Clarke PW80A Operation & Maintenance Instructions Manual

PETROL DRIVEN WATER PUMP

MODEL NO: PW80A

PART NO: 7140671

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC0819 - ISS1

INTRODUCTION

Thank you for purchasing this CLARKE water pump.

Before attempting to use the pump, 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 the pump giving
you long and satisfactory service.

GUARANTEE

This CLARKE product is guaranteed against faulty manufacture for a period of
12 months from the date of purchase. Please keep your receipt 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 RECYCLING POLICY

If disposing of this product or any damaged components, do not dispose of
with general waste. This product contains valuable raw materials. Metal
products should be taken to your local civic amenity site for recycling of metal
products.

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SAFETY PRECAUTIONS

CAUTION: As with all machinery, there are certain hazards involved
with the operation and use of this water pump. Exercising caution will
reduce the risk of personal injury.

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

2. Thoroughly familiarise yourself with this unit & 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 ensure the unit cannot be started inadvertently by using the ON/
OFF switch whenever carrying out maintenance or making adjustments.

5. 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.

6. ALWAYS keep the machine itself dry and well clear of water discharge

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

8. ALWAYS use at least 1ft (30cm) of flexible hose to make pipe connections
to the pump. Rigid piping may put stress on the pump, causing damage. If
rigid piping is used, it should be supported so as to eliminate stress.

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

10. NEVER use for pumping petrol (or other flammable liquids), or corrosive
chemicals. These pumps are designed to pump water only.

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

12. NEVER allow children to use this pump.

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

14. NEVER attempt any major repairs to this product unless you are qualified.

15. NEVER direct the discharge flow towards another person.

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

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

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OVERVIEW

1 Inlet Strainer 11 Hose Securing Clips

2 Inlet Adaptor/locking ring with O-ring 12 Suction Chamber Drain Plug

3 Water Filler Plug 13 Spark Plug Spanner

4 Outlet Adaptor/locking ring with O-ring 14 Fuel Shut-off Valve

5 Fuel Filler Cap 15 Choke Lever

6 Air Filter Housing 16 Throttle Lever

7 Carburetor Drain Plug 17 Starter Recoil

8 Spark Plug 18 ON/OFF Switch

9 Suction Chamber Bolt 19 Oil Drain Plug

10 Inlet or Suction Chamber 20 Oil Filler and Dipstick

21 Rubber feet/fixings

The PW80A petrol driven pump is designed for pumping clean water, or water
containing small solids in suspension. 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.

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BEFORE USE

The pump is supplied with four rubber feet. Use the retaining nuts to secure
these to the base of the frame.

Stand the pump on a firm foundation as near to the water source as possible.

Ensure there is adequate drainage for the discharged water and that there is
no danger of damage to property as a result of water being discharged.

ADDING OIL

This pump is supplied without engine oil or fuel. Use any engine oil of SAE 15-40
rating unless operating at very high or low ambient temperatures.

Fill the engine crankcase with oil as
follows:

1. Remove the filler plug/dipstick.

2. Fill with oil until visible inside.

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

NOTE: The pump is fitted with a low oil sensor which will stop the engine if the

oil level drops below the safe level to avoid internal damage. Refer to
troubleshooting section.

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

ADDING FUEL

• Use unleaded petrol.

1. Open the fuel cap and top up as
required. Located within the fuel
tank is a filter. Check this filter
periodically and remove any
contaminants which may have
accumulated. Do not fill above
the fuel filter shoulder.

2. After refuelling, tighten the fuel
filler cap securely.

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GENERAL USE OF THE PUMP

1. Connect the suction and discharge hoses to the pump housing using the
hose clamps and gaskets supplied to achieve an airtight seal. There must
be no damage of any kind to the hoses which must be well protected and
supported.

NOTE: Hoses or pipes should be supported independently and not have their

weight carried by the pump.

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

2. Pay particular attention to the following:

• Always ensure the hose adaptor gasket is in place and correctly fitted.

• Always use a flexible hose at the pump body connection of at least 1ft

(300 mm).

• 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 water being discharged.

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).

3. Attach the suction 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 clean. 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.

• Tie the strainer inside a basket or bucket.

4. Remove the filler plug on top of the pump case and prime the pump with
water, leaving no air gap. Remember 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 or if the water has been lost.
Never allow the pump to run dry.

5. If the discharge line runs vertically more than 30ft it is advisable to install a
check valve in the discharge line near the pump to stop destructive water
hammer when the pump is shut down. If a check valve is installed, it may

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also be necessary to vent the top of the pump so that air can be expelled
during automatic re-priming.

Properly fuelled and lubricated your pump will run without further attention.

OPERATION

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.

Ensure the site and pump are prepared as detailed on page 6, then proceed
as follows:

PRIMING & CONTROL

1. Open the fuel shut-off valve and pull the starter recoil rope slowly two or
three times to allow fuel to reach the carburettor.

2. To start a cold engine, set the choke lever to the closed position, but if the
engine is already warm the choke should be in the open position.

3. Set the throttle about one third open and turn the engine switch to ON.

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

5. Once the engine starts to warm up, gradually return the choke to the open
position and use the engine throttle to gradually increase engine speed.

STARTING

After starting the engine, control the output by adjusting the engine speed.

NOTE: With a suction lift of 5 to 10ft, the pump should begin discharging liquid

in less than a minute. A lift of 25ft (at sea level) should require not more
than 2 minutes for initial prime. 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 the engine and check
carefully to find the problem. (See TROUBLESHOOTING on page 10).

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.

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In the event of blockages, where debris has entered the suction chamber, this
can be opened and cleaned out by removing the bolts (9) shown in the

layout on page 4.

SHUTTING DOWN

1. Gradually reduce engine speed to minimum using the throttle lever.

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

3. Close the fuel valve.

MAINTANENCE

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. Clean the foam filter
element with domestic detergents
and clean the mesh element by
knocking against a solid object or
blow out any dust with a high
pressure air jet. Never operate the pump without the air cleaner installed as
this would cause premature wear to the engine.

3. Replace the spark plug after the
first month or every 50 hours of
use. 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 0.70-

0.80mm.

• The recommended spark plug

for the PW80A pump is LD F7RTC.

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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 5.

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

After use, drain the pump body whenever there is danger of freezing. 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. 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
carburettor completely by
opening the drain plug in the
carburettor float chamber and
draining all remaining fuel into a
suitable container ensuring the
fuel shut-off valve is open.

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.

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TROUBLESHOOTING

Problem Cause Solution

Engine fails to start Lack of fuel in the tank Fill the tank as necessary

Engine stops and
will not restart.

Pump fails to
prime

No fuel reaching the
carburetor

Engine switch is in the Off
position

Lack of spark at the spark
plug.

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

Priming chamber not filled
correctly.

Air leaks through the suction
line joints (damaged hose,
broken hose clamps, broken
/ ill-fitting gasket).

Blocked inlet hose. Clean strainer & ensure it is

Engine speed too low. Increase engine speed.

Damaged impeller. Renew the impeller after

Air leaks through damaged
seal.

Fuel valve is closed.

Set the engine switch to the
On position.

Check that the spark plug
wire is securely attached to
the plug head. With the
switch in the ON position,
hold the spark plug side
electrode against the
engine and pull the starter
cord to observe the spark. If
a spark is present but the
engine still cannot start
consult your dealer for help.

Fill the oil sump as necessary
(see page 5)

Fill priming chamber leaving
no air gap.

Carry out repairs as
necessary. Check/repair
connections as required.

not submerged in mud or
sediment etc. Ensure there
are no kinks in the delivery
hose.

dismantling the pump.

Renew seal.

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Problem Cause Solution

Low output from
pump

Engine speed too low. Increase the engine speed.

Impeller clogged Clean the strainer and

ensure it is not submerged in
mud or sediment etc.

Suction or delivery line
obstructed.

High friction losses in the
suction line.

Suction lift too high Set the pump as close as

Congested material inside
pump.

Damaged impeller Dismantle the pump and

Clear any obstruction and
ensure there are no kinks in
the delivery line.

Avoid unnecessary curves,
restrictions or valves.

possible to the level of the
liquid being pumped.

Dismantle the pump and
clean out.

renew the impeller.

COMPONENT PARTS - GENERAL

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ENGINE COMPONENTS DIAGRAM

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ENGINE COMPONENTS LIST

NO DESCRIPTION NO DESCRIPTION

1 Flange bolt M6 x 8 30 Flywheel key

2 Recoil starter 31 Connecting rod lever

3 Flange bolt M6 x 12 32 Connecting rod bolt

4 Fan cover 33 Crankcase gasket

5 Flywheel nut M14 x1.5 34 Dipstick

6 Starting cup 35 Dipstick gasket

7 Fan 36 Low crankcase cover

8 Flywheel 37 Flange bolt M8x33

9 Governor pull rod 38 Flange bolt M6x25

10 Small governor spring 39 High tension lead assembly

11 Governor arm 40 Cylinder head pin 8 x16

12 Water pump governor spring 41 Flange bolt M8x55

13 Flange nut M6 42 Air cleaner

14 Gasket 6 43 Air cleaner gasket

15 Governor lever 44 Carburetor assembly

16 Square bolt M6x21 45 Carburetor gasket

17 Water pump governing base 46 Carburetor insulator

18 Oil seal 47 Carburetor insulator gasket

19 Flywheel side cover 48 Carburetor stud bolt M6 x113

20 Drain plug 49 Cylinder head

21 Drain plug gasket 50 Cylinder head gasket

22 Flange bolt M6 x12 51 Inlet valve

23 On/off switch 52 Exhaust valve

24 Crankcase 53 Valve lifter

25 Crankcase pin 54 Camshaft

26 Oil sensor 55 Breather tube

27 Flange bolt M6 x12 56 Exhaust valve hat

28 Bearing 6205 57 Exhaust valve spring retainer

29 Governor gear 58 Inlet valve spring retainer

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ENGINE COMPONENTS LIST (CONT)

NO DESCRIPTION NO DESCRIPTION

59 Valve spring 88 Nut M6

60 Spark plug 89 Low tension lead

61 Flange bolt M6 x12 90 Fuel filler cap

62 Cylinder head cover 91 Fuel filter

63 Cylinder head cover gasket 92 Fuel tank

64 Rocker nut 93 Flange bolt M6 x 25

65 Rocker adjusting nut 94 Fuel outlet /gasket

66 Rocker arm 95 Nut M6

67 Rocker bolt 96 Circlip

68 Push rod guide frame 97 Flameout switch

69 Push rod 98 Flange bolt M8 x16

70 Exhaust gasket 99 Flange bolt M6 x12

71 Exhaust cover 100 Exhaust pipe guard

72 Flange bolt M6x8 101 Cylinder head cover guard

73 Stud bolt

74 Circlip

75 Connecting rod

76 Muffler

77 Nut M8

78 Top compression ring

79 Second compression ring

80 Oil ring

81 Gudgeon pin

82 Piston

83 Crankshaft

84 Spring washer

85 Muffler cover

86 Fuel pipe

87 Circlip

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PUMP COMPONENTS DIAGRAM

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PUMP COMPONENTS LIST

NO Description NO Description

1 Pipe joint gland nut 13 Small gasket

2 Pipe joint 14 O-type sealing ring-1

3 Pipe joint gasket 15 Guide flow cover

4 Bolt M10 x 20 16 Bolt M8 x 25

5 Water inlet flange 17 Pump impeller

6 Check valve 18 Flat key 5 x 18

7 Outlet flange gasket 19 Bolt M8 x 55

8 Discharge water joint 20 M8 bolt gasket

9 Drain screw 21 O-type sealing ring-3

10 O-type sealing ring-1 22 Water seal

11 Pump casing 23 Pump base

12 Bolt M10 x 25

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SPECIFICATIONS

Item Spec

Engine Model PT170F

Engine Type 4-stroke OHV single cylinder with

forced air cooling

Motor HP 6.0 HP (4.6kw)

Rotational velocity 3600 rpm

Fuel tank Capacity 3.6 L

Oil Capacity 0.6 L

Fuel consumption 0.86 l/h (1.5 hours on full tank)

Guaranteed sound power 106 LWA dB

Sound power level 103.2 dB

Sound pressure level 90.2 dB

Uncertainty factor 2.7 dB

Outlet size 3” (80 mm)

Max Water Flow

Max Head 28 m

Max Suction 7 m

Pressure (measured) 0.25 MPa / 2.5 bar

Length (mm) 500

Width (mm) 365

Height (mm) 415

Weight 24 kg

1100 L/m (66m

3

/h)

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DECLARATION OF CONFORMITY

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DECLARATION OF CONFORMITY

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