Clarke PW50 Operation & Maintenance Instructions Manual

OPERATION & MAINTENANCE

INSTRUCTIONS

GC0816

ENGINE DRIVEN 2” PUMP

MODEL NO: PW50

PART NO: 7140650

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INTRODUCTION

Thank you for purchasing this CLARKE Pump.

This pump is designed for pumping clean or dirty water, that is water
containing solids in suspension. It is NOT designed for pumping slurry, sludge,

mud or heavily polluted water, or any water containing chemicals or other
acidic contaminants including salt water.

This pump has the ability to pump solids in suspension as large as 4 mm.

Before attempting to use this product, please read this manual thoroughly and
follow the instructions carefully. In doing so you will ensure the safety of yourself
and that of others around you, and you can look forward to your purchase
giving you long and satisfactory service.

GUARANTEE

This product 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 product is found
to have been abused or tampered with in any way, or not used for the
purpose for which it was intended.

Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission. This guarantee does not effect your
statutory rights.

ENVIRONMENTAL PROTECTION

Through purchase of this product, the customer is taking on the
obligation to deal with Waste Electrical/Electronic Equipment (WEEE)
in accordance with the WEEE regulations in relation to the treatment,
recycling & recovery and environmentally sound disposal of the
equipment.

In effect, this means that this product must not be disposed of with general
household waste. It must be disposed of according to the laws governing
Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal
facility.

At the end of its working life, do not dispose of this product or its components
with general household waste. Any tools, accessories and packaging should
be sorted, taken to a recycling centre and disposed of appropriately.

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GENERAL SAFETY RULES

1. ALWAYS observe all safety precautions for the handling of fuel.

2. ALWAYS thoroughly familiarise yourself with this pump & its operation, and
follow all instructions in this manual.

3. ALWAYS ensure that the pump is properly positioned where necessary to
prevent it from moving during operation, and that the immediate area
surrounding the pump is kept clear.

4. ALWAYS use the strainer connected to the suction hose to prevent stones
and other solids from being drawn up, which could cause severe damage
to the pump.

5. ALWAYS keep the pump itself dry and well clear of water discharge.

6. ALWAYS use only replacement parts supplied by the manufacturer. The use
of non-standard parts could be hazardous.

7. ALWAYS use at least 300mm of flexible hose to make plumbing connections
to the pump. Rigid piping may put stress on the pump, causing damage. If
rigid piping must be used, it should be supported so as to eliminate stress on
the pump.

8. NEVER refuel the engine whilst it is running and allow the engine to cool
sufficiently before refuelling.

9. NEVER use for pumping petrol (or other flammable liquids), or corrosive
chemicals. This pump is designed to pump WATER ONLY.

10. NEVER operate an engine driven pump in an explosive atmosphere, near
combustible materials, or where there is insufficient ventilation.

11. NEVER allow children to use this pump.

12. NEVER run the pump dry. Always fill the pump with water before starting.

13. NEVER direct the discharge flow towards another person.

14. NEVER over-tighten drain or filler plugs. Excessive force may damage the
threads or the pump body.

15. NEVER direct the water discharge towards electrical wiring or equipment.

WARNING: WHEN USING POWERED PRODUCTS, BASIC SAFETY
PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE THE RISK OF
FIRE, ELECTRIC SHOCK AND PERSONAL INJURY. READ ALL THESE
INSTRUCTIONS BEFORE ATTEMPTING TO OPERATE THIS PRODUCT AND
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.

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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. Keep other persons away. Do not let persons, especially children, not
involved in the work, touch the pump and keep them away from the work
area.

4. Always ensure the workplace is well lit. Ensure that lighting is placed so that
you will not be working in your own shadow.

5. Dress properly. Loose clothing or other jewellery may get caught in moving
parts. Non-slip footwear is recommended. Wear protective hair covering to
contain long hair.

6. Always wear safety glasses. (Everyday glasses are not safety glasses).

CARE OF PUMPS

1. A component that is damaged should be properly repaired or replaced by
your Clarke service department.

2. Always check for any damage or any condition that could affect the
operation of the pump. Damaged parts should be properly repaired.

3. Have your pump repaired by a qualified person. Repairs should only be
carried out by qualified persons using original spare parts, otherwise this
may result in considerable danger to the user.

Please keep these instructions in a safe place for future reference.

SAFETY SYMBOLS

The meanings of the markings and symbols on the product are shown below

The following symbols are shown on the product or it’s packaging.

Read this manual
before use and keep
in a safe place for
future reference

Falls within Waste
Electrical Equipment
(WEEE) Directive

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INVENTORY

The items above should be supplied in the carton. If any items are missing or
damaged, please contact the Clarke dealer where you purchased the
product.

The pump is fitted with an open impeller. The suction strainer supplied, must
always be used, to ensure that large stones or other objects cannot be drawn
up, as this would cause severe damage to the pump.

1Hose Clamps 5 Hose Adaptor / Locking Collar

2 Plastic Inlet Strainer/Filter 6 Spark plug box spanner

3 Rubber Feet c/w nuts 7 Tommy Bar

4 Sealing Rings

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BEFORE USE

FITTING THE FEET

1. Fit the 4 x rubber feet to the frame
using the nuts and washers
supplied.

FILLING WITH OIL

This pump is not supplied containing
engine oil or fuel. Use any engine oil
of SAE 10-30 rating unless operating
at very high or low ambient
temperatures.

To fill the engine crankcase with oil:

1. Remove the filler plug/dipstick.

2. Fill the unit with oil until visible
inside.

3. Check the level by inserting the
dipstick back into the filler tube
and checking the level is within
the indicated range. If correct
replace the dipstick/filler cap.

FILLING WITH FUEL (ONLY USE REGULAR UNLEADED PETROL)

Fill the fuel tank with unleaded petrol
or check the level by opening the
fuel cap and topping up as required.

Located within the fuel tank is a
strainer. Check this filter periodically
and remove any contaminants
which may have accumulated. Do
not fill above the fuel strainer
shoulder.

After refuelling, tighten the fuel filler
cap securely.

WARNING: WIPE UP ANY SPILT FUEL BEFORE RUNNING THE PUMP.
ALLOW THE ENGINE TO COOL DOWN BEFORE REFUELLING

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INSTALLING THE PUMP

1. Position the pump on a firm foundation and as near to the water source as
possible.

2. Connect the suction and
discharge hoses to the pump
using the hose clamps and sealing
rings supplied, to achieve an
airtight seal.

• There must be no damage to

the hoses which must be
adequately protected and
supported.

NOTE: Hoses or pipes should be

supported independently
and not carried by the
pump.

IMPORTANT: An air leak in the suction
line will prevent priming, and reduce
the performance of the pump.

3. Pay particular attention to the
following:

• Always ensure the hose adaptor sealing ring is in place and correctly

fitted.

• Always use a flexible hose at the pump body connection of at least

1ft (300 mm) length.

• Keep all pipes/hoses as short and straight as possible and avoid

sharp bends. If a flexible hose must be laid across a roadway,
protect it with planking.

• Ensure there is adequate drainage for the discharged water, and

that there is no danger of damage to property as a result of the
pumping activity..

NOTE: Instantaneous shut off pressure, applied when a vehicle runs

across an unprotected hose, will cause “hydraulic shock”, which
can damage the pump and/or the hose.

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4. Attach the inlet strainer to the end
of suction hose using a further
hose clamp, to prevent large
stones etc, from being drawn up
which could cause severe
damage. Keep the strainer free of
debris.

5. If it is likely to clog with dirt or
debris, proceed by either:

• preparing a bed of stones on

which to rest the strainer.

• tying the strainer so that it stays off the bottom of the pit, pond or

excavation.

• rest the strainer inside a basket or bucket to keep undue debris

away.

6. Prime the pump with water by
removing the filler plug on top of
the pump and filling with water,
leaving no air gap.

• The pump is self-priming only

when the pump is filled. It will
prime and re-prime itself
without refilling. Refilling is
necessary only if the pump has
been drained.

7. Never allow the pump to run dry.

8. If the discharge hose runs
vertically more than 30ft a check
valve should be installed in the
discharge hose near the pump to
stop water hammer when the
pump is shut down.

• It is the pump owners

responsibility to supply and
instal a check valve to protect
the pump in this way.

9. Properly fuelled and lubricated, the pump will run without further attention.

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OPERATION

Ensure the site and pump are prepared, then proceed as follows:

STARTING

• Note the markings displayed on the engine parts, for the following

settings.

1. Set the engine On/Off switch to
On.

2. Move the fuel valve to the right
side (open position).

3. Pull the starter recoil rope slowly
two or three times to allow fuel to
reach the carburetor.

• The direction of operation is

marked on the machine.

4. To start a cold engine, set the
choke lever to the left (closed
position), but if the engine is
already warm, the choke should
be in the open position to the
right.

5. Set the throttle about one third
open. Set the engine switch ON.

6. Pull the starter recoil rope firmly
until the engine starts. Do not
snatch at the starter rope and allow it to recoil slowly after each pull.

7. Once the engine starts, gradually return the choke to the open position as
the engine warms up and use the engine throttle to gradually increase
engine speed.

PRIMING & CONTROL

After starting the engine, move the throttle to the open position for priming of
the pump and checking for pump output. Output is controlled by adjusting
the engine speed.

WARNING: WHEN THE ENGINE IS RUNNING THE EXHAUST MUFFLER
IS VERY HOT. TAKE CARE TO AVOID BURNS. NEVER RUN THE ENGINE
IN AN ENCLOSED SPACE - ENSURE THERE IS ADEQUATE
VENTILATION.

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With a suction lift of 5 to 10ft, the pump should begin discharging liquid in a
few moments. To further reduce priming time, the engine speed may be

increased after the engine is properly run in. If pumping does not start within
this time, shut off engine and check carefully to find the problem. See
TROUBLESHOOTING.

NOTE: Filling the suction pipe with water will speed up the priming

process, and it is recommended that a non-return valve be fitted
to the end of the suction pipe.

On higher vertical lifts, a higher engine speed is necessary but on shallow lifts
or when there is little water to pump, preserve fuel and engine wear by
reducing engine speed.

In the event of blockages, where debris has entered the suction chamber, the
suction chamber can be opened and cleaned out by removing the bolts (12)
shown in the layout on page 18.

SHUTTING DOWN

1. Reduce engine speed to minimum using the throttle lever.

2. Stop the engine by switching OFF the ignition switch.

3. Close the fuel valve.

MAINTENANCE

1. Always maintain the pump in a clean condition, checking regularly for
loose bolts etc.

2. Clean the air filter once every 50 hours of use (or more often in unusually
dusty conditions) as follows.

3. Unscrew the wingnut and lift off the air filter assembly from the engine.

4. Remove the components shown
and clean the foam filter element
with a high flashpoint solvent.
Squeeze dry, then dip in clean
engine oil and squeeze oil excess
oil.

• Never operate the pump

without the air cleaner installed
as this would cause premature
wear to the engine.

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5. Replace the spark plug after the
first month or every 50 hours of
use.

6. Check when installing that the
spark plug has the correct
clearance by measuring with a
feeler gauge and adjusting the
side electrode as required.

• Clearance should be 0.7-

0.8mm.

• The recommended spark plug

is LDF7RTC.

CHANGING THE OIL

The oil in the engine should be changed after the first 20 hours use and
thereafter every 6 months or 100 running hours.

Remove the dipstick and drain plug and then drain the oil. Re-fill and check
the level as described on page 7.

We recommend SAE15W-40 or equivalent motor oil.

ENVIRONMENTAL PROTECTION

One of the most damaging sources of pollution is oil. Do not throw away used
oil with domestic refuse or flush down a sink or drain. Collect old oil in a leak­proof container and take it to your local waste disposal site.

STORAGE

After use, drain the pump body whenever there is danger of freezing, and if
the pump has been used with contaminated or salty water, It should be
thoroughly flushed with clean water following use, both inside and out and
drained before replacing the drain plug.

CAUTION: PROLONGED EXPOSURE TO USED OIL IS HARMFULL,
ALWAYS WASH YOUR HANDS THOROUGHLY AFTER HANDLING USED
OIL.

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Always transport the pump with the fuel cock turned off and keep the unit
level to prevent any fuel from spilling.

If the pump is not to be used for some time, it should be flushed thoroughly
with clean water, and drained completely before storing in a clean dry
environment. Additionally, it should be prepared as follows:

1. Drain the fuel tank and carburetor
completely by opening the drain
plug in the carburetor float
chamber and draining all
remaining fuel into a suitable
container ensuring the fuel shut­off valve is closed.

2. Remove the spark plug, and pour
2-3 teaspoons of light oil into the
cylinder through the spark plug
hole.

3. Pull the starter recoil rope slowly 2 or 3 times so that the oil is deposited on
the cylinder walls and replace the spark plug.

• Suction and delivery hoses, additional connectors and filters are

available froom your Clarke stockist.

TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

Engine fails to
start

Lack of fuel in tank. Fill tank as necessary.

No fuel reaching
carburetor.

Fuel tap is set to OFF. Turn on fuel
tap.

Engine switch is in the
OFF position.

Set engine switch to the ON
position.

Lack of spark at the
spark plug.

Check the spark plug cable is
securely fitted to the plug. With
the switch in the ON position, hold
the spark plug electrode against
the engine and pull the starter
cord to observe the spark. If spark
is present but engine will not start,
consult your Clarke dealer.

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If, after reading the troubleshooting chart you are still unable to rectify any
faults, please contact your local dealer or Clarke International for assistance.

Engine stops and
will not re-start.

Lack of fuel in tank Fill tank as necessary.

Lack of oil in engine
causing ‘Low Oil Pro­tector’ sensor to stop
engine from running.

Top up oil sump as necessary.

Pump fails to
prime.

Priming chamber not
filled correctly.

Fill priming chamber leaving no
air gap.

Air leaking through the
suction line joints due
to damaged hose,
broken hose clamps,
split/ill-fitting gasket.

Carry out repairs as necessary.

Blocked inlet hose. Clean strainer and ensure it is not

submerged in mud or sediment.
Ensure there are no kinks in the
delivery hose.

Engine speed too low. Increase engine speed.

Damaged impeller. Dismantle pump and replace

impeller.

Air leaking through
damaged seal.

Replace seal.

Low output from
pump.

Engine speed too low. Increase engine speed.

Impellor clogged. Clean strainer and ensure it is not

submerged in mud or sediment.

Pickup or delivery hose
obstructed.

Clear obstruction and ensure
there are no kinks in hose.

High frictional losses in
long inlet hose.

Avoid un-necessary curves,
restrictions or valves.

Suction lift too high. Position pump as close as possible

to the water level.

Congested material
inside pump.

Dismantle pump and clean out.

Damaged impeller. Dismantle pump and replace

impeller.

PROBLEM CAUSE SOLUTION

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SPECIFICATION

COMPONENT PARTS - GENERAL

Item Spec

Product dimensions (L x W x H) 470 x 375 x 400 mm

Product Weight (kgs) 23.3 kg

Water classification Dirty/Clean

Max solids in suspension 4 mm

Inlet/Outlet Size 2” BSP

Maximum Flow

550 l/min (33m

3

/h)

Max Head 30 m

Suction Head 7 m

Max Pressure 0.25 MPa (2.5 bar)

Run time @75% rated load 2.65 hrs

Engine type/speed 6.5HP (4 stroke) 3600rpm

Fuel tank capacity (petrolium) 3.6 L

Lubrication oil capacity/grade 0.6 L (SAE/SW40)

Sound Pressure Level 89.0 dB LpA

Sound Power Level 101.60 dB LWA

Guaranteed sound power level 106 dB LWA

Uncertainty Factor (K) 4.42

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COMPONENT PARTS - ENGINE ASSEMBLY

No Description No Description

1 Fuel Tank Cover 31 Air Deflector

2 Fuel Strainer 32 Oil Drain Plug

3 Fuel Tank 33 Gasket

4 Tension Spring 34 M6 x 12 Bolt

5 Governor Arm 35 Suppressor

6Nut M6 36Crankcase

7Gasket 37Pin

8 Governor Lever 38 Oil proximity Sensor

9 Governor Rod 39 Bolt M6 x 15

10 Governor Spring 40 Bearing 205

11 Bolt 41 Governor Gear

12 Governor Assembly 42 Woodruff Key

13 Bolt M6 x 10 43 Bearing Cap

14 Pulling Tray Cover 44 Big End Bolt

15 Spring 45 Crankcase Gasket

16 Pulling Tray 46 Oil Dipstick

17 Spring 47 Sealing Ring

18 Starting Pawls 48 Crankcase Cover

19 Pin 49 Bolt M8 x 35

20 Clip Spring 50 Starting Handle

21 Starting Engagement Disc 51 Starting Cord

22 Bolt M6 x 15 52 Wingnut

23 Bolt M6 x 12 53 Air Cleaner Cover

24 On/Off Switch 54 Filter Sponge

25 Recoil Cover 55 Air Cleaner Base

26 Flywheel Nut 56 Nut M6

27 Starting Claw 57 Intake Duct Assembly

28 Fan 58 Bolt M6 x 25

29 Flywheel Assembly 59 Ignition Block Assembly

30 Oil Seal 60 Cylinder Head Stud

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61 Bolt 85 Rocker Arm

62 Gasket 86 Muffler Cover

63 Carburetor 87 Rocker Bolt

64 Gasket 88 Pushrod retainer Frame

65 Fixing plate 89 Pushrod

66 Gasket 90 Exhaust Gasket

67 Stud 91 Cable Bracket

68 Cylinder Head 92 Screw

69 Cylinder Head Gasket 93 Bolt

70 Exhaust Valve 94 Circlip

71 Inlet Valve 95 Connecting Rod

72 Tappet 96 Muffler

73 Camshaft 97 Nut M8

74 Rubber Tube 98 Compression Ring

75 Exhaust Valve Adjusting Nut 99 Piston Ring

76 Inlet Valve Spring Retainer 100 Oil Ring

77 Exhaust Valve Spring Retainer 101 Small End Journal

78 Valve Spring 102 Piston

79 Spark Plug (type LD F7RTC) 103 Crankshaft

80 Bolt M6 x 14 104 Oil Dipstick

81 Valve Cover 105 Spark Plug Lead/Cover

82 Cover Gasket 106 Air Filter Seating Ring

83 Nut 107 Sealing Ring

84 Nut 108 Flanged Washer

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COMPONENT PARTS - ENGINE ASSEMBLY

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COMPONENT PARTS - PUMP ASSEMBLY

No Description No Description

1 Locking Collar 13 Washer

2 Hose Adaptor 14 O-Ring

3 Sealing Ring 15 Guide Flow Cover

4 Bolt M8 x 20 16 M8 x 25 Bolt

5 Water Inlet Flange 17 Pump Impeller

6 Check Valve 18 Flat Key

7Gasket 19Bolt M8 x 45

8 Discharge Elbow 20 Sealing Ring

9Drain Plug 21O-Ring

10 O-Ring 22 Water Seal

11 Pump Casing 23 Joining Flange

12 Flange Bolt M8 x 25

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DECLARATION OF CONFORMITY