharged (T) and someunits are turbocharged and intercooled (W).The engines are clockwise (CW) rotating reference is made from a front view (HeatExchanger End) of the engine to determine the rotation ofthe output shaft.

10 Also cylinder designation is made from thefront to rear of the engine in ascending sequence startingwith one. All other engine references, (rightor left) aremade from a rear view of the engine, looking at the rear faceof the PDFP engines are Underwriters Laboratories (UL) list-ed, Underwriters Laboratories of Canada (ULC) listedand/or Factory Mutual (FM) approved and meet the require-ments of the National Fire Protection Association (NFPA) Numbering & IdentificationThere are two model numbers associated with this is the Clarke FM/UL/ULC approved model numbershowing the prefix PDFP. Figure 2 explains the identifica-tion system on PDFP units. Second is the Perkins basicengine model number. Figure 3 provides details for under-standing this Clarke model number appears on the FM/UL/ULC tagattached to the left rear engine mount.