Clarke DW75 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
LS1117 ISS 1
ORIGINAL INSTRUCTIONS
ENGINE DRIVEN 3” DIESEL PUMP
MODEL NO: DW75
PART NO: 7230175

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INTRODUCTION
Thank you for choosing this Clarke Pump.
The function of this pump is to move clean /dirty water (maximum solid
diameter of 10 mm).
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 Washers
2 x 3" Hose Adaptors 3 x 'Jubilee Clip' style hose clip
2 x 3" BSP Locking Rings 1 x Filter / Strainer

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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, let the engine cool 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 hose 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.
• 3" Reinforced Hose is available
from your Clarke Stockist (Part
number - 7955030)
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 onto the adaptor
and lock in position with the hose
clip supplied.
• 3" Reinforced Hose is available
from your Clarke Stockist (Part
number - 7955030.

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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 SAE
15W40 or SAE10W30 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 ENGINE
WHEN CHECKING THE OIL LEVEL.

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ADD DIESEL FUEL
RECOMMENDED FUEL
Only use regular diesel.
1. Remove the fuel tank 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 band on 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 with water.
4. Replace the filler cap and tighten
it securely.
WARNING: CHECK THE PUMP FOR DAMAGE BEFORE USE, DO NOT USE THE
PUMP IF IT IS DAMAGED IN ANY WAY.
WARNING: THE WATER BEING PUMPED WILL BE POLLUTED IF THIS PUMP
BECOMES DAMAGED AND LUBRICANT WITHIN THE ENGINE ESCAPES.
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 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: If the engine fails to start go
back to step 4 and try again.
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.
4. Replace the drain plug.
5. Fill the crankcase with oil to the
‘Upper Level’ mark on the
dipstick.
• Oil capacity is 1 Litre.
• We recommend you use SAE
15W40 or SAE10W30 oil in this
pump, available from your
Clarke dealer.
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 air filter assembly.
3. Remove the air filter element.
4. Clean the air filter or replace if
necessary.
• If the filter is dirty, wash the
foam 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.
CAUTION: DO NOT OPERATE THE PUMP WITHOUT THE AIR FILTER
INSTALLED AS THIS WILL CAUSE EXCESSIVE WEAR TO THE ENGINE.

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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 Pump 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.

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SPECIFICATION
Item Spec
Pump dimensions (L x W x H) 575 x 540 x 595 mm
Pump Weight (kgs) 49.8 kg
Water classification Dirty / Clean (NOT SEWAGE)
Max solids in suspension 10 mm
Inlet/Outlet Size 3” BSP
Maximum Flow 750lL/min
Max Head 30 m
Suction Head 7 m
Max Pressure 3 bar
Run time @75% rated load 4.5 hrs
Engine type/speed 5.4 HP @ 3600 rpm
Fuel tank capacity (petrol) 3.5 L
Lubrication oil capacity/grade 1Litre (SAE 15W40 or SAE10W30) based on
temperature
Sound Pressure Level 89.64 dB LpA
Sound Power Level 103.3 dB LWA
Guaranteed sound power level 106 dB LWA
Uncertainty Factor (K) 2.5 dB

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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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EXPLODED DIAGRAMS AND PARTS LIST
A full set of parts list and diagrams are available from the Clarke International
service department.
PUMP
NO DESCRIPTION PART NUMBER NO DESCRIPTION PART NUMBER
1 PUMP COMPLETE ZGDW75K01 14 FLANGE ZGDW75K14
2 PUMP COVER ZGDW75K02 15 LINK SEAL ZGDW75K15
3 WASHER ZGDW75K03 16 TUBE TIE-IN ZGDW75K16
4 FLANGE BOLT ZGDW75K04 17 TUBE LOOP ZGDW75K17
5 MACHINERY SEAL ZGDW75K05 18 TUBE LINK ZGDW75K18
6WATERPUMP
IMPELLER
ZGDW75K06 19 FLAT WASHER ZGDW75K19
7 VOLUTE CASING ZGDW75K07 20 FLANGE BOLT ZGDW75K20
8 O-RING ZGDW75K08 21 FLANGE BOLT ZGDW75K21
9 O-RING ZGDW75K09 22 OUTPUT SEAL ZGDW75K22
10 HOUSING OF PUMP ZGDW75K10 23 OUTPUT FLANGE ZGDW75K23
11 O-RING ZGDW75K11 24 FILTER COVER ZGDW75K24
12 PLUG ZGDW75K12 25 FILTER ZGDW75K25
13 CHECK VALVE ZGDW75K13

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FRAME
NUMBER DESCRIPTION PART NUMBER
1 FRAME COMPLETE ZGDW75L01
2 DECORATIVE FRAME ZGDW75L02
3 RIGHT BOTTOM RUBBER,L=15 ZGDW75L03
4 FLANGE NUT ZGDW75L04
5 RIGHT BOTTOM RUBBER ZGDW75L05