How it Works
Clarke
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7230175
User guide
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User guide
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Clarke DW 75, 7230175 User guide

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Page 1
ENGINE DRIVEN 3” DIESEL PUMP
MODEL NO: DW75
PART NO: 7230175
OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS
LS0618 ISS 2
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INTRODUCTION

Thank you for choosing this Clarke Pump.
The function of this pump is to move clean /dirty water (with solids in suspension upto 10 mm in diameter).
DO NOT use it to pump:
•Sewage
• Dangerous liquids
• Salt water
Before you use this pump read the manual fully.

GUARANTEE

This pump is guaranteed against faulty manufacture for a period of 12 months from the date of purchase.
Please keep your receipt which will be required as proof of purchase.
This guarantee is invalid if the pump has been abused, tampered with, or not used for its primary function.
Faulty goods must be returned to their place of purchase, no pump can be returned to us without prior permission.
This guarantee does not effect your statutory rights.

INVENTORY

You should find the items in the list below in the carton.
1 x Diesel Powered Water Pump 2 x Rubber Washers
2 x 3" Hose Adaptors 3 x 'Jubilee Clip' style hose clip
2 x 3" BSP Locking Rings 1 x Filter / Strainer
1 x Tailpipe
Speak to your Clarke dealer if items are missing or damaged.
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GENERAL SAFETY RULES

WARNING: WHEN USING PUMPS, ALWAYS FOLLOW BASIC SAFETY PRECAUTIONS TO REDUCE THE RISK OF FIRE, ELECTRIC SHOCK AND PERSONAL INJURY. READ ALL INSTRUCTIONS BEFORE YOU OPERATE THIS PUMP AND SAVE THEM FOR FUTURE REFERENCE.
1. ALWAYS obey all safety precautions for the handling of fuel.
2. ALWAYS make sure that you are familiar with this pump and follow all instructions in this manual.
3. ALWAYS make sure that the pump is positioned correctly to prevent it from moving during operation.
4. Keep the area adjacent to the pump clear.
5. ALWAYS connect the strainer to the suction hose to stop stones and other solids from being pulled into the pump. These can cause damage to the pump.
6. ALWAYS keep the pump dry and clear of the discharge hose.
7. Only use parts supplied by the manufacturer. Using non-standard parts can be dangerous.
8. ALWAYS use at least 300mm of flexible hose to make plumbing connections to the pump. Rigid piping can put stress on the pump, causing damage. If you use rigid piping, it must be supported to eliminate strain on the connections.
9. DO NOT refuel the engine while it is operating, let the engine cool before refuelling.
10. DO NOT use to pump petrol (or other flammable liquids), or corrosive chemicals. The function of this pump is to pump WATER ONLY.
11. DO NOT operate this pump in an explosive atmosphere, near combustible materials, or where there is insufficient ventilation.
12. DO NOT let children use this pump.
13. DO NOT run the pump dry. Always fill the pump with water before starting.
14. DO NOT direct the discharge flow towards another person.
15. DO NOT over-tighten drain or filler plugs. Excessive force can damage the threads or the pump body.
16. DO NOT direct the water discharge towards electrical wiring or equipment.
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GENERAL SAFETY IN THE WORKPLACE

1. Always keep work area clean & tidy. Cluttered work areas invite accidents.
2. Never over-reach. Keep proper footing and balance at all times.
3. Always make sure that the workplace is well lit. Make sure that that lighting is placed so that you will not be working in your own shadow.
4. Dress correctly. Loose clothing or jewellery can get caught in moving parts. Non-slip footwear is recommended. Wear protective hair covering to contain long hair.
5. Always wear safety glasses. (Everyday glasses are not safety glasses).

CARE OF PUMPS

1. Always examine the pump for damage that can effect the operation.
2. The Clarke service department will only replace damaged components using original spare parts.
Keep the instructions for future reference.

SAFETY SYMBOLS

The meanings of the markings and symbols on the pump are shown below.
Read this manual before use and keep it for future reference

ENVIRONMENTAL PROTECTION

At the end of its working life, do not discard this pump or its components with general household waste. Packaging must be taken to a recycling centre and discarded appropriately.
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ASSEMBLY

INSTALL THE SUCTION HOSE

1. Put the rubber washer into the adaptor.
• Make sure that it is seated
correctly.
2. Screw the hose adaptor onto the pump.
• PTFE tape can be used to
ensure a good seal.
3. Slide the hose on to the adaptor and lock in position with the hose clip supplied.
• 3" Reinforced Hose is available
from your Clarke Stockist (Part number - 7955030)
4. Install the strainer on to the other end of the hose following the picture on the right.
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INSTALL THE DISCHARGE HOSE

1. Put the rubber washer into the adaptor.
• Make sure that it is seated
correctly.
2. Screw the adaptor onto the pump.
• PTFE tape can be used to
ensure a good seal.
3. Slide the hose onto the adaptor and lock in position with the hose clip supplied.
• 3" Reinforced Hose is available
from your Clarke Stockist (Part number - 7955030.

FIT THE TAILPIPE

1. Fit the tailpipe to the existing exhaust outlet as shown.
2. Secure in place using the screw and nut attached.
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BEFORE USE

POSITIONING THE PUMP

For optimum performance, place the pump near the water level and use hoses that are no longer than necessary.
As “head” (pumping height) increases, pump output decreases. The length and size of the suction and discharge hoses can also effect pump output.
The discharge head is always greater than the suction head, so it is important for the suction head to be the smaller part of the total head.
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CHECK THE ENGINE OIL LEVEL

WARNING: TO DO THIS CHECK, STAND THE PUMP ON LEVEL GROUND WITH THE ENGINE SWITCHED OFF.
WARNING: BE CAREFUL NOT TO TOUCH HOT PARTS OF THE ENGINE WHEN CHECKING THE OIL LEVEL.
1. Turn the oil filler cap anti­clockwise and remove from the oil filler tube.
2. Wipe the dipstick clean with a lint free cloth.
3. Slide the dipstick into the oil filler tube and remove it again. Do not screw in the oil filler cap/dipstick when doing this.
4. If the oil level is at or below the ‘Lower level’ mark on the dipstick, Fill the crankcase with oil to the ‘Upper Level’ mark.
• Oil capacity is 1 Litre.
• We recommend you use SAE
15W40 or SAE10W30 oil in this pump, available from your Clarke dealer.
5. Replace the oil filler cap.
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ADD DIESEL FUEL

WARNING: REFUEL IN A VENTILATED AREA, AWAY FROM SOURCES OF IGNITION.
WARNING: IF THE ENGINE IS HOT, LET IT COOL BEFORE REFUELING.
WARNING: KEEP FUEL OUT OF THE REACH OF CHILDREN.
RECOMMENDED FUEL
Only use regular diesel.
1. Remove the fuel tank cap.
• Inside the fuel tank is a fuel filter
which collects contaminants as you refuel.
2. Slowly add fuel to the fuel tank.
• Make sure that the fuel level is
not above the maximum fuel level band on the fuel filter.
3. Replace the fuel tank cap.
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OPERATION

WARNING: CHECK THE PUMP FOR DAMAGE BEFORE USE, DO NOT USE THE PUMP IF IT IS DAMAGED IN ANY WAY.
WARNING: THE WATER BEING PUMPED WILL BE POLLUTED IF THIS PUMP BECOMES DAMAGED AND LUBRICANT WITHIN THE ENGINE ESCAPES.
WARNING: WHEN YOU OPERATE THE PUMP THE EXHAUST MUFFLER WILL BECOME VERY HOT.
WARNING: DO NOT OPERATE THE ENGINE IN A CLOSED SPACE, MAKE SURE THAT THERE IS SUFFICIENT AIRFLOW AROUND THE PUMP.

PRIME THE PUMP

1. The pump MUST be primed before use.
2. Before starting the engine, remove the filler cap from the pump chamber.
3. Fill the pump chamber and inlet hose with water.
• A foot valve (not supplied)
connected to the lower end of the inlet hose between the hose and the strainer will help to maintain priming.
4. Replace the filler cap and tighten it securely.
WARNING: OPERATING THE PUMP DRY WILL DESTROY THE PUMP SEAL. IF THE PUMP IS OPERATED DRY, STOP THE ENGINE IMMEDIATELY AND LET THE PUMP COOL BEFORE PRIMING
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START THE ENGINE

1. MAKE SURE THE PUMP IS PRIMED (SEE PAGE 10)
2. Set the fuel valve to the ON position.
3. Set the speed adjusting knob to the START position.
4. Hold the starting handle tightly and pull until you start to feel resistance, then return it slowly to its initial position.
5. Push the decompression lever down and release.
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6. Pull the starting handle lightly until you start to feel resistance. Then pull up and away suddenly to start the engine.
NOTE: If the engine fails to start go
back to step 4 and try again.
WARNING: WHEN THE ENGINE HAS STARTED, RETURN THE STARTING HANDLE SLOWLY TO PREVENT INJURY/DAMAGE AS IT RETURNS.
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STOPPING THE ENGINE

1. Set the speed adjusting knob to “Stop” position.
• You do not need to use the
decompression lever when stopping the engine.
2. Turn fuel switch back to “S” (OFF) position.
3. Hold the starting handle tightly and pull until you start to feel resistance, then return it slowly to its original position.
NOTE: This can help to prevent
cylinder corrosion.

AFTER USE

1. Remove the pump drain plug to drain the pump chamber.
2. Remove the filler cap and flush the pump chamber with clean, fresh water.
3. Let the water drain from the pump chamber, then replace the filler cap and drain plug.
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MAINTENANCE

CHANGING THE ENGINE OIL

CAUTION: PROLONGED EXPOSURE TO USED ENGINE OIL IS DANGEROUS, ALWAYS WASH YOUR HANDS THOROUGHLY AFTER HANDLING USED ENGINE OIL.
The oil in the engine must be changed after the first 20 hours use and then every 6 months or 100 running hours.
1. Unscrew and remove the oil filler cap/dipstick.
2. Put an oil collection tray below the drain plug.
3. Unscrew the drain plug and let the used engine oil drain from the crankcase into the oil collection tray.
NOTE: Drain the engine oil when the
engine is warm; as the oil will flow more freely.
4. Replace the drain plug.
5. Fill the crankcase with oil to the ‘Upper Level’ mark on the dipstick.
• Oil capacity is 1 Litre.
• We recommend you use SAE
15W40 or SAE10W30 oil in this pump, available from your Clarke dealer.
6. Replace the oil filler cap/dipstick.
ENVIRONMENTAL PROTECTION
One of the most damaging sources of pollution is oil, do not throw it away or pour it down drains. Put it in a leak proof container and take it to your local waste disposal site.
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CHANGING THE AIR FILTER

CAUTION: DO NOT OPERATE THE PUMP WITHOUT THE AIR FILTER INSTALLED AS THIS WILL CAUSE EXCESSIVE WEAR TO THE ENGINE.
Clean the air filter after 50 hours of operation (or more often in unusually dusty conditions) as follows.
1. Remove the wingnut and lift off the air filter cover.
2. Remove the air filter assembly.
3. Remove the air filter element.
4. Clean the air filter or replace if necessary.
• If the filter is dirty, wash the
foam filter in a solution of warm water and mild detergent and rinse thoroughly. Let the filter dry fully.
• When it is dry, dip the filter in
clean engine oil and squeeze out excess oil.
• It is normal for blue smoke to come out of the exhaust for a short
time when the filter has been cleaned.
5. Replace the filter and cover.
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STORAGE

Before long-term storage:
1. The pump must be cleaned by flushing with clean water, otherwise, the impeller may be damaged in next operation. After flushing, remove the Pump drain plug and drain all the water from the pump. Then replace the drain plug.
2. Discharge the fuel in the fuel tank. Remove the fuel pipe connector to drain the fuel, then retighten the fuel pipe connector.
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SPECIFICATION

Item Spec
Pump dimensions (L x W x H) 575 x 540 x 595 mm
Pump Weight (kgs) 49.8 kg
Water classification Dirty / Clean (NOT SEWAGE)
Max solids in suspension 10 mm
Inlet/Outlet Size 3” BSP
Maximum Flow 750lL/min
Max Head 30 m
Suction Head 7 m
Max Pressure 3 bar
Run time @75% rated load 4.5 hrs
Engine type/speed 5.4 HP @ 3600 rpm
Fuel tank capacity (petrol) 3.5 L
Lubrication oil capacity/grade 1Litre (SAE 15W40 or SAE10W30) based on
temperature
Sound Pressure Level 89.64 dB LpA
Sound Power Level 103.3 dB LWA
Guaranteed sound power level 106 dB LWA
Uncertainty Factor (K) 2.5 dB
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TROUBLESHOOTING

PROBLEM CAUSE SOLUTION
The engine does not start.
The engine stops and will not restart.
The pump fails to prime.
Low output from pump.
No fuel in tank. Add fuel.
Fuel valve is set to OFF, Set the fuel valve to ON,
No fuel in tank. Add fuel to the tank.
Priming chamber not filled correctly.
Air leaking due to damaged hose, broken hose clamps, split/ill-fitting gasket.
Blocked inlet hose. Clean strainer and make sure that
Damaged impeller. Disassemble the pump and
Air leaking through damaged seal.
The impellor is clogged.
Pickup or delivery hose obstructed.
Suction lift too high. Set the pump nearer to the water
Congested material inside pump.
Damaged impeller. Disassemble the pump and
Fill priming chamber leaving no air gap.
Repair as necessary.
it is not submerged in mud or sediment. Make sure that there are no kinks in the delivery hose.
replace the impeller.
Replace seal.
Clean strainer and make sure that it is not submerged in mud or sediment.
Clear obstruction and make sure that there are no kinks in hose.
level.
Disassemble the pump and clean out.
replace the impeller.
If you cannot correct the fault, speak to your local dealer or the Clarke International service department.
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EXPLODED DIAGRAMS AND PARTS LIST

FIG 1 - CRANKCASE ASSEMBLY

NUMBER DESCRIPTION PART NUMBER
1 SEAL PLUG M16×16 ZGDW75A01
2 WASHER Ø16.5×Ø22.5×1.8 ZGDW75A02
3 CRANKCASE ZGDW75A03
4 PIN 8×16 ZGDW75A04
5 OLL FILLER CAP ASSEMBLY, ZGDW75A05
6 BEARING 6203 ZGDW75A06
7 SEAL ZGDW75A07
8 OIL SEAL 35×52×7 ZGDW75A08
9 BEARING PLATE ZGDW75A09
10 FLANGE BOLT, M8×16 ZGDW75A10
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FIG 2 - CRANKCASE COVER
NUMBER DESCRIPTION PART NUMBER
1 FLANGE BOLT, M8×35 ZGDW75B01
2 OIL SEAL 30×46×8 ZGDW75B02
3 SEAL PLUG 1/8-27NPTF ZGDW75B03
4 OIL FILLER ASSEMBLY ZGDW75B04
5 OLL FILLER CAP ASSEMBLY ZGDW75B05
6 BOLT M12×16 ZGDW75B06
7 WASHER Ø12×Ø20×2 ZGDW75B07
8 COMPRESS SPRING ZGDW75B08
9 BALL ZGDW75B09
10 CRANKCASE COVER ZGDW75B10
11 OIL PUMP ZGDW75B11
12 BEARING 6203 ZGDW75B12
13 PIPE INLET OIL ZGDW75B13
14 OIL PUMP PLATE ZGDW75B14
15 FLANGE BOLT, M6×20 ZGDW75B15
16 GOVERNOR GEAR ASSEMBLY ZGDW75B16
17 CRANKCASE GASKET, COVER ZGDW75B17
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FIG 3 - CYLINDER HEAD ASSEMBLY
NUMBER DESCRIPTION PART NUMBER
1 FLANGE BOLT, M6×25 ZGDW75C01
2 CYLINDER HEAD COVER COMP ZGDW75C02
3 CYLINDER GASKET, HEAD COVER ZGDW75C03
4 HEAD BOLT, M10×1.25×90 ZGDW75C04
5 CYLINDER HEAD COMP ZGDW75C05
6 CYLINDER GASKET ZGDW75C06
CYLINDER GASKET
CYLINDER GASKET
7 PIN 4×12 ZGDW75C07
8 FLANGE BOLT, M8×20 ZGDW75C08
9 LIFTING EYE ZGDW75C09
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FIG 4 - CONNECTING RODS AND CRANKSHAFT
NUMBER DESCRIPTION PART NUMBER
1 RING SET ZGDW75D01
2 PISTON PIN CLIP ZGDW75D02
3 PISTON ZGDW75D03
4 PISTON PIN ZGDW75D04
5 CONN ROD ASSEMBLY ZGDW75D05
6 CRANK PIN SHELL ZGDW75D06
7 CRANKSHAFT COMP.(A) ZGDW75D07
8 BALANCE SHAFT ZGDW75D08
9 WASHER Ø13×Ø38×3.5 ZGDW75D09
10 BOLT M12×12.5×35 ZGDW75D10
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FIG 5 - VALVE TRAIN
NUMBER DESCRIPTION PART NUMBER
1 INTAKE ROCKER ARM ASSEMBLY ZGDW75E01
2 EXHAUST ROCKER ARM ASSEMBLY ZGDW75E02
3 VALVE CAP EXHAUST ZGDW75E03
4 SEAT, VALVE ZGDW75E04
5 VALVE LOCK CLAMP ZGDW75E05
6 VALVE SPRING ZGDW75E06
7 VALVE STEM SEAL ZGDW75E07
8 VALVE SEAT BOTTOM ZGDW75E08
9 VALVE KIT ZGDW75E09
10 CAMSHAFT COMP ZGDW75E10
11 GUIDE VALVE PLATE ZGDW75E11
12 PUSH ROD COMP ZGDW75E12
13 TAPPET VALVE ZGDW75E13
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FIG 6 - PULLSTART ASSEMBLY
NUMBER DESCRIPTION PART NUMBER
1 FAN ZGDW75F01
2 FAN PLATE ZGDW75F02
3 CUP STARTER ZGDW75F03
4 WASHER Ø13×Ø38×3.5 ZGDW75F04
5 BOLT M12×12.5×35 ZGDW75F05
6 SEAL ZGDW75F06
7 PULLSTART ASSEMBLY ZGDW75F07
8 WASHER Ø6×Ø18×1.2 ZGDW75F08
9 FLANGE BOLT, M6×30 ZGDW75F09
10 FLYWHEEL ZGDW75F10
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FIG 7 - AIR CLEANER
NUMBER DESCRIPTION PART NUMBER
1 STUD M8×47 ZGDW75G01
2 GASKET ZGDW75G02
3 AIR CLEANER ASSEMBLY ZGDW75G03
4 PAPER ELEMENTS ZGDW75G04
5 NUT M8 ZGDW75G05
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FIG 8 - MUFFLER
NUMBER DESCRIPTION PART NUMBER
1 FLANGE BOLT, M6×25 ZGDW75H01
2 WASHER Ø6×Ø18×1.2 ZGDW75H02
3 AIR CONDUCTION COVER ZGDW75H03
4 NUT M8 ZGDW75H04
5 STUD M8×34 ZGDW75H05
6 MUFFLER GASKET ZGDW75H06
7 FLANGE BOLT, M8×20 ZGDW75H07
8 MUFFLER ZGDW75H08
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FIG 9 - FUEL SYSTEM
NUMBER DESCRIPTION PART NUMBER
1 FUEL FILTER ZGDW75I01
2 FUEL NET SEAL ZGDW75I02
3 CAP COMP. ZGDW75I03
4 FUEL TANK ZGDW75I04
5 FUEL TAP SEAL, ZGDW75I05
6 FUEL TAP ASSYembly ZGDW75I06
7 FLANGE NUT M6 ZGDW75I07
8 LATHE DOG ZGDW75I08
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9 VITTA ZGDW75I09
10 FLANGE BOLT, M8×20 ZGDW75I10
11 FUEL TANK, BRACKET ZGDW75I11
12 RUBBER BUSH ZGDW75I12
13 SEAL PLUG M12×1.25×14 ZGDW75I13
14 WASHER ?12.5×?20×2 ZGDW75I14
15 LATHE DOG COMP.?9 ZGDW75I15
16 VITTA ZGDW75I16
17 STUD M6×54 ZGDW75I17
18 INJECTOR,PLATE ZGDW75I18
19 INJECTOR ZGDW75I19
20 WASHER ?8×?16.5×0.5 ZGDW75I20
21 VITTA ZGDW75I21
22 STUD M6×38 ZGDW75I22
23 STUD M6×38 ZGDW75I23
24 FUEL PUMP,PLATE ZGDW75I24
25 FUEL PUMP GASKET ZGDW75I25
26 FUEL PUMP ZGDW75I26
27 ADJUSTING GASKET,FUEL PUMP ZGDW75I27
ADJUSTING GASKET,FUEL PUMP
ADJUSTING GASKET,FUEL PUMP
28 FUEL FILLER,ASSY. ZGDW75I28
29 UNDERPROP,FUEL TANK ZGDW75I29
30 FLANGE BOLT M8×40 ZGDW75I30
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FIG 10 - GOVERNOR SYSTEM
NUMBER DESCRIPTION PART NUMBER
1 FLANGE BOLT M6×14 ZGDW75J01
2 KNOB CONTROL ZGDW75J02
3 NONMETAL HEXAGON NUTS M6 ZGDW75J03
4 CONTROL ASSY ZGDW75J04
5 FUEL STOP ASSY. ZGDW75J05
6 TORSIONAL SPRING ZGDW75J06
7 SPRING ZGDW75J07
8 SPRING,GOVERNOR ZGDW75J08
9 OIL SEAL 8×14×5 ZGDW75J09
10 WASHER ZGDW75J10
11 FORK ZGDW75J11
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FIG 11 - PUMP
NUMBER DESCRIPTION PART NUMBER
1 PUMP COMPLETE ZGDW75K01
2 PUMP COVER ZGDW75K02
3 WASHER ZGDW75K03
4 FLANGE BOLT ZGDW75K04
5 MACHINERY SEAL ZGDW75K05
6 WATER PUMP IMPELLER ZGDW75K06
7 VOLUTE CASING ZGDW75K07
8 O-RING ZGDW75K08
9 O-RING ZGDW75K09
10 HOUSING OF PUMP ZGDW75K10
11 O-RING ZGDW75K11
12 PLUG ZGDW75K12
13 CHECK VALVE ZGDW75K13
14 FLANGE ZGDW75K14
15 LINK SEAL ZGDW75K15
16 TUBE TIE-IN ZGDW75K16
17 TUBE LOOP ZGDW75K17
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18 TUBE LINK ZGDW75K18
19 FLAT WASHER ZGDW75K19
20 FLANGE BOLT ZGDW75K20
21 FLANGE BOLT ZGDW75K21
22 OUTPUT SEAL ZGDW75K22
23 OUTPUT FLANGE ZGDW75K23
24 FILTER COVER ZGDW75K24
25 FILTER ZGDW75K25
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FIG 12 - FRAME
NUMBER DESCRIPTION PART NUMBER
1 FRAME COMPLETE ZGDW75L01
2 DECORATIVE FRAME ZGDW75L02
3 RIGHT BOTTOM RUBBER,L=15 ZGDW75L03
4 FLANGE NUT ZGDW75L04
5 RIGHT BOTTOM RUBBER ZGDW75L05
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DECLARATION OF CONFORMITY

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DECLARATION OF CONFORMITY

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