Clarke DW50 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
LS0518 ISS 2
ORIGINAL INSTRUCTIONS
ENGINE DRIVEN 2” DIESEL PUMP
MODEL NO: DW50
PART NO: 7230170

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INTRODUCTION
Thank you for choosing this Clarke Pump.
The function of this pump is to move clean /dirty water (with solids in
suspension upto 10-12 mm in diameter).
DO NOT use it to pump:
•Sewage
• Dangerous liquids.
• Salt water
Before you use this pump read the manual fully.
GUARANTEE
This pump 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 pump has been abused, tampered with, or not
used for its primary function.
Faulty goods must be returned to their place of purchase, no pump can be
returned to us without prior permission.
This guarantee does not effect your statutory rights.
INVENTORY
You should find the items in the list below in the carton.
Speak to your Clarke dealer if items are missing or damaged.
1 x Diesel Powered Water Pump 2 x Rubber Sealing Rings
2 x 2" Hose adaptors 2 x 2" Hose clips
1 x Inlet Strainer (in two pieces) with 2" Hose
Coupling/clip

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GENERAL SAFETY RULES
1. ALWAYS obey all safety precautions for the handling of fuel.
2. ALWAYS make sure that you are familiar with this pump, and follow all
instructions in this manual.
3. ALWAYS make sure that the pump is positioned correctly to prevent it from
moving during operation.
4. Keep the area adjacent to the pump clear.
5. ALWAYS connect the strainer to the suction hose to stop stones and other
solids from being pulled into the pump. These can cause damage to the
pump.
6. ALWAYS keep the pump dry and clear of the discharge hose.
7. Only use parts supplied by the manufacturer. Using non-standard parts can
be dangerous.
8. ALWAYS use at least 300mm of flexible hose to make plumbing connections
to the pump. Rigid piping can put stress on the pump, causing damage. If
you use rigid piping, it must be supported to eliminate strain on the
connections.
9. DO NOT refuel the engine while it is operating and let the engine cool
sufficiently before refuelling.
10. DO NOT use to pump petrol (or other flammable liquids), or corrosive
chemicals. The function of this pump is to pump WATER ONLY.
11. DO NOT operate this pump in an explosive atmosphere, near combustible
materials, or where there is insufficient ventilation.
12. DO NOT let children use this pump.
13. DO NOT run the pump dry. Always fill the pump with water before starting.
14. DO NOT direct the discharge flow towards another person.
15. DO NOT over-tighten drain or filler plugs. Excessive force can damage the
threads or the pump body.
16. DO NOT direct the water discharge towards electrical wiring or equipment.
WARNING: WHEN USING PUMPS, ALWAYS FOLLOW BASIC SAFETY
PRECAUTIONS TO REDUCE THE RISK OF FIRE, ELECTRIC SHOCK AND
PERSONAL INJURY. READ ALL INSTRUCTIONS BEFORE YOU
OPERATE THIS PUMP AND SAVE THEM 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. Always make sure that the workplace is well lit. Make sure that that lighting
is placed so that you will not be working in your own shadow.
4. Dress correctly. Loose clothing or jewellery can get caught in moving parts.
Non-slip footwear is recommended. Wear protective hair covering to
contain long hair.
5. Always wear safety glasses. (Everyday glasses are not safety glasses).
CARE OF PUMPS
1. Always examine the pump for damage that can effect the operation.
2. The Clarke service department will only replace damaged components
using original spare parts.
Keep the instructions for future reference.
SAFETY SYMBOLS
The meanings of the markings and symbols on the pump are shown below.
ENVIRONMENTAL PROTECTION
At the end of its working life, do not discard this pump or its components with
general household waste. Packaging must be taken to a recycling centre and
discarded appropriately.
Read this manual before use and keep it for future reference

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ASSEMBLY
INSTALL THE SUCTION HOSE
1. Put the rubber washer into the
adaptor.
• Make sure that it is seated
correctly.
2. Screw the adaptor onto the
pump.
• PTFE tape can be used to
ensure a good seal.
3. Slide the hose on to the adaptor
and lock in position with the hose
clip supplied.
• 2" Reinforced Hose is available
from your Clarke supplier (Part
number - 7955020)
4. Install the strainer on to the other
end of the hose following the
picture on the right.

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INSTALL THE DISCHARGE HOSE
1. Put the rubber washer into the
adaptor.
• Make sure that it is seated
correctly.
2. Screw the adaptor onto the
pump.
• PTFE tape can be used to
ensure a good seal.
3. Slide the hose on to the adaptor
and lock in position with the hose
clip supplied.
• 2" Reinforced Hose is available
from your Clarke supplier (Part
number - 7955020)
• 2" Lay Flat Hose is available
from your Clarke supplier (Part
number - 7955160)

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BEFORE USE
POSITIONING THE PUMP
For optimum performance, place the pump near the water level and use
hoses that are no longer than necessary.
As “head” (pumping height) increases, pump output decreases. The length
and size of the suction and discharge hoses can also effect pump output.
The discharge head is always greater than the suction head, so it is important
for the suction head to be the smaller part of the total head.

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CHECK THE ENGINE OIL LEVEL
1. Turn the oil filler cap anti-
clockwise and remove from the oil
filler tube.
2. Wipe the dipstick clean with a lint
free cloth.
3. Slide the dipstick into the oil filler
tube and remove it again. Do not
screw in the oil filler cap/dipstick
when doing this.
4. If the oil level is at or below the
‘Lower level’ mark on the dipstick,
Fill the crankcase with oil to the
‘Upper level’ mark.
• Oil capacity is 1 Litre.
• We recommend you use
SAE15W40 oil in this pump,
available from your Clarke
dealer.
5. Replace the oil filler cap.
WARNING: TO DO THIS CHECK, STAND THE PUMP ON LEVEL GROUND
WITH THE ENGINE SWITCHED OFF.
WARNING: BE CAREFUL NOT TO TOUCH HOT PARTS OF THE PUMP
WHEN CHECKING THE OIL LEVEL.

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ADD DIESEL FUEL
RECOMMENDED FUEL
Only use regular diesel.
1. Remove the fuel filler cap.
• Inside the fuel tank is a fuel filter
which collects contaminants as
you refuel.
2. Slowly add fuel to the fuel tank.
• Make sure that the fuel level is
not above the maximum fuel
level mark in the fuel filter.
3. Replace the fuel tank cap.
WARNING: REFUEL IN A VENTILATED AREA, AWAY FROM SOURCES
OF IGNITION.
WARNING: IF THE ENGINE IS HOT, LET IT COOL BEFORE REFUELING.
WARNING: KEEP FUEL OUT OF THE REACH OF CHILDREN.

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OPERATION
PRIME THE PUMP
1. The pump MUST be primed before
use.
2. Before starting the engine,
remove the filler cap from the
pump chamber.
3. Fill the pump chamber and inlet
hose with water.
NOTE: A foot valve (not supplied)
connected to the lower end
of the inlet hose between
the hose and the strainer will
help to maintain priming,
4. Replace the filler cap and tighten
it securely.
WARNING: WHEN YOU OPERATE THE PUMP, THE EXHAUST MUFFLER
WILL BECOME VERY HOT.
WARNING: DO NOT OPERATE THE ENGINE IN A CLOSED SPACE,
MAKE SURE THAT THERE IS SUFFICIENT AIRFLOW AROUND THE
PUMP.
WARNING: OPERATING THE PUMP DRY WILL DESTROY THE PUMP
SEAL. IF THE PUMP IS OPERATED DRY, STOP THE ENGINE
IMMEDIATELY, AND LET THE PUMP COOL BEFORE PRIMING

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START THE ENGINE
1. MAKE SURE THE PUMP IS PRIMED (SEE PAGE 10)
2. Set the fuel valve to the (O) ON
position.
3. Set the speed adjusting knob to
the START position.
4. Hold the starting handle tightly
and pull until you start to feel
resistance, then return it slowly to
its initial position.
5. Push the decompression lever
down and release.

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6. Pull the starting handle lightly until
you start to feel resistance. Then
pull up and away suddenly to
start the engine.
NOTE: You may need to use 2
hands to pull the recoil
starter, If so get another
person to hold the pump
steady.
NOTE: If the engine fails to start go
back to step 4 and try again.
FIRST 20HOURS USE ONLY
Run the engine/pump at mid power
for the first 20 hours.
WARNING: WHEN THE ENGINE HAS STARTED, RETURN THE
STARTING HANDLE SLOWLY TO PREVENT INJURY/DAMAGE AS IT
RETURNS.

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STOPPING THE ENGINE
1. Set the speed adjusting knob to
“Stop” position.
• You do not need to use the
decompression lever when
stopping the engine.
2. Turn fuel switch back to “S” (OFF)
position.
3. Hold the starting handle tightly
and pull until you start to feel
resistance, then return it slowly to
its original position.
NOTE: This can help to prevent
cylinder corrosion.
AFTER USE
1. Remove the pump drain plug to
drain the pump chamber.
2. Remove the filler cap, and flush
the pump chamber with clean,
fresh water.
3. Let the water drain from the pump
chamber, then replace the filler
cap and drain plug.

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MAINTENANCE
CHANGING THE ENGINE OIL
The oil in the engine must be changed after the first 20 hours use and then
every 6 months or 100 running hours.
1. Unscrew and remove the oil filler
cap/dipstick.
2. Put an oil collection tray below
the drain plug.
3. Unscrew the drain plug and let
the used engine oil drain from the
crankcase into the oil collection
tray.
NOTE: Drain the engine oil when the
engine is warm; as the oil will
flow more freely this will make sure that the oil flows out faster.
4. Replace the drain plug.
5. Fill the crankcase with oil to the
‘Upper level’ mark on the dipstick.
6. Replace the oil filler cap/dipstick.
ENVIRONMENTAL PROTECTION
One of the most damaging sources of pollution is oil, do not throw it away or
pour it down drains. Put it in a leak proof container and take it to your local
waste disposal site.
CAUTION: PROLONGED EXPOSURE TO USED ENGINE OIL IS DANGEROUS,
ALWAYS WASH YOUR HANDS THOROUGHLY AFTER HANDLING USED
ENGINE OIL.

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CHANGING THE AIR FILTER
Clean the air filter after 50 hours of operation (or more often in unusually dusty
conditions) as follows.
1. Remove the wingnut and lift off
the air filter cover.
2. Remove the nut that holds the air
filter in position.
3. Remove the air filter element.
4. Clean the air filters or replace if
necessary.
• If the filter is dirty, wash the filter
in a solution of warm water and
mild detergent and rinse
thoroughly. Let the filter dry
fully.
• When it is dry, dip the filter in clean engine oil and squeeze out
excess oil.
• It is normal for blue smoke to come out of the exhaust for a short
time when the filter has been cleaned.
5. Replace the filter and cover.
STORAGE
Before long-term storage:
1. The pump must be cleaned by flushing with clean water, otherwise, the
impeller may be damaged in next operation. After flushing, remove the
drain plug and drain all the water from the pump. Then replace the drain
plug.
2. Discharge the fuel in the fuel tank. Remove the fuel pipe connector to
drain the fuel, then retighten the fuel pipe connector.
CAUTION: DO NOT OPERATE THE PUMP WITHOUT THE AIR FILTER
INSTALLED AS THIS WILL CAUSE EXCESSIVE WEAR TO THE ENGINE.

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TROUBLESHOOTING
If you cannot correct the fault, speak to your local dealer or the Clarke
International service department.
PROBLEM CAUSE SOLUTION
The engine does
not start.
No fuel in tank. Add fuel.
Fuel valve is set to OFF, Set the fuel valve to ON,
The engine stops
and will not
restart.
No fuel in tank. Add fuel to the tank.
The pump fails to
prime.
Priming chamber not
filled correctly.
Fill priming chamber leaving no
air gap.
Air leaking due to
damaged hose,
broken hose clamps,
split/ill-fitting gasket.
Repair as necessary.
Blocked inlet hose. Clean strainer and make sure that
it is not submerged in mud or
sediment. Make sure that there
are no kinks in the delivery hose.
Damaged impeller. Disassemble the pump and
replace the impeller.
Air leaking through
damaged seal.
Replace seal.
Low output from
pump.
The impellor is
clogged.
Clean strainer and make sure that
it is not submerged in mud or
sediment.
Pickup or delivery hose
obstructed.
Clear obstruction and make sure
that there are no kinks in hose.
Suction lift too high. Set the pump nearer to the water
level.
Congested material
inside pump.
Disassemble the pump and clean
out.
Damaged impeller. Disassemble the pump and
replace the impeller.

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SPECIFICATION
Item Spec
Pump dimensions (L x W x H) 501 x 423 x 520 mm
Pump Weight (kgs) 43.68 kg
Water classification Dirty / Clean (NOT SEWAGE)
Max solids in suspension 10-12 mm
Inlet/Outlet Size 2” BSP
Maximum Flow 450lL/min max
Max Head 27 m
Suction Head 7 m
Max Pressure 2.3 bar
Run time @75% rated load 4 hrs
Engine type/speed 5.4 HP @ 3600 rpm
Fuel tank capacity 2.5 L
Lubrication oil capacity/grade 1Litre (SAE 15W40)
Sound Pressure Level 90.69 dB LpA
Sound Power Level 104.08 dB LWA
Guaranteed sound power level 107 dB LWA
Uncertainty Factor (K) 2.5 dB

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EXPLODED DIAGRAMS AND PARTS LIST
FIG 1 - CRANKCASE ASSEMBLY
NUMBER DESCRIPTION PART NUMBER
1 SEAL PLUG M16×16 ZG1102600510001
2 WASHER Ø16.5×Ø22.5×1.8 ZG3804508300001
3 CRANKCASE ZG1108102080001
4 PIN 8×16 ZG3806001690001
5 OLL FILLER CAP ASSEMBLY, ZG1106900510001
6 BEARING 6203 ZG3806300020001
7 SEAL ZG3808407920001
8 OIL SEAL 35×52×7 ZG3806503370001
9 BEARING PLATE ZG1302400040001
10 FLANGE BOLT, M8×16 ZG380140040000

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FIG 2 - CRANKCASE COVER
NUMBER DESCRIPTION PART NUMBER
1 FLANGE BOLT, M8×35 ZG3801400510005
2 OIL SEAL 30×46×8 ZG3806503360001
3 SEAL PLUG 1/8-27NPTF ZG1102600530001
4 OIL FILLER ASSEMBLY ZG1502900210001
5 OLL FILLER CAP ASSEMBLY ZG1106900510001
6 BOLT M12×16 ZG3800702880001
7 WASHER Ø12×Ø20×2 ZG3804505160001
8 COMPRESS SPRING ZG3811505140001
9 BALL ZG3806400160001
10 CRANKCASE COVER ZG1108200640001
11 OIL PUMP ZG1500100680001
12 BEARING 6203 ZG3806300020001
13 PIPE INLET OIL ZG3807801230001
14 OIL PUMP PLATE ZG1500400290001
15 FLANGE BOLT, M6×20 ZG3801400030005
16 GOVERNOR GEAR ASSEMBLY ZG1717500180001
17 CRANKCASE GASKET, COVER ZG1108300420001

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FIG 3 - CYLINDER HEAD ASSEMBLY
NUMBER DESCRIPTION PART NUMBER
1 FLANGE BOLT, M6×25 ZG3801401020004
2 CYLINDER HEAD COVER COMP ZG1202200400001
3 CYLINDER GASKET, HEAD COVER ZG1202500310001
4 HEAD BOLT, M10×1.25×90 ZG3801405960001
5 CYLINDER HEAD COMP ZG1200805280001
6 CYLINDER GASKET ZG1201501530001
CYLINDER GASKET ZG1201501900001
CYLINDER GASKET ZG1201501910001
7 PIN 4×12 ZG3806001670001
8 FLANGE BOLT, M8×20 ZG3801400040004
9 LIFTING EYE ZG1205500050001