Clarke PW2 Instruction Manual

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC0317

PETROL DRIVEN WATER PUMP

MODEL NO: PW2 & PW3

PART NO: 7140640 & 7140645

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

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

Through purchase of this product, the customer is taking on the

obligation to deal with the WEEE in accordance with the WEEE

regulations in relation to the treatment, recycling & recovery and

environmentally sound disposal of the WEEE.

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.

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.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

SAFETY PRECAUTIONS

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.

CAUTION: As with all machinery, there are certain hazards involved

with its operation and use. Exercising caution will reduce the risk of

personal injury.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

OVERVIEW

The PW2/PW3 petrol driven pumps are designed for pumping clean water, or

water containing small solids in suspension. The pumps are 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. The images may show a PW3 pump although PW2

pumps are similar.

1 Inlet or Suction Chamber 10 Choke Lever

2 Output or Discharge Pipe 11 Throttle Lever

3 Water Filler Plug 12 Spark Plug

4 Inlet Strainer 13 Carburetor Drain Plug

5 Suction Chamber Drain Plug 14 Air Filter Housing

6 Suction Chamber Bolt 15 Fuel Filler Cap

7 Starter Recoil 16 ON/OFF Switch

8 Oil Filler and Dipstick 17 Oil Drain Plug

9 Fuel Shut-off Valve (cock)

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

BEFORE USE

REMEMBER: Contaminated water is water containing small solids in suspension,

NOT slurry, sludge, sand or mud.

Place 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 dischaged.

ADDING OIL

This pump is supplied without engine oil or fuel. Use any engine oil of SAE 10-30

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.

ADDING FUEL

Use unleaded petrol with a pump

octane rating of 86 or higher.

1. 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

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

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

(300mm).

• 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 dischaged.

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

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

also be necessary to vent the top of the pump so that air can he expelled

during automatic re-priming. This air bleed may he accomplished by

providing a 1/4" line from the top of the pump back to the liquid source.

Clarke International will not assume any responsibility for damage to the

pump if no check valve is used in the discharge line.

Properly fuelled and lubricated your pump will run without attention.

OPERATION

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

as follows:.

PRIMING & CONTROL

1. With the fuel cock open, 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. 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, gradually return the choke to the open position as

the engine warms up and use the engine throttle to gradually increase

engine speed.

STARTING

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.

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 engine and check

carefully to find the problem. (See TROUBLESHOOTING on page 10).

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.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

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, this

can be opened and cleaned out by removing the bolts 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 cock.

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 both the PW2 and PW3 pump is

“Torch/F6RTC”.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

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.

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 leak-

proof 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.

4. For longer term storage, use the starter to turn the engine until the triangle

mark on the starter wheel lines up with the starter screw hole. In this

location both the inlet and exhaust valves are closed which may prevent

the engine from suffering internal corrosion during storage.

CAUTION: PROLONGED EXPOSURE TO USED OIL IS HARMFULL. ALWAYS

WASH YOUR HANDS THOROUGHLY AFTER HANDLING USED OIL.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

TROUBLESHOOTING

Problem Cause Solution

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

No fuel reaching the

carburetor

Fuel cock is isolated

Engine switch is in the Off

position

Set the engine switch to the

On position.

Lack of spark at the spark

plug.

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 con-

sult your dealer for help.

Engine stops and

will not restart.

Lack of oil in engine causing

‘Low Oil Protection’ sensor

to stop engine from running.

Fill the oil sump as

necessary.

Pump fails to

prime

Priming chamber not filled

correctly.

Fill priming chamber leaving

no air gap.

Air leaks through the suction

line joints (damaged hose,

broken hose clamps, broken

/ ill-fitting gasket).

Carry out repairs as

necessary. Check/repair

connections as required.

Blocked inlet hose. Clean strainer & ensure it is

not submerged in mud or

sediment etc. Ensure there

are no kinks in the delivery

hose.

Engine speed too low. Increase engine speed.

Damaged impeller. Renew the impeller after dis-

mantling the pump.

Air leaks through damaged

seal.

Renew seal.

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