Hyundai 1 inch User manual

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Preface
Thank you for purchasing a Hyundai water pump.
Please keep a copy of this manual for your reference.
This manual should be kept with this water pump for future reference and be
given with it if resold. This is important to ensure the correct and safe running
of this water pump for all current and future users. This owner's manual
contains instructions for the 1",1.5",2",3" and 4" water pumps. It is
extremely important that these instructions are read thoroughly before
operating the water pump in order to obtain the best results. If any problems
occur in relation to this water pump, please call us to speak to a technical
advisor.
All of the information and diagrams contained in this manual are correct and
relevant at the time of publishing. We reserve the right to make changes to
this manual at any time without prior notice.

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Contents
1.
Safety.....................................................................................
5
2.
Component Identification.....................................................
7
3. Control System...................................................................... 13
4.
Pre-Operation Inspection......................................................
15
5.
Operation..............................................................................
19
6.
Starting the Engine................................................................
23
7.
Stopping the Engine..............................................................
25
8.
Maintenance.........................................................................
27
9.
Storage..................................................................................
31
10. Troubleshooting.................................................................... 32
11. Electric Diagram.................................................................... 34
12.
13.
Specification..........................................................................
Declaration of Conformity.....................................................
35
38

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1. SAFETY
Our range of water pumps is designed to give a safe and reliable service if the
instructions contained in this manual are followed carefully. For this reason it is
important to read and understand all information contained in this manual
before attempting to operate the water pump. Failure to comply with these
instructions may result in personal injury or damage to the water pump.
Safety Messages
The safety of yourself and others is extremely important to us. For this reason,
we have provided important safety messages in this manual as well as on the
water pump and engine. Please read these safety messages carefully.
Safety Label - on the water pump and engine
Safety Message - alerts you to potential hazards that could hurt you or others.
Each safety message is preceded by a safety alert symbol and one of three
words: WARNING, CAUTION, or NOTICE. These mean:
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
Your water pump or other property could be damaged if you don’t follow
instructions.

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Safety Instructions
The clean water pumps and high pressure water pumps in our range have been
designed for pumping clean fresh water only.
Trash pumps have been designed to deal with debris up to 25mm in diameter.
Chemical pumps can be used for the transmission of weak acid and bases (PH4-
11) and commonly used for liquid fertiliser and seawater.
To prevent fire hazards and to ensure that the pump is used in a well
ventilated area, it is important to keep the pump away from all building walls
and other equipment during operation. Do not place flammable objects near
the water pump and ensure the water pump is drained of all fuel before
transportation.
The muffler becomes very hot during operation and for a while after the
engine has been stopped. Do not touch the muffler or store the water pump
until it has fully cooled down.
Due to petrol being extremely flammable, do not smoke in the refuelling and
fuel storage area. When filling the water pump with fuel, ensure you do so in a
well ventilated area with the engine stopped. If any spillage occurs, clean it up
immediately. After refuelling, replace the fuel cap and screw it on tightly.
Always place the water pump on a firm, level surface. If the pump is tilted or
overturned, fuel spillage may result.
Exhaust fumes from the pump's engine contain poisonous carbon monoxide
gas that can build up in closed areas. For this reason, ensure that the pump is
used in a well ventilated area at all times. Breathing in carbon monoxide can
result in death.
Due to the possibility of burns from the hot engine components, do not allow
children or pets near the water pump whilst it is in operation.
For safety reasons, this water pump must not be used in potentially explosive
atmospheres.

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2. COMPONENT IDENTIFICATION
1" Clean Water Pump

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1.5" Clean Water Pump

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2" / 3" / 4" Clean Water Pump

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Chemical Pump

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High Pressure Pump
This diagram shows the 2" high pressure pump

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Trash Pump

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3. Control System
Before operating the water pump, please ensure that you are familiar with
each control function and know how to operation these functions in the event
of an emergency.
1) Fuel Lever
The fuel lever allows the fuel to flow from the fuel tank to the carburettor.
Set the fuel level to the 'OPEN' position.
When the water pump is not in operation, please ensure the fuel lever is set
back into the 'CLOSE' position.
2) Engine Switch
The engine switch is used for opening and closing the ignition circuit. Set the
engine switch to the 'ON' position to run the engine and to the 'OFF' position
to stop the engine.
ENGINE SWITCH
OFF
ON

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3) Choke Lever
The choke lever is used for opening and closing the choke of the carburettor.
Set the choke lever to the 'CLOSE' or 'START' position for cold starting, or the
'OPEN' or 'RUN' position for normal operation or starting when the engine is
warm.
4) Throttle Lever
Adjust the throttle lever to change the speed of the engine, which will change
the flow rate of water. For a higher flow rate set the throttle lever to the
'HIGH' position, and for lower flow rate set the throttle lever to a 'LOW'
position.
START
RUN

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5) Recoil Starter
Pull the recoil starter to start the engine.
Do not allow the starter grip to snap back against the engine. Return it gently
to prevent damage to the engine.
4. PRE-OPERATION INSPECTION
For your safety and to maximise the service life of the water pump, it is
important to check the pump over before use. If any problems are found,
ensure these are dealt with by the appropriate person before you operate the
pump.
Failure to maintain this pump or deal with any problems that arise before
operation could cause a malfunction in which you could be seriously injured.
The exhaust gas contains poisonous carbon monoxide gas and so it is
important to avoid inhalation of these fumes. Ensure that you are using the
water pump in a well ventilated area and never use in a closed garage or other
closed area. To prevent fire hazards, keep the water pump away from all walls
and do not place flammable objects close to the engine. Before beginning your

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pre-inspection checks ensure the pump is on a level surface and the ignition
switch is in the 'OFF' position.
1) Routine Check
Check around and underneath the water pump for signs of oil or fuel leaks.
Remove any dirt or debris, especially from the engine muffler and recoil
starter.
Look for any signs of damage.
Check that all nuts, bolts, screws, hose connectors and clamps are tightened.
2) Check the Suction and Discharge Hoses
Check the general condition of the hoses. Before connecting the hoses to the
water pump, make sure that they are in good condition.
Remember that the suction hose must be of a reinforced construction to
prevent the hose from collapsing.
Check that the sealing washer in the suction hose connector is in good
condition. If there are any leaks or a poor connection, the pump will draw in air
and will not function.
Check that the hose connectors and clamps are securely installed.
Check that the strainer is in good condition and is secured on the suction hose.
3) Check Engine Oil
Place the engine on a level surface before checking the engine oil.
1. Remove the oil filler cap and wipe the dipstick clean.
2. The oil level should be at the top of the filler neck.
3. If the oil level is low, add the recommended oil to bring the level to the
top of the filler neck.
4. After adding the oil, remember to refit and screw down the oil dipstick.

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Operating the water pump with a low oil level will damage the engine.
4) Check Air Filter
A dirty air filter will restrict air flow to the carburettor, reduce engine
performance and thereby reduce the water pump performance. For this
reason, it is important to check the air filter regularly.
Screw off the butterfly nut and remove the air filter housing. Clean any dirt
that is present. If damaged, it must be replaced before usage. If it is an oil bath
air filter, check the oil capacity.
Replace the air filter and screw the butterfly nut down.
OIL DIPSTICK
OIL FILLER HOLE
LOWER OIL LEVEL MARK
UPPER OIL LEVEL MARK

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Ensure that the assembly of the air filter is correct. Never run the water pump
without the air filter or with a damaged air filter.
5) Check the Fuel
Before each operation of the water pump, check the fuel level with the water
pump placed on a level ground. Screw off the fuel tank cap and check the fuel
level. If the level is too low, add fuel, screw on the fuel tank cap and tighten it.
ONLY USE STRAIGHT UNLEADED PETROL.
Do not add fuel over the fuel strainer shoulder (maximum level)
Refuel in a well ventilated area. Ensure the engine has had time to cool down
before refuelling.
Fuel can damage paint and plastic. Be careful not to spill fuel when filling
your fuel tank.
6) Fuel Recommendations
Use straight unleaded petrol.
Never use stale or contaminated petrol or a mixture of oil and petrol and avoid
getting dirt or water in the fuel tank.

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5. OPERATION
1) Safe Operating Precautions
To ensure safe usage of the water pump, you must make sure that you fully
understand how to operate it properly and how to use the controls.
Before operating the water pump for the first time, please make sure you have
read the 'Safety Instructions' and 'Pre-Operation inspection' elements of this
manual carefully. Exhaust contains poisonous carbon monoxide gas that can
build up to dangerous levels in closed areas. Breathing carbon monoxide can
cause unconsciousness or death.
2) Pump Placement
For best pump performance, place the water pump near the water level and
use hoses of the correct length and no longer than is necessary. This will allow
the pump to produce the greatest output with the least self priming time.
As the head increases, the pump output decreases. The length, type and size of
both the suction and discharge hose can also significantly affect the pumps
output. By placing the pump near water level, therefore minimising the suction
head, this also reduces priming time.
3) Suction Hose Installation
Use the hose and hose connector and the hose clamp provided with the pump
to install the suction hose and tighten the clamp. Firmly fix the suction hose so
it can't move.

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The hose diameter should be no wider than the water suction port diameter.
Minimum hose diameters should be as follows:
1" Water Pump: 25mm
1.5" Water Pump: 40mm
2" Water Pump: 50mm
3" Water Pump: 80mm
4" Water Pump: 100mm
Use the hose clamp to securely fasten the hose connector to the suction in
order to prevent air and water leakage. Before using the connector sealing
washer ensure that it is in good condition.
Install the strainer (provided with the pump) on the end of the suction hose
and secure it with a hose clamp. The strainer will help prevent the pump from
becoming clogged or damaged by debris.
4) Discharge Hose Installation