Clarke PW2 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
Model Nos: PW2 & PW3
PART NOS: 7140640 & 7140645
GC01/14
PETROL DRIVEN WATER PUMP

2
INTRODUCTION
Thank you for purchasing this CLARKE Petrol Driven Water Pump.
Before attempting to use the machine, 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 product 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 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.
1 x Water Pump Assembly 2 x Hose Adaptor (2” or 3”)
2 x Hose Adaptor Clamp (2” or 3”) 2 x Hose Adaptor Gasket (2” or 3”)
1 x Two-Piece Inlet Filter Assembly 3 x Hose Clamp
1 x Spark Plug Box Spanner 1 x Tommy Bar
1 x Instruction Manual
EQUIPMENT SUPPLIED
ENVIRONMENTAL PROTECTION
At the end of its working life, do not dispose of this product or its components with
general household waste. Any tools, accessories and packaging should be sorted,
taken to a recycling centre and disposed of appropriately.
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.

3
GENERAL SAFETY RULES
As with all machinery, there are certain hazards involved with its
operation and use. Exercising caution will reduce the risk of
personal injury.
1ALWAYS observe all safety precautions for the handling of fuel.
2. ALWAYS 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 (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.
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 machine.
13. NEVER run the pump dry. Always fill the pump with water before starting.
14. NEVER attempt any major repairs to this machine unless you are properly 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.

4
OVERVIEW
These petrol driven pumps are designed for pumping 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 show a PW3 pump although PW2 pumps are
similar.
10 Choke Lever
11 Throttle Lever
12 Spark Plug
13 Carburettor Drain Plug
14 Air Filter Housing
15 Fuel Filler Cap
16 ON/OFF Switch
17 Oil Drain Plug
1. Inlet or Suction Chamber
2. Output or Discharge Pipe
3. Water Filler Plug
4. Inlet Strainer
5. Suction Chamber Drain Plug
6. Suction Chamber Bolt
7. Starter Recoil
8. Oil Filler and Dipstick
9. Fuel Shut-off Valve (cock)
1 3 2 15 10 11 9 7
4 5 6 12 13 14 16 17 8

5
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 and 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 the pumping operation.
ADDING OIL
This pump is not supplied with 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 the unit with oil until visible inside.
3. Check the level by inserting the dipstick
back into the filler tube and checking the
level is within the indicated range. If correct
replace the dipstick/filler cap.
NOTE: The unit 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.
WARNING: WIPE UP ANY SPILT FUEL BEFORE RUNNING THE PUMP.
ALLOW THE ENGINE TO COOL DOWN BEFORE REFUELLING
ADDING FUEL
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.
Use unleaded petrol with a pump octane rating
of 86 or higher.

6
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 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:
a. Always ensure the hose adaptor gasket is in place, and correctly fitted.
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. If a flexible hose must be laid across a roadway, protect it with planking.
e. Ensure there is adequate drainage for the discharged water.
(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:
a. Preparing a bed of stones on which to rest the strainer.
b. Tying the strainer so that it stays off the bottom of the pit, pond or excavation.
c. 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 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.
Properly fuelled and lubricated your pump will run without attention.

7
OPERATION (REFER TO THE ILLUSTRATION ON PAGE 4)
WARNING: WHEN THE ENGINE IS RUNNING, THE EXHAUST MUFFLER IS
VERY HOT, TAKE CARE TOAVOID BURNS.
WARNING: NEVER RUN THE ENGINE IN AN ENCLOSED SPACE - ENSURE
THERE IS ADEQUATE VENTILATION.
Ensure the site and pump is 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 9).
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, the suction chamber
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.

8
MAINTENANCE
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 RK34200/168F.
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.
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 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, 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. 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. 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.

9
TROUBLESHOOTING
MELBORP ESUAC NOITULOS
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10
MELBORP ESUAC NOITULOS
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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: Part[email protected]
SERVICE: [email protected]
PARTS AND SERVICING

11
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SPECIFICATIONS

12
PUMP PARTS DIAGRAM
MODEL - PW2

13
PUMP PARTS LIST
Model - PW2
ItemPart Description
114 RK41100 23” Frame sub-assy.
115 GB/T923-88 Nut M6
116 RK41310 Rubber
117 GB/T5787 Bolt, M6×12
118 GB/T6170 Nut, M8
119 GB/T5787 Bolt, M8×32
120 RK44112 Housing, rear
121 RK44121 O-ring
122 RK44230 Seal, mechanical
123 RK44121 O-ring
124 RK44122 Washer, copper
125 GB5787-86 Bolt, allen headed
126 RK44211 Impeller
127 RK44212 Cover, Impeller
128 RK44221 O-Ring
129 RK44111 Housing, Front
130 RK44412 Pipe, 2”
131 GB5787-86 Bolt, Hex
132 RK44142 O-Ring
133 RK44141 Plug, Drain
134 RK44413 Union, hose 2”
135 RK44511 Flange, Inlet 2”
136 RK44521 Gasket, Inlet Flange
137 RK44321 Gasket, Outlet Flange
138 RK44311 Flange, Outlet 2”
139 RK44411 Gasket, 2”

14
ENGINE PARTS DIAGRAM-MODEL PW2

15
Item Part Description
1 RK11212 Oil drain plug
2 RK11213 Washer
3 GB276-89 Bearing 6205
4 RK13180 Crankshaft oil seal
5 RK11100 Crankcase
6 RK26311 Regulating sway bar
7 RK26329 Washer
8 RK26321 Split pin
9 RK37810 Oil Sensor
10 GB5787-86 M6 × 14 bolt
11 RK25151 Regulating shaft
12 RK25165 Washer
13 RK25120 Regulator gear assy
14 RK25164 Snap ring
15 RK25132 Washer
16 RK25131 Sleeve
17 GB5787-86 M6 × 12 bolt (6 off)
18 RK20651 Air duct
19 RK19721 Wind cover
20 RK12252 M6 × 113 bolt
21 RK12218/168F Set pin10 × 16
22 RK12220 Cylinder head gasket
23 RK12210 Cylinder head assy
24 RK12253/168F M8×34 bolt
25 RK34200/168F Spark plug
26 RK12256/168F Bolt
27 RK12312/168F Cylinder head cover gasket
28 RK12310/168F Cylinder head cover assy
29 RK15650/168F Oil plug assy
30 RK15651/168F Oil plug
31 RK15612/168F Seal
32 RK11311/168F Crankcase cover
33 GB276-89 Bearing 6205
34 RK11119/168F Crankcase gasket
35 RK11118/168F Set pin
36 RK15611/168F Oil dipstick
37 RK15610/168F Oil dipstick assy
38 RK13180/168F Crankshaft oil seal
39 GB5787-86 M8 × 32 bolt
40 RK13311/168F Piston ring (‘!)
41 RK13312/168F Piston ring (a!)
42 RK13322/168F Side rail
43 RK13321/168F Expander
44 RK13320/168F Scraper ring set
45 RK13300/168F Piston ring assy
46 RK13222/168F Piston pin clip
47 RK13211 Piston
48 RK13221/168F Piston pin
49 RK13131/168F Shank
50 RK13132/168F Connecting rod cover
51 RK13133/168F Bolt
52 RK13130/168F Connecting rod assy
53 RK13118/168F Woodruff key
54 RK13110 Crankshaft assy
55 RK14416/168F Lock nut
56 RK14413/168F Sleeve
57 RK14411/168F Valve rocker
58 RK14415/168F Adjusting bolt for valve gap
59 RK14410/168F Valve rocker assy
60 RK14261/168F Pusher guide
61 RK14250/168F Pusher
62 RK14455 Tappet
63 RK14100 Camshaft assy
64 RK14721/168F Exhaust valve
PARTS LIST-MODEL PW2 ENGINE
Item Part Description
65 RK14711/168F Intake valve
66 RK14755/168F Valve spring
67 RK14751/168F Intake valve spring seat
68 RK14757/168F Exhaust valve spring seat
69 RK14758/168F Cap
70 RK12254/168F Inlet gasket
71 RK16141/168F Connecting block
72 RK16142/168F Carburetor gasket
73 RK17330/168F Air cleaner gasket
74 RK16100 Carburetor assy
75 RK17100/168F Air cleaner
76 GB6177-86 M6 nut
77 RK16937/168F Pipe clamp
78 RK16931/168F Outlet pipe
79 GB5787-86 M6 × 22 bolt
80 RK16950/168F Connector
81 RK16961/168F Packing ring
82 GB6177-86 M6 nut
83 RK16916/168F Filter cup
84 RK16521/168F Packing ring
85 RK16510/168F Fuel cap 86
86 RK16500/168F Fuel cap with assy
87 RK16610/168F Fuel tank
88 RK18000/168F Exhaust muffler
89 RK12255/168F Exhaust gasket
90 GB6177-86 M6 nut
91 GB5787-86 M6 × 22 bolt
92 RK19810/168F 1 Crankcase side plate assy
93 GB577-86 M6×8 bolt
94 RK19710/168F Fan hood assy
95 RK27300/168F Recoil starter
96 GB5787-86 M6×12 bolt
97 RK35410/168F Engine switch
98 RK27100/168F Recoil starter assy
99 RK32211/168F Plastic clip
100 RK37850/168F Diode
101 RK26410/168F Regulating frame assy
102 RK26363/168F Back spring
103 RK26364/168F Regulating spring
104 RK26341/168F Pulling rod
105 RK26362/168F Lock bolt
106 RK26331/168F Regulating arm
107 GB6177-86 M6 nut
108 GB5787-86 M6 × 25 screw
109 RK27515/168F M14 × 1.5 nut
110 RK27370/168F Starting flange
111 RK19722/168F Flywheel fan
112 RK27500/168F Flywheel
113 RK34500/168F Ignition coil assy
140 RK19216/168F Ring SpacerAssembly

16
PUMP PARTS DIAGRAM
MODEL - PW3

17
PARTS LIST - MODEL PW3 PUMP
MODEL - PW3
Item Part Description
114 RK41100 23” Frame sub-assy.
115 GB/T923-88 Nut M6
116 RK41310 Rubber
117 GB/T5787 Bolt, M6 × 12
118 GB/T6170 Nut, M8
119 GB/T5787 Bolt, M8 × 32
120 RK44112 Housing, rear
121 RK44121 O-ring
122 RK44230 Seal, mechanical
123 RK44122 Washer, copper
124 GB5787-86 Bolt, allen headed
125 RK44211 Impeller
126 RK44212 Cover, Impeller
127 RK44221 O-Ring
128 GB5787-86 Bolt, Hex
129 RK44142 O-Ring
130 RK44141 Plug, Drain
131 RK44413 Union, hose 3”
132 RK44511 Flange, Inlet 3”
133 RK44521 Gasket, Inlet Flange
134 RK44111 Housing, Front
135 RK44321 Gasket, Outlet Flange
136 RK44311 Flange, Outlet 3”
137 RK44411 Gasket, 3”
138 RK44412 Pipe, 3”

18
PARTS DIAGRAM - PW3 ENGINE

19
PARTS LIST- MODEL PW3 ENGINE
ItemPart Description
1 RK11212/168F Oil drain plug
2 RK11213/168F Washer
3 GB276-89 Bearing 6205
4 RK13180/168F Crankshaft oil seal
5 RK11100 Crankcase
6 RK26311/168F Regulating sway bar
7 RK26329/168F Washer
8 RK26321/168F Split pin
9 RK37810/168F Oil sensor
10 GB5787-86 M6 × 14 bolt
11 RK25151/168F Regulating shaft
12 RK25165/168F Washer
13 RK25120/168F Regulator gear assy
14 RK25164/168F Snap ring
15 RK25132/168F Washer
16 RK25131/168F Sleeve
17 GB5787-86 M6 × 12 bolt
18 RK20651/168F Air duct
19 RK19721/168F Wind cover
20 RK12252/168F M6 × 113 bolt
21 RK12218/168F Set pin 10 × 16
22 RK12220 Cylinder head gasket
23 RK12210 Cylinder head assy
24 RK12253/168F M8 × 34 bolt
25 RK34200/168F Spark plug
26 RK12256/168F Bolt
27 RK12312/168F Cylinder head cover gasket
28 RK12310/168F Cylinder head cover assy
29 RK15650/168F Oil plug assembly
30 RK15651/168F Oil plug
31 RK15612/168F Seal
32 RK11311/168F Crankcase cover
33 GB276-89 Bearing 6205
34 RK11119/168F Crankcase gasket
35 RK11118/168F Set pin
36 RK15611/168F Oil dipstick
37 RK15610/168F Oil dipstick assy
38 RK13180/168F Crankshaft oil seal
39 GB5787-86 M8 × 32 bolt
40 RK13311/168F Piston ring (‘!)
41 RK13312/168F Piston ring (a!)
42 RK13322/168F Side rail
43 RK13321/168F Expander
44 RK13320/168F Scraper ring set
45 RK13300/168F Piston ring assy
46 RK13222/168F Piston pin clip
47 RK13211 Piston
48 RK13221/168F Piston pin
49 RK13131/168F Shank
50 RK13132/168F Connecting rod cover
51 RK13133/168F Bolt
52 RK13130/168F Connecting rod assy
53 RK13118/168F Woodruff key
54 RK13110 Crankshaft assy
55 RK14416/168F Lock nut
56 RK14413/168F Sleeve
57 RK14411/168F Valve rocker
ItemPart Description
58 RK14415/168F Adj bolt for valve gap
59 RK14410/168F Valve rocker assy
60 RK14261/168F Pusher guide
61 RK14250/168F Pusher
62 RK14455 Tappet
63 RK14100 Camshaft assy
64 RK14721/168F Exhaust valve
65 RK14711/168F Intake valve
66 RK14755/168F Valve spring
67 RK14751/168F Intake valve spring seat
68 RK14757/168F Exhaust valve spring seat
69 RK14758/168F Cap
70 RK12254/168F Inlet gasket
71 RK16141/168F Connecting block
72 RK16142/168F Carburetor gasket
73 RK17330/168F Air cleaner gasket
74 RK16100 Carburetor assy
75 RK17100/168F Air cleaner
76 GB6177-86 M6 nut
77 RK16937/168F Pipe clamp
78 RK16931/168F Outlet pipe
79 GB5787-86 M6 × 22 bolt
80 RK16950/168F Connector
81 RK16961/168F Packing ring
82 GB6177-86 M6 nut
83 RK16916/168F Filter cup
84 RK16521/168F Packing ring
85 RK16510/168F Fuel cap
86 RK16500/168F Fuel cap with assy
87 RK16610/168F Fuel tank
88 RK18000/168F Exhaust muffler
89 RK12255/168F Exhaust gasket
90 GB6177-86 M6 nut
91 GB5787-86 M6 × 22 bolt
92 RK19810/168F Crankcase sideplate assy
93 GB5787-86 M6×8 bolt
94 RK19710/168F Fan hood assy
95 RK27300/168F Recoil starter
96 GB5787-86 M6×12 bolt
97 RK35410/168F Engine switch
98 RK27100/168F Recoil starter assy
99 RK32211/168F Plastic clip
100 RK37850/168F Diode
101 RK26410/168F Regulating frame assy
102 RK26363/168F Back spring
103 RK26364/168F Regulating spring
104 RK26341/168F Pulling rod
105 RK26362/168F Lock bolt
106 RK26331/168F Regulating arm
107 GB6177-86 M6 nut
108 GB5787-86 M6 × 25 screw
109 RK27515/168F M14 × 1.5 nut
110 RK27370/168F Starting flange
111 RK19722/168F Flywheel fan
112 RK27500/168F Flywheel
113 RK34500/168F Ignition coil assy
139 RK19216/168F Ring SpacerAssembly

20
DECLARATION OF CONFORMITY - PW2