Clarke CU150 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS GC0410
PETROL DRIVEN WATER PUMP
Model CU150
Part No: 7140635

2
INTRODUCTION
Thank you for purchasing this CLARKE Petrol Driven Water Pump.
Before attempting to operate the pump, it is essential that you read this
manual thoroughly and carefully follow all instructions given. In doing so you
will ensure the safety of yourself and that of others around you, and you can
also 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 PROTECTION
Do not dispose of this product with general household waste. All tools,
accessories and packaging should be sorted, taken to a recycling
centre and disposed of appropriately.
PARTS & SERVICE
For parts & Servicing, 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: [e-mail]
SERVICE: [email protected]

3
CONTENTS
Introduction ............................................................................................ 2
Guarantee .............................................................................................. 2
Environmental Protection ...................................................................... 2
Parts & Service Contacts ....................................................................... 2
Table of Contents ................................................................................... 3
Accessories & Consumables ................................................................ 3
General Safety Precautions .................................................................. 4
Component Identification .................................................................... 6
Preparation for Use ................................................................................ 8
Installation .............................................................................................. 9
Operation ............................................................................................. 11
Maintenance ........................................................................................ 12
Technical Specification ....................................................................... 14
Troubleshooting .................................................................................... 15
Parts Lists and Diagrams ..................................................................... 19
Declaration of Conformity .................................................................. 26
ACCESSORIES & CONSUMABLES
A wide range of accessories is available, including suction hose, lay-flat
delivery hose, hose clips, couplings, adaptors & filters etc. Contact your
CLARKE dealer for further information, or CLARKE International Sales
Department on 01992 565333.
IMPORTANT: The use of parts other than genuine CLARKE replacement parts
may result in safety hazards, decreased tool performance, and will invalidate
your warranty.

4
GENERAL SAFETY PRECAUTIONS
As with all machinery, there are certain hazards involved with its
operation and use. Exercising caution will reduce the risk of
personal injury.
WORK AREA
1. ALWAYS keep the work area clean and well lit. Floors should always be
kept clear. Cluttered or dark areas invite accidents.
2. ALWAYS keep children and bystanders away while operating machines.
Distractions can cause loss of control.
PERSONAL SAFETY
1. ALWAYS stay alert, watch what you are doing and use common sense
when operating this pump. Do not use the pump while you are tired or
under the influence of medication, drugs or alcohol. A moment of
inattention can result in personal injury.
2. ALWAYS wear suitable protective clothing and eye protection including
industrial gloves, ear defenders and approved impact resistant safety
glasses. (Eye glasses are NOT safety glasses)
3. NEVER over-reach. Keep your proper footing and balance at all times
when positioning or operating the pump.
4. NEVER direct the water discharge towards electrical wiring or equipment.
5. ALWAYS dress properly. Never wear loose clothing or jewellery which could
be caught on moving parts.
6. ALWAYS store the pump out of reach of children and do not allow persons
unfamiliar with these instructions to operate this appliance.
7ALWAYS observe all safety precautions for the handling of fuel.
8. NEVER direct the discharge flow towards another person.
9. ALWAYS thoroughly familiarise yourself with this pump & its operation, and
follow the instructions in this manual.
10. 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.
11. ALWAYS take care not to touch the exhaust pipe/ muffler when the pump
has been running and is hot. This assembly becomes hot enough to inflict
severe burns.

5
GENERAL EQUIPMENT USE AND CARE
1. ALWAYS maintain the pump with care and keep it clean for best / safest
performance.
2. NEVER use this pump if any part is damaged. Have it inspected and
repaired by your local Clarke dealer. Always turn the pump off before
carrying out any maintenance.
3. NEVER modify this pump in any way. Use it ONLY for the purpose for which
it is designed.
4. ALWAYS use at least 1ft (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.
5. NEVER refuel the engine whilst it is running, and allow the engine to cool
sufficiently before refuelling.
6. NEVER use for pumping petrol (or other flammable liquids), or corrosive
chemicals. These pumps are designed to pump WATER ONLY.
7. NEVER operate an engine driven pump in an explosive atmosphere, near
combustible materials, or where there is insufficient ventilation.
8. NEVER run the pump dry. Always fill the pump with water before starting.
9. ALWAYS keep the pump engine dry and well clear of water discharge.
10. NEVER overtighten drain or filler plugs. Excessive force may damage the
threads and make the plug difficult to remove in future.
11. ALWAYS use the strainer connected to the suction (inlet) hose, to prevent
stones and other solids from being drawn up, which could cause severe
damage to the pump.
SERVICING
1. ALWAYS have the pump serviced by your local CLARKE dealer, using only
identical replacement parts. This will ensure the safety of the pump is
maintained. The use of non standard parts could be hazardous.
2. NEVER attempt any repairs yourself. If you have a problem with the
machine contact your local CLARKE dealer.
Your CLARKE water pump has been designed to give long and trouble free
service. If, however, having followed the instructions in this booklet carefully,
you encounter problems, take the unit to your local CLARKE dealer.

6
INTRODUCTION
The CU150 Pump consists of a petrol (gasoline) engine and water pump
which is fixed to the frame via a shock absorbing mounting.
The self-priming pump consists of a pump body, cover, impeller and
mechanical seal assembly. The inlet of the pump is higher than the inlet of the
impeller so that it can start operating when only the body of the pump is filled
with water. The inlet of the pump is fitted with a one-way valve to prevent
water syphoning back out of the pump and ensure the pump is always
primed for the next start-up.
The engine used is an air-cooled, 4-stroke OHV unit which is lightweight and
compact. It is designed to run on unleaded petrol, with a manual pull-cord
starter and simple carburettor.
The CU150 is designed only for pumping water, or water containing small
solids in suspension. It is fitted with an open impeller, therefore the suction
strainer supplied, must always be fitted to the suction hose to ensure that
debris cannot be drawn up, causing damage to the pump.
Upon receipt, unpack and lay out the components, checking against the
following list. Any damage or deficiency should be reported to your CLARKE
dealer immediately.
Plastic Inlet Strainer (32-34)
Spark Plug Box Spanner
Tommy Bar
2 x Hose coupling adaptors (24*)
The following component parts of the machine are shown in Figures 1 & 2.
10. Inlet Port
11. Suction Chamber Drain Plug
12. Inlet or Suction Chamber
13. Suction Chamber Bolt
14. Oil Filler and Dipstick (both sides)
15. Oil Drain Plug (both sides)
16. Carburettor Drain Plug
17. Air Filter Housing
1. Choke Lever
2. Fuel Pipe
3. Starter Pull Cord / Recoil
4. Throttle Lever
5. ON/OFF Switch
6. Water Filler (priming) Plug
7. Output or Discharge Pipe
8. Fuel Filler Cap
9. Spark Plug
2 x O-rings (23*)
2 x Adaptor Clamp Rings (25*)
3 x Wire Hose Clamps (loose)
Operators manual
* numbers in brackets refer to
Parts Diagram -Pages 24/25

7
1 2 3 4 5 Fig 1
7 6 8 9
10 11 12 13 14 15 16 17 Fig 2

8
PREPARATION FOR USE
INSTALLING THE HANDLE
The handle must be bolted to the frame using two
M8 x 12 bolts (item 2 - pages 20/21). Bolt the handle
to the frame & tighten securely as shown in Fig 3.
ADDING OIL
Note: This pump is not supplied with engine oil. Use
any engine oil of SAE 10W-30 rating unless
operating the pump at very high or low ambient
temperatures.
1. Remove the filler plug/dipstick from either side of
the crankcase.
2. Fill the engine with oil until visible
inside the filler tube.
3. Insert the dipstick back into the
filler tube and check the level is
within the indicated range. If
correct, replace the dipstick/filler
cap.
Note: Never add oil to the engine
when the machine is running.
ADDING FUEL
1. Open the fuel cap and top up as
required with unleaded petrol. Do
not fill above the shoulder of the
fuel strainer located inside the fuel
tank as shown in Fig 5. Ensure the
fuel is clean.
2. Inspect this filter during
subsequent refuelling and remove
any contaminants which may
have accumulated. After
refuelling, tighten the fuel filler
cap securely.
Note: Never add fuel to the engine when the pump is running.
WARNING: WIPE UP ANY SPILT FUEL BEFORE RUNNING THE
PUMP. ALLOW THE ENGINE TO COOL BEFORE REFUELLING.
Fig 4
Fig 5
Fig 3

9
INSTALLATION
POSITIONING THE PUMP
1. Place the pump on a firm foundation and as near to the water source as
possible.
2. 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
operation.
CONNECTING THE HOSES
1. Connect the suction and discharge hoses to the pump housing using the
hose coupling adaptors, hose clamps and O-rings supplied to achieve an
air-tight seal. There must be no damage to the hoses which must be well
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 inhibit priming, and reduce the
capacity of the pump.
2. Pay particular attention to the following:
a. Always ensure the O-ring is placed between the hose
adaptor and pump casting.
b. Always use a flexible hose at the pump body connection of at
least 1ft (300mm).
c. Keep all pipes/hoses as short and straight as possible and
avoid sharp bends.
d. Ensure there is adequate drainage for the discharged water.
e. Ensure machine is on level ground or base to avoid spilling fuel.
f. If a flexible hose must be laid across a roadway, protect it with
planking.
(Instantaneous shut off pressure, applied when a vehicle runs across an
unprotected hose, could cause “hydraulic shock”, which can damage the
pump and/or the hose).
3. 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
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.
We will not assume any responsibility for damage to the pump if no check
valve is used in the discharge line.

10
REMEMBER: Contaminated water is water containing small solids in
suspension, do not pump slurry, sludge, sand, or mud.
CONNECTING THE STRAINER
1. Attach the suction strainer to the end of suction hose using the third hose
clamp (of the three supplied), to prevent stones etc, from being drawn
up, which could cause severe damage to the pump. Keep the strainer
clean. If it is likely to clog with dirt or debris, proceed by either:
a. Preparing a bed of stones on which to rest the strainer.
b. Tying the strainer so that it stays clear of the bottom of the pit, pond
or excavation.
c. Tie the strainer inside a basket or bucket.
PRIMING THE PUMP
1. 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
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.
OPERATION
WARNING: WHEN THE ENGINE IS RUNNING, THE EXHAUST PIPE &
MUFFLER ARE VERY HOT, TAKE CARE TO AVOID BURNS.
WARNING: NEVER RUN THE ENGINE IN AN ENCLOSED SPACE - ENSURE
THERE IS ADEQUATE VENTILATION.
1. 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 level to the right
(CHOKE) position, but if the
engine is already warm, the
choke should be in the RUN
position.
3. Set the throttle about one
third OPEN (to the right).
4. Switch the engine ON/OFF rocker switch ON.
5. Pull the recoil starter rope firmly but without snatching and allow
it to retract slowly after each pull. Repeat until the engine starts.
Fig 6

11
6. Once the engine starts, gradually return the choke to the left (RUN)
position as the engine warms up, and use the engine throttle to gradually
increase engine speed.
7. After starting the engine, move the throttle to the LEFT (open) position
during priming of the pump and checking for pump output which is
controlled by adjusting the engine speed.
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 high 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
suction chamber bolts shown in Fig 2 (page 7).
When the machine is new, it should only be run at low speed and subject to a
reduced load for the first 20 hours of normal running. Do not run the pump flat
out until the machine has been run in and the oil replaced for the first time as
itemised under MAINTENANCE.
Properly fuelled and lubricated, your pump will run without attention.
SHUTTING DOWN
1. Gradually reduce engine speed to minimum using the throttle lever.
2. Stop the engine by switching the ON/OFF switch to OFF.
3. In an emergency, simply move the ON/OFF switch to the OFF position.

12
MAINTENANCE
1 Always maintain the pump in a clean condition, checking regularly for
loose bolts etc.
AIR FILTER
1. Clean the air filter once every
50 hours of use (or more often
in unusually dusty conditions)
as follows. Unscrew both the
plastic wingnuts and lift out the
cleaner element. 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.
SPARK PLUGS
1. 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 0.6-0.7mm (0.024-0.028in). The
recommended type is F6TC.
FUEL STRAINER
1. Clean the fuel tank strainer every
100 hours running. Remove the filler
cap, lift out the filter and strainer
and clean it with a soft brush before
replacing and topping up with fresh
fuel to the level of the shoulder of
the strainer.
2. Check the condition of the fuel
hose after approx 2- years use. It
should be replaced if there is signs
of aging and cracking. Ensure it is
tightly secured to prevent leakage.
Fig 7
Fig 8
Fig 9

13
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.
1. Remove the dipstick and drain plug and then gently tilt the machine to
drain the oil into a suitable container.
2. Replace and tighten the drain plug before refilling with fresh oil and
checking the level as described on page 8.
CAUTION: PROLONGED EXPOSURE TO USED OIL IS DANGEROUS,
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, 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.
If the pump has been used under arduous
conditions leading to internal fouling or
damage, the impellor housing can be
dismantled by undoing the four bolts shown
and the impellor inspected for damage.
Always transport the pump level to prevent
fuel spillage.
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. Alternatively, drain the fuel tank completely, then start
the engine in the normal manner and allow it to run until it stops due to
lack of fuel.
NOTE: If prolonged storage is likely, fuel could deteriorate,
causing the components to ‘gum up’.
2. Remove the spark plug and pour 2 - 3 teaspoons of light oil into the
cylinder through the spark plug hole.
Fig 10

14
3. Pull the starter recoil rope slowly 2 or 3 times so that the oil is deposited on
the cylinder walls before replacing the spark plug.
4. Finally, wipe the pump clean with a cloth and store in a dry place
protected from the weather.
In the event that a situation occurs requiring the dismantling and overhaul of
the machine, contact your CLARKE International Service Department on
020 8988 7400.
TECHNICAL SPECIFICATION
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epytgulpkrapSCT6E
dohtemnoitingIICT/otengaM
Please note that the details and specifications contained herein, are correct at the
time of going to print. However, CLARKE International reserve the right to change
specifications at any time without prior notice.

15
TROUBLESHOOTING 1 (PUMP)
MELBORP ESUAC NOITULOS
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.pmupehtfonoitisop

16
MELBORP ESUAC NOITULOS
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TROUBLESHOOTING 2 (PUMP)

17
TROUBLESHOOTING 3 (ENGINE)
MELBORP ESUAC NOITULOS
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18
TROUBLESHOOTING 4 (ENGINE)
MELBORP ESUAC NOITULOS
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19
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PARTS LIST - ENGINE
RECOIL STARTER & IGNITION ASSEMBLY

20
PARTS LIST - ENGINE
FUEL SYSTEM
AIR CLEANER & MUFFLER ASSEMBLIES
CYLINDER HEAD ASSEMBLY
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