DDFP SERIES ENGINES FOR FIRE PUMP APPLICATIONS MP-4. Manual - part 1

Operation and Maintenance
Instructions Manual

DDFP SERIES ENGINES

FOR

FIRE PUMP APPLICATIONS

This manual covers Detroit Diesel engines

modified by Clarke DD-A

for fire pump service

Printed in U.S.A.

LISTED

APPROVED

LISTED

MP-4

7/96

C13194

FM

ABBREVIATIONS

AC

Alternating Current

AEC

Automatic Engine Controller

API

American Petroleum Institute

CCW

Counter-clockwise engine rotating (front view)

CDD-A

Clarke Detroit Diesel-Allison

CW

Clockwise engine rotation (front view)

DC

Direct Current

DDC

Detroit Diesel Corporation

DDFP

Detroit Diesel Engines approved for Fire Pump Service

as certified by FM/UL/ULC for Clarke Detroit Diesel-Allison

FM

Factory Mutual Research

GM

General Motors Corporation

ID

Identification

IP

Instrument Panel

I-53

In-Line Cylinder arrangement 53 Series DDC Engine

I-71

In-Line Cylinder arrangement 71 Series DDC Engine

NA

Naturally Aspirated

NC

Normally Closed

NO

Normally Open

NFPA

National Fire Protection Association

P/N

Part Number

PSI

Pounds Per Square Inch

PTO

Power Take Off

RPM

Revelutions Per Minute

SAE

Society of Automotive Engineers

S/N

Serial Number

T

Turbocharged

TA

Turbocharged and Aftercooled

UL

Underwriters Laboratories Inc.

ULC

Underwriters Laboratories of Canada

V-92

Vee cylinder arrangement 92 Series DDC engines

V-71

Vee cylinder arrangement 71 Series DDC engines

LISTED

APPROVED

LISTED

FM

TABLE OF CONTENTS

SUBJECT

PAGE

ABBREVIATIONS........................................................................................................................................ Inside Front Cover

DESCRIPTION — Section 1

Principles of Operation .................................................................................................................................................... 1

General Description .......................................................................................................................................................... 2

Model and Serial Number Designation ............................................................................................................................ 3

Engine Equipment ............................................................................................................................................................ 4

FM/UL Nameplate ............................................................................................................................................................ 5

General Specifications ...................................................................................................................................................... 6

OPERATING INSTRUCTIONS — Section 2

Engine Start-Up and Operating Instructions .................................................................................................................... 8

Standard Model Views  .................................................................................................................................................... 9

Electronic Speed Switch .................................................................................................................................................. 10

Preventative Maintenance Schedule.................................................................................................................................. 11

ENGINE SYSTEMS — Section 3

Fuel System — Section 3.1 .............................................................................................................................................. 12

Operation.................................................................................................................................................................... 12

Maintenance & Service Procedures .......................................................................................................................... 15

Fuel System Schematic.............................................................................................................................................. 14

Air Intake and Exhaust System — Section 3.2 ................................................................................................................ 16

Air System Operation ................................................................................................................................................ 16

Maintenance & Service Procedures .......................................................................................................................... 19

Exhaust Operation...................................................................................................................................................... 19

Lubrication System — Section 3.3 .................................................................................................................................. 20

Operation.................................................................................................................................................................... 20

Lubricating System Schematics ................................................................................................................................ 21

Maintenance & Service Procedures .......................................................................................................................... 22

Cooling System — Section 3.4 ........................................................................................................................................ 25

Operation.................................................................................................................................................................... 25

Maintenance & Service Procedures .......................................................................................................................... 30

Electrical System — Section 3.5 ...................................................................................................................................... 31

Operation.................................................................................................................................................................... 31

Maintenance & Service Procedures .......................................................................................................................... 35

DC Wiring Diagram.............................................................................................................................................. 37, 38 

Engine Heater AC Wiring Diagram .......................................................................................................................... 39

Falk Drive Coupling Instructions — Section 3.6 ............................................................................................................ 40

Installation Procedures .............................................................................................................................................. 41

ENGINE TUNE-UP — Section 4

Tune Up ............................................................................................................................................................................ 46

TECHNICAL DATA — Section 5 .......................................................................................................................................... 47

PARTS INFORMATION — Section 6

Basic Engine Parts ............................................................................................................................................................ 48

Standard Option Parts ...................................................................................................................................................... 49

OWNER ASSISTANCE — Section 7 ............................................................................................................................ 50, 51
WARRANTY — Section 8 ................................................................................................................................................ 52, 53
STORAGE — Section 9  .......................................................................................................................................................... 54
ALPHABETICAL INDEX — Section 10 .......................................................................................................................... 55, 56

SECTION 1

DDFP

Page 1

PRINCIPLES OF OPERATION

The diesel engine is an internal comb ustion power unit, in

which the heat of fuel is converted into work in the cylinder

of the engine.
In the diesel engine, air alone is compressed in the cylinder;

then, after the air has been compressed, a charge of fuel is

sprayed into the c ylinder and ignition is accomplished by

the heat of compression.

The Two-Cycle  Principle

In the tw o-cycle engine, intake and e xhaust functions tak e

place during part of the compression and po wer strokes re-

spectively (Fig. 1) or (Fig. 2). In contrast,

a four -cycle

engine requires four piston strokes to complete an operating

cycle; thus, during one half of its operation, the four-cycle

engine functions merely as an air pump.
A blo wer is pro vided to force air into the c

ylinders for

expelling the exhaust gases and to supply the cylinders with

fresh air for combustion. The cylinder wall contains a row of

ports which are above the piston when it is at the bottom of

its stroke. These ports admit the air from the blower into the

cylinder as soon as the rim of the piston unco vers the ports

(Fig. 1 & 2 - Scavenging).

The unidirectional flow of air toward the exhaust valves pro-

duces a scavenging effect, leaving the cylinders full of clean

air when the piston again covers the inlet ports.
As the piston continues on the upw ard stroke, the exhaust

valves close and the charge of fresh air is subjected to com-

pression (Fig. 1 & 2 - Compression).
Shortly before the piston reaches its highest position,

the

required amount of fuel is sprayed into the comb

ustion

chamber by the unit fuel injector (Fig. 1 & 2 - Po wer). The

intense heat generated during the high compression of the

air ignites the f ine fuel spray immediately. The combustion

continues until the fuel injected has been b urned.
The resulting pressure forces the piston do wnward on its

power stroke. The exhaust valves are again opened when the

piston is about half way down, allowing the burned gases to

escape into the e xhaust manifold (Fig. 1 & 2 - Exhaust).

Shortly thereafter , the do wnward mo ving piston unco vers

the inlet ports and the c ylinder is again swept with clean

scavenging air. This entire combustion cycle is completed in

each cylinder for each re volution of the crankshaft, or, in

other words, in two strokes; hence, it is a "two-stroke cycle".

Exhaust

Power

Compression

Scavenging

AIR

AIR

FUEL

AIR

AIR

AIR

12240

SCAVENGING

EXHAUST

POWER

COMPRESSION

AIR

AIR

AIR

AIR

FUEL

AIR

EXHAUST

Fig. 1 - In-Line Cylinder Arrangement 

Fig. 2 - Vee Block Cylinder Arrangement

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