Clarke CD1 - 1 Installation and operation manual

Model No. CD1 - 1
Petrol Driven Water Pump
Part No. 7230034
Petrol Driven Water Pump
OPERATING & MAINTENANCE
INSTRUCTIONS

Thank you for purchasing this Clarke CD1 petrol driven water pump. Before
attempting to operate this pump please read this instruction manual
thoroughly and follow all directions carefully. This is for your own safety
and that of others around you, and to help you achieve long and trouble
free service from your pump.
Guarantee
This product is guaranteed against faults in manufacture for 12 months
from purchase date. Keep your receipt as proof of purchase. This
guarantee is invalid if the product has been abused or tampered with in
any way, or not used for the purpose for which it is intended. The reason
for return must be clearly stated. This guarantee does not affect your
statutory rights.
Contents Page
Installation ................................................................................ 3
Operating Instructions ............................................................ 4
Starting ..................................................................................... 4
Stopping ................................................................................... 4
Maintenance ....................................................................... 4-5
Storage ..................................................................................... 5
Troubleshooting ....................................................................... 5
Parts List and Exploded view - Engine ............................... 6-7
Parts List and Exploded view - B53 Recoil Starter ................ 8
Parts List and Exploded view - Standard Recoil Starter ...... 9
Parts List and Exploded view - Pump ............................. 10-11
Parts and Service .................................................................. 11
2

Installation
WARNING! Never run the engine in an enclosed space. Ensure adequate
ventilation at all times.
The pump must be situated on a firm, flat, level surface. Make sure that
the pump is placed away from the edge of any pit or pool and cannot
fall in. The suction and discharge fittings supplied with the pump are suitable
for 1" I.D. hose (not supplied). For best performance, keep the suction
pipe as short as possible, and make sure that all connections are airtight.
The pump will not work with air in the suction pipe.
For applications where the suction level is below the pump, we
recommend the use of a foot valve (non-return valve) to retain water in
the suction pipe. To prevent clogging of the pipes or pump, we suggest
that you fit a suction strainer to the end of the suction pipe.
Protect the pipework and the pump from freezing as the formation of ice
in the pump can cause damage. If the pump is installed in a location
likely to freeze, drain the pump (by removing the pump drain plug), and
the pipework after use.
General Arrangement
3

Operating Instructions
The pump is designed to pump water. Do not use it to pump flammable
liquids or chemicals.
Before starting the pump engine, prime the pump by removing the vent
plug and filling the pump casing with water. Do not run the pump dry as
damage can result. Fitting a foot valve (non-return valve) to the end of
the suction pipe, and filling the suction pipe with water will speed priming.
Fill the fuel tank with 2-stroke fuel, mixed at the ratio of 20:1 petrol to 2-
stroke oil (50ml of oil per litre of petrol).
WARNING!
Never fill the fuel tank whilst the engine is running. Always stop the
engine and allow to cool before filling with fuel.
Starting
1. Open the fuel cock.
2. Set the choke lever to position ‘C’.
3. Set the throttle lever to approximately 1/2 throttle.
4. Pull the starter recoil rope slowly two or three times to allow fuel to
reach the carburettor.
5. Hold the pump down and pull the starter recoil rope firmly until the
engine starts. Do not snatch at the starter rope, and allow the rope to
retract slowly after each pull.
6. Once the engine starts, return the choke lever to position ‘A’, and use
the throttle to gradually increase the engine revs to the desired speed.
Note: Do not run the pump at more than approximately 1/2 speed, or run
it for more than 3 hours continuously, for the first 20 to 30 hours of use. This
allows the pump to run-in.
Stopping
1. Gradually reduce the engine speed to minimum.
2. Stop the engine by pressing the Stop button, situated just above the
recoil unit at the back of the engine.
3. Close the fuel cock.
4. If the pump is not to be used for some time, or is in a location likely to
freeze, remove the drain plug and drain the pump completely.
If the pump has been used with dirty or salt water, rinse it through with
clean water.
4

Maintenance
Clean the engine and pump assembly regularly, checking for any loose
bolts etc. Lubricate linkages with a general purpose oil or grease as
appropriate. The engine is lubricated internally by the 2-stroke fuel.
Clean the air filter at least every 30 hours of operation; more frequently if
the pump is used in a particularly dusty environment. Remove the air filter
cover and the air filter element, and wash the filter in petrol or paraffin.
Check the spark plug gap, and clean the electrodes, every 50 hours of
operation. The spark plug gap must be 0.6 -0.7mm.
Occasionally remove the exhaust silencer and shake out any rust flakes
which may be loose inside it, and check that the fuel filter is clean.
Storage
Clean the pump and engine, and drain the pump completely. Drain any fuel
from the carburettor and fuel tank, and store the pump in a clean and dry area.
Additionally, if the pump is not to be used for some time, remove the spark
plug and pour 2 or 3 teaspoons full of oil into the cylinder through the spark
plug hole. Pull the starter recoil rope slowly 2 or 3 times to allow the oil to coat
the internal parts of the engine, and replace the spark plug.
Troubleshooting
CAUTION: Do not run the pump dry as damage can result.
If your CD1fails to pump check that:
1. The pump is primed - prime the pump by removing the vent plug and
filling the pump casing with water.
2. The suction pipe is in water.
3. The suction filter (if fitted) is not blocked.
4. The suction hoses are not blocked or collapsed.
5. All suction pipe connections are airtight.
6. The discharge pipe is not blocked.
If the engine fails to start, or runs erratically, check that:
1. There is fuel in the tank.
2. The fuel is mixed at the correct ratio (20:1 petrol to 2-stroke oil).
3. The fuel cock is fully opened.
4. The spark plug is clean and the gap is correctly set.
5. The air filter is clean.
6. The fuel filter is clean.
5

No.Qty Description Part No
1 4 Screw M5 x 25 GM7306
2 1 Cover (std recoil starter) GMB219
2A 1 Cover (B53 recoil starter)GMB387
3 1 Stop button GMB191
4 1 Button spring GMB190
5 1 Circlip GMB207
6 2 Screw M4 x 15 GM7308
7 2 Washer GM7570
8 1 Flywheel GMB133
9 1 Coil GMB132
10 4 Screw M5 x 20 GM7319
11 4 Washer GMA661
12 1 Carburettor GMB135
13 1 Inlet duct GMB244
14 1 Duct gasket GMB241
15 1 Diaphragm plate GMB243
16 1 Inlet diaphragm GMB240
17 1 Diaphragm plate GMB239
18 1 Duct gasket GMB241
19 1 Fuel pipe GMA611
20 1 Fuel cock GMB148
21 1 Nut GMB333
22 1 Washer MB334
23 1 Tank gasket GM7222
24 1 Fuel tank GM7605
25 1 Fuel filler cap GM7611
26 4 Washer GM6157
27 4 Gasket GM7604
28 4 Nut M6 GM6276
29 1 Seal ring GMA338
30 2 Tie rod GMB237
31 1 Cylinder gasket GMB186
32 1 Crankcase GMB299
33 2 Bush GMB290
34 1 Bearing GMA656
35 1 Cylinder shaft GMB362
35A 1 Conical shaft GMB221
36 1 Bush GMB323
37 1 Con rod assembly GMB152
38 1 Piston pin GMB146
39 2 Circlip GMB147
40 1 Piston GMB144
41 2 Piston ring GMB145
42 1 Cylinder GMB249
43 1 Head gasket GMB185
44 1 Cylinder head GMB160
45 4 Nut M6 GM6304
46 1 Spark plug GMB253
47 2 Washer GM6156
48 2 Screw M6 GMA699
49 1 Gasket GMB189
50 6 Nut M4 GM6719
51 1 Key GMB242
52 1 Bearing GMA656
53 1 Silencer gasket GMB188
54 1 Gasket GMB187
55 1 Silencer GMB168
56 2 Tie rod GMB237
57 6 Screw M4 x 25 GM7307
58 1 Crankcase GMB223
59 4 Screw M5 x 40 GM7305
60 1 Seal ring GMA338
61 1 Silencer cover GMB369
62 4 Rubber foot GMA576
63 1 Engine support GM5318
64 4 Screw GMA691
65 4 Washer GM6156
66 1 Insert (B53 recoil starter) GMB388
67 1 Nut (B53 recoil starter) GMB386
Gasket set GMB366
(Items 23, 29, 31, 43, 53, 54)
Complete piston GMB381
(Items 38, 39, 40, 41)
Complete cylinder GMB355
(Items 38, 39, 40, 41, 42)
Parts List and Exploded view - Engine
No.Qty Description Part No
6

7

Parts List and Exploded View - B53 Recoil Starter
No. Qty Description Part No
1 4 Screw M5 x 25 GM8110
2 1 Cover GMA430
3 1 Spring cover GMA399
4 1 Return spring GMA378
5 1 Start pulley GMA447
6 1 Plastic insert GMA136
7 1 Spring GMA207
8 1 Cover GMA409
9 1 Screw M6 x 35 GMA655
10 1 Handgrip and cord GMA741
Complete recoil starter GMA712
8

Parts List & Exploded View - Standard Recoil Starter
No. Qty Description Part No
1 1 Starter case GMB233
2 1 Cotter GMB213
3 1 Return spring GMB159
4 1 Start pulley GMB329
5 1 Washer GMB327
6 1 Washer GMB238
7 1 Screw GM7525
8 1 Handgrip and cord GMA741
9 1 Complete pawl box GMB225
Complete recoil starter GM8145
9

Parts List and Exploded view - Pump
No. Qty Description Part No
1 1 Pump body GM5120
2 1 Support GM7033
3 1 Impeller GM7479
4 1 Gasket GM5129
5 1 Counterface GM6344
6 1 Mechanical Seal GM6332
7 1 Valve body GM7039
8 1 Rivet GM5133
9 1 Valve gasket GM5128
10 1 Washer GM6168
11 1 O ring GM5326
12 1 Plug 3/8” GM6217
13 1 Plug 1/8” GM6208
14 1 O ring GM5127
15 1 Diffusor GM7025
16 2 Connection GM1011
17 1 Bush GM5125
18 Complete motor GM8104
(with B53 recoil starter)
18 Complete motor GM7381
(with standard recoil starter)
For Spare Parts and Service, please contact your nearest dealer, or
CLARKE International, on one of the following numbers.
PARTS & SERVICE TEL: [phone]
PARTS & SERVICE FAX: [phone]
or e-mail as follows:
PARTS: [email protected]
SERVICE: [email protected]
Spare Parts and Service Contacts
10