Hyundai DHY50E User manual

DIESEL WATER/TRASH/
CHEMICAL PUMPS
Models DHY50E/DHYC50LE/DHY80E/
DHYT80E

RECORD OF IDENTIFICATION NUMBERS
If you need to contact an Authorised Dealer or aftersales on 01646 687 880 for information on servicing,
always provide the product model and identification numbers.
You will need to locate the model and serial number for the machine and record the information in the
places provided below.
Date of Purchase:
Dealer Name:
Dealer Phone:
Product Identification
Numbers;
Model Number:
Serial Number:
Engine:
Horse Power:
This unit is shipped without oil and fuel. You Must make sure that
the unit is filled with oil and fuel before attempting to start.
See section 4.
PAGE 2

CONTENTS
Section Description
Page No/No’s
OPERATION NOTES & RECORD of IDENTIFICATION NUMBERS
2
1. SAFETY
4 - 6
2. SAFE OPERATION
7 - 10
3. MACHINE PARTS
11
4.
OIL & FUEL 11
5.
ASSEMBLY 12 – 13
6.
OPERATION 13 - 15
7.
STARTING/STOPPING 15 - 16
8.
MAINTENANCE 17
9.
TROUBLESHOOTING 18
10.
WINTER STORAGE
19
11.
ENVIRONMENTAL DISPOSAL
20
12. SPECIFICATIONS
20
13. CONTACT DETAILS
20
14.
DECLARATIONS of CONFORMITY 21 - 22
PAGE 3

1. SAFETY.
1.1. The operator of the machine;
1.1.1. Is responsible for and has a duty of care in making sure that the machine is operated safely
and in accordance with the instructions in this user manual.
1.1.2. Should never leave it in a condition which would allow an untrained or unauthorised
person/s to operate this machine.
1.1.2.1. Should take care and show due diligence for the safety of and with regard to those
around whilst using the machine, to include but not limited to;
1.1.2.1.1. Elderly, children, pets, livestock and property.
1.2. Some or all of the following PPE, Warning Signs and symbols may appear throughout this manual
and you must adhere to their warning/s. Failure to do so may result in personal injury.
Warning Signs and Symbols – FOLLOW safety messages to avoid or reduce risk of injury or death.
DANGER - indicates a
hazard which if not
avoided could result in
serious injury or death.
WARNING - indicates a
hazard which if not
avoided could result in
serious injury or death.
CAUTION - indicates a
hazard which if not
avoided might result
in minor or moderate
injury.
NOTE - indicates a
situation that could
easily result in
equipment damage.
READ MANUAL
Personal Protective clothing (PPE)
PAGE 4

1.3. Carbon monoxide.
1.3.1. Carbon monoxide is a colourless and odourless gas. Inhaling this gas can
cause death as well as serious long term health problems such as brain damage.
1.3.2. The symptoms of Carbon monoxide poisoning can include but not limited to the following;
1.3.2.1. Headaches, Dizziness, Nausea, Breathlessness, Collapsing or Loss of consciousness.
1.3.2.2. Carbon monoxide symptoms are similar to flu, food poisoning, viral infections and
simply tiredness. It is quite common for people to mistake this very dangerous poisoning
for something else.
1.3.3. To avoid Carbon monoxide poisoning DO NOT Use Petrol/Diesel powered equipment inside
a home, garage, tent, camper-van, mobile home, caravan or boat. The list is not exhaustive if
you are in any doubt contact your dealer.
1.3.4. If you think you or someone around you has been affected by carbon monoxide poisoning;
1.3.4.1. Get fresh air immediately, by opening doors and windows, turning off machine and
leaving the affected area.
1.3.4.2. See your doctor immediately or go to hospital - let them know that you suspect
carbon monoxide poisoning.
1.3.5. DO NOT use in an enclosed area or a moving vehicle.
1.4. General fuel safety.
1.4.1. Fuel Safety additional information can be obtained from the Health and Safety Executive
(HSE) document SR16.
1.4.2. All fuels are Flammable.
1.4.3. Keep away from all ignition sources i.e. Heaters, lamps, sparks from grinding or welding.
1.4.4. Hot work on tanks that have contained fuel is extremely dangerous and should not be
carried out.
1.4.5. Keep work area clean and tidy.
1.4.6. Clean up all spills promptly using correct methods i.e. absorbent granules and a lidded bin.
1.4.7. Dispose of waste fuels correctly.
PAGE 5

1.5. Diesel safety.
1.5.1. Always fuel and defuel in well-ventilated area.
1.5.2. Always wear correct, suitable and fit for purpose Personal Protective Equipment (PPE),
suggested items are as follows, but are not limited too.
1.5.3. Hand protection.
1.5.4. Protective clothing.
1.5.5. Respiratory protective equipment should be used when in an unventilated area.
1.5.6. When defueling always use a propriety fuel retriever.
1.5.7. Always carry fuel in the correct and clearly marked container.
PAGE 6

2. SAFE OPERATION
A running engine gives off carbon monoxide, which is an
odourless, colourless, poisonous gas.
Inhaling carbon monoxide can cause headache, fatigue, dizziness,
vomiting, confusion, seizures, nausea, fainting or death.
2.1. Operate water pump ONLY outdoors.
2.2. Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes, or
other openings.
2.3. DO NOT start or run engine indoors or in an enclosed area, even if windows and doors are open.
Use of water pump can create puddles and slippery surfaces.
2.4. Operate water pump from a stable surface.
2.5. The area should have adequate drainage to reduce the possibility of a fall due to slippery surfaces.
Fuel and its vapours are extremely flammable and explosive.
Fire or explosion can cause severe burns or death.
2.6. When adding or draining fuel.
2.6.1. DO NOT overfill tank. Allow space for fuel expansion.
2.6.2. Turn water pump OFF and let it cool at least 2 minutes before removing fuel cap.
Loosen cap slowly to relieve pressure in tank.
2.6.3. Fill or drain fuel tank outdoors.
2.6.4. If fuel is split clean it up and/or allow it to evaporate before starting engine.
2.6.5. Keep fuel away from sparks, open flames, pilot lights, heat, and other ignition sources.
2.6.6. DO NOT use near any naked flames, other sources of ignition and lighting cigarettes?
2.7. When starting equipment.
2.7.1. Make sure that muffler/exhaust, fuel cap, and air cleaner are in place.
2.9. When operating equipment
2.9.1. DO NOT tip engine or equipment at angle which can cause fuel to spill.
2.9.2. DO NOT Use pump for fuels, sea water, beverages, acids, chemical solutions (Except for the
DHYC50LE), or any other liquid that promotes corrosion.
PAGE 7

2.10. When transporting or repairing equipment
2.10.1. Transport/repair with fuel tank EMPTY or with fuel shutoff valve OFF.
2.10.2. Disconnect spark plug wire.
2.11. When storing fuel or equipment with fuel in the tank
2.11.1. Store away from furnaces, stoves, water heaters, clothes dryers, or other appliances that
have pilot light or other ignition source.
2.12. Electric shock risk.
Risk of electrocution.
Contact with power source can cause electric shock or burn.
2.12.1. NEVER allow pumped water and spray to come into or near power sources.
2.13. Starter cord kickback (Rapid retraction)
Starter cord kickback (rapid retraction) can result in bodily injury.
Kickback will pull hand and arm toward engine faster than you can let
go.
Broken bones, fractures, bruises, or sprains could result.
Keep hands and body clear from discharge of pump.
2.13.1. When starting engine, pull cord slowly until resistance is felt and then pull rapidly to avoid
kickback.
2.13.2. Secure discharge hose to avoid whipping.
Contact with muffler/exhaust area can result in serious burns. Exhaust
heat/gases can ignite combustible materials and/or structures, which
can cause fires.
2.14.3. DO NOT touch hot parts and AVOID hot exhaust gases.
2.14.4. Allow equipment to cool before touching.
2.14.5. Keep at least 6 feet (2.0 m) of clearance on all sides of water pump including overhead.
PAGE 8

2.16. Starting and rotating parts.
Starter and other rotating parts can entangle hands, hair, clothing,
or accessories.
2.16.1. NEVER operate the water pump without protective guards, housing or covers. 2.16.2.
DO NOT wear loose clothing, jewellery or anything that may be caught in the starter or
other rotating parts.
2.16.3. Tie up long hair and remove jewellery.
2.17. Eye protection.
Risk of eye injury - Spray can splash back or propel objects.
2.17.1. Always wear safety goggles when using this equipment or in vicinity of where equipment is
in use.
2.17.2. Before starting the water pump, be sure you are wearing adequate safety goggles.
2.17.3. NEVER substitute safety glasses for safety goggles.
Excessively high operating speeds increase risk of injury and damage to water
pump.
Excessively low speeds impose a heavy load.
2.18.
2.19.
2.20.
DO NOT tamper with the governed speed.
DO NOT modify the water pump.
DO NOT allow unqualified/untrained persons or children to operate or service water pump.
The Improper treatment of water pump can damage it and shorten its life.
2.21.
2.22.
2.23.
2.24.
2.25.
2.26.
If you have questions about intended use, ask dealer or contact nearest authorised dealer.
Be sure pump chamber is filled with water before starting the engine.
Never run pump without priming.
Use a non-collapsible hose on the suction side of the hose.
Use water pump only for intended uses.
Pumping sea water, beverages, acids, chemical solutions, or any other liquid that promotes
corrosion can damage the pump.
2.27.
2.28.
2.29.
2.30.
Ensure all connections are air tight.
DO NOT obstruct the suction or discharge hose in any way.
NEVER operate pump without strainer basket connected to end of suction hose.
NEVER allow vehicles to drive over hoses. If a hose must be positioned across a roadway,
use planking on each side of hose to allow vehicles to pass over without obstructing or collapsing
hose.
PAGE 9

2.31. Anchor pump to avoid equipment movement.
2.32. Keep equipment away from edge of river or lake where it could cause the bank to collapse.
2.33. DO NOT insert any objects through cooling slots.
2.34. NEVER operate units with broken or missing parts, or without protective housing or covers.
2.35. DO NOT by-pass any safety device on this machine.
2.36. NEVER move machine by pulling on hoses. Use frame on unit.
2.37. Check fuel system for leaks or signs of deterioration, such as chafed or spongy hose, loose or
missing clamps, or damaged tank or cap.
2.38. Correct all defects before operating water pump.
PAGE 10

3. MACHINE PARTS
Generic image showing parts – locations will vary on each model - For engine locations please supplied engine manual.
1
Oil Drain.
5
Battery.
9
Recoil Starter.
13
Stop/Run.
2
Oil Filler.
6
Starter Motor.
10
Pump Priming Cap.
14
Pump Outlet.
3
Pump Drain Plug.
7
Pump Housing
11
Exhaust.
4
Pump Inlet.
8
On/Off Key Switch
12
Fuel Tank.
4. OIL & FUEL
Do Not fill with oil and fuel whilst engine is hot or running.
Before checking and or filling with oil and fuel check that the pump is on stable
and level ground.
4.1. Oil.
4.1.1. Undo oil filler plug (1), fill with
clean 15W 40 Oil.
4.1.2. Fill to the top of the threads.
4.1.3. Do not overfill.
4.1.4. Clean up any spilt oil before
starting machine.
4.1.5. Do not allow any dust or dirt
to enter the oil system.
4.2. Fuel.
4.2.1. Undo filler cap (1).
4.2.2. Fill with fresh Diesel.
4.2.3. Fill to bottom of the filler neck (2).
4.2.4. Do not overfill.
4.2.5. Clean up any spilt fuel before starting machine.
4.2.6. Do not allow any dust or dirt to enter the fuel
system.
PAGE 11

5. ASSEMBLY
Your water pump requires some assembly and is ready for use after it has been properly filled with the
recommended oil and fuel. If you have any problems with the assembly of your water pump, please call
the water pump help line at 01646 687 880. If calling for assistance, please have the model and serial
number available.
5.1. Connecting the suction hose to the pump.
5.1.1. Slide hose clamp (A) over end of hose (B). Slide suction hose onto hose barb (C). Tighten
hose clamp securely to the hose.
5.2. Attaching the suction hose to the strainer basket.
5.2.1. Slide hose clamp over the hose. Attach open end of the suction hose to strainer hose barb.
Tighten hose clamp securely.
5.3. Insert connect discharge hose (Optional).
5.3.1. If desired, use a commercially available hose. DO NOT use a hose with an inside diameter
smaller than the pump’s discharge port size.
5.3.2. Slide barb cuff over hose barb. Insert rubber seal into end of barb cuff as shown earlier.
5.3.3. Screw hose barb assembly onto pump in clockwise rotation until hose barb assembly is
tightened securely.
Hose connections are supplied.
Hoses ARE NOT supplied as standard with pump.
PAGE 12

5.3.4. Slide hose clamp over end of discharge hose. Slide discharge hose onto hose barb. Tighten
hose clamp securely.
5.3.5. You may choose to assemble the discharge and suction hose as shown above or by using
cam lock connections. Cam locks are another commonly used water pump connection.
6. OPERATION.
6.1. What is head?
6.1.1. Head refers to the height of a column of water that can be delivered by the discharge of the
pump.
6.1.2. Suction Head is the vertical distance between the centre of the pump and the surface of the
liquid on the suction side of the pump. May also be referred to as “suction lift”. The
atmospheric pressure of 14.7 psi at sea level limits suction head lift to less than approximately
26 feet for any pump.
6.1.3. Discharge Head is the vertical distance between the pump’s discharge port and the point of
discharge, which is the liquid surface if the hose is submerged or pumping into the bottom of a
tank.
6.1.4. Total Head is the sum of the suction head value plus the discharge head value.
6.1.5. As water pumping height increases, pump output decreases. The length, type, and size of
the suction and discharge hoses can also significantly affect pump output.
6.1.6. It is important for the suction operation to be the shorter part of the total pumping action.
This will decrease the priming time and improve pump performance by increasing the
discharge head.
6.1.7. Suction head is a maximum of 25 feet and discharge head should be a maximum of 81 feet.
Total head cannot be more than 106 feet as shown on next page.
PAGE 13

6.2. Pump positioning.
6.2.1. For best pump performance, locate the pump on a flat, level surface as close as possible
(but avoiding soft edges) to the water to be pumped.
6.2.2. Secure water pump to prevent it tipping over. Use hoses that are no longer than necessary.
6.2.3. IMPORTANT - Direct open end of discharge hose away from property, electrical supply
sources and other equipment that you do not want to get wet.
Fuel and its vapours are extremely flammable and explosive.
Fire or explosion can cause severe burns or death.
6.2.4. This water pump is not for use in mobile equipment or marine applications
6.2.5. DO NOT tip engine or equipment at angle which causes fuel to spill.
6.2.6. Secure water pump. Loads from hoses may cause tip over.
6.3. Priming the pump.
6.3.1. Be sure chamber is filled with water before starting
the engine. NEVER run pump without priming
6.3.2. Remove priming plug from top of pump.
6.3.3. Fill pump with clean, clear water up to top of
discharge outlet.
6.3.4. Replace priming plug.
6.4. Locating strainer basket into water source.
The Improper treatment of water pump can damage it and shorten its life.
PAGE 14

6.4.1. Place strainer basket into water to be pumped, basket must be fully immersed in water.
7. STARTING/STOPPING
Starter cord kickback (rapid retraction) can result in bodily injury. Kickback
will pull hand and arm toward engine faster than you can let go.
When starting engine, pull cord slowly until resistance is felt and then pull
rapidly to avoid kickback.
Broken bones, fractures, bruises, or sprains could be a result of incorrect use.
7.1. Electric start.
7.1.1.1. Make sure the water pump is on a stable flat
level surface.
7.1.1.2. Make sure the water pump has been filled with
both oil and diesel and to the correct levels.
7.1.1.3. Turn the fuel tap (1) down to the “ON” position.
7.1.1.4. Unscrew the STOP/RUN lever (3) then move it to the
RUN position, lock it into position by tightening the screw.
7.1.1.5. Turn the key switch (4) in an clockwise direction
against spring tension, once engine has started release
the key.
7.1.1.6 The water pump speed can be adjusted by moving the
STOP/RUN lever (3) to suit the load.
The Improper treatment of water pump can damage it and shorten its life.
NEVER operate pump without strainer connected to end of suction hose.
Keep strainer out of sand or silt, place in bucket or on stones.
DO NOT let pump run dry or damage to seals may result.
7.2. Recoil start.
7.2.1.1. Make sure the water pump is on a stable flat level surface.
7.2.1.2. Make sure the water pump has been filled with both oil and diesel and to the correct
levels.
7.2.1.3. Turn the fuel valve (1) down to the “ON” position.
7.2.1.4. Unscrew the STOP/RUN lever (3) then move it to the RUN position, lock it into position by
tightening the screw.
7.2.1.5. Slowly pull the recoil handle (2) until resistance is met, then move the de-compression
lever (5) to the down position.
7.2.1.6. Grasp recoil handle (2) and pull back quickly. DO NOT let go of handle instead let it return
slowly.
7.2.1.7. If engine fails to start first time repeat from 7.2.1.3.
7.2.1.8. If engine still does not start, hold the de-compression lever (5) in down position and pull
recoil handle two/three times. Then repeat from 7.2.1.3.
7.1.1.6 The water pump speed can be adjusted by moving the STOP/RUN lever (3) to suit the load.
PAGE 15

7.2.1.9. Important: It may take a few minutes for water pump to begin pumping water.
Contact with muffler/exhaust area can result in serious burns.
Exhaust heat/gases can ignite combustibles, structures or damage fuel
tank causing a fire.
7.2.1.10. DO NOT touch hot parts and AVOID hot exhaust gases.
7.2.1.11. Allow equipment to cool before touching.
7.2.1.12. Keep at least 6 feet (2.0 m) of clearance on all sides of water pump
including overhead.
7.3. Stopping the water pump.
7.3.1. Move the STOP/RUN lever (3) to the STOP position.
7.3.2. Turn the key switch (4) anti-clockwise to the OFF position
7.3.3. Turn fuel valve to “OFF” position.
7.4. Draining and flushing the water pump.
7.4.1. Disconnect and drain the suction and discharge hoses.
7.4.2. Remove the drain plug at bottom of the pump.
7.4.3.To protect the unit from damage caused by freezing temperatures, make sure
unit is fully drained of water.
7.4.4. Remove the primer plug from top of the pump and flush the internal
components of the pump with clean water.
7.4.5. Replace both plugs and finger tighten.
PAGE 16

8. MAINTENANCE
Service and maintenance must be performed by an authorised agent.
DO NOT tamper with, or attempt to adjust, the pressure switch or safety valve.
Before moving, or carrying out any maintenance on the compressor, ensure
the ignition switch is OFF, and that the tank pressure has been vented.
Allow the compressor to cool down for a period of time.
8.1. In order to keep the engine in good working condition, periodic maintenance is essential.
8.2. Engine.
8.2.1. For all engine maintenance please refer to the engine manufacturers’ handbook (supplied)
for the full schedule.
PAGE 17

9. TROUBLESHOOTING
9.1. If you are experiencing a problem that is not listed in this chart, or have checked all the possible
cause listed and you are still experiencing the problem, see your authorized dealer.
Engine lacks power. 1. Dirty air filter. 1. Replace air filter.
Engine will not start
1. STOP/RUN lever in STOP position. 1. Move lever to RUN position.
2. No fuel in engine. 2. Fill fuel tank or turn on fuel supply.
3. Battery discharged, 3. Charge or replace battery.
4. Faulty starter solenoid/motor. 4. Check replace as required.
Engine runs well at no load
but “bogs” down under full
load
1. Engine speed is too slow. 1. Adjust STOP/RUN lever to suit load.
Engine will not start; or starts
and runs rough
1. Low oil level. 1. Fill crankcase to proper level.
2. Dirty air cleaner. 2. Clean or replace air cleaner.
3. Out of diesel.3. Fill fuel tank.
4. Water in diesel. 4. Drain diesel tank, fill with fresh fuel.
5. STOP/RUN lever incorrectly set. 5. Move STOP/RUN lever.
Engine shuts down during
operation
1. Out of diesel. 1. Fill fuel tank.
2. Low oil level. 2. Fill crankcase with oil, to proper
level.
Engine lacks power 1. Dirty air filter. 1. Replace air filter.
Engine “putts” or falters 1. STOP/RUN lever incorrectly set.
1. Move STOP/RUN lever until
engine runs smoothly.
* All engine servicing to be taken to
Manufacturer’s authorised
service outlet.
PAGE 18

10. WINTER STORAGE
10.1. To protect the unit.
10.1.1. To protect unit from damage caused by freezing temperatures, make sure unit is fully
drained of water. Failure to drain water from the pump fully may cause damage
due to freezing, this damage will not be covered under warranty.
10.2. Long term storage.
10.2.1. If you do not plan to use the water pump for more than 30 days, you must prepare the
engine and pump for long term storage.
10.3. Fuel system.
10.3.1. Fuel will become stale when stored over 30 days. Stale fuel causes acids and gum deposits
to form in the fuel system or on essential carburetor parts.
10.3.2. Prior to storage, the diesel must be drained from the engine into an approved container.
10.3.3. Then run engine until it stops from lack of fuel.
10.4. Storing the engine.
10.4.1. See the engine operator’s manual for instructions on how to properly prepare the engine for
storage.
10.5. Additional storage tips.
10.5.1. DO NOT store fuel from one season.
10.5.2. Replace fuel container if it starts to rust. Rust and/or dirt in fuel can cause problems if it’s
used with this unit.
10.5.3. Once unit has cooled down cover unit with a suitable protective cover that does not retain
moisture.
10.5.4. Store unit in a clean and dry area.
Storage covers can be flammable.
DO NOT place a storage cover over a hot water pump.
Let equipment cool for a sufficient time before placing the cover on
the equipment.
PAGE 19

11. EVIROMENTAL DISPOSAL
11.1. Never pour remainders of oils, fuel mixtures into any drain, sewerage system or soil.
Dispose of it in a proper, environmentally friendly way, e.g., at a special collecting point or re-
cycling facility.
11.2. At the end of your pressure washers’ life, dispose of it in an environmentally friendly
manner.
11.3. Thoroughly empty the oil/lubricant and fuel tanks and dispose of the remainders at a special
collecting point or re-cycling facility.
11.4. At machine end of life please also dispose of at your local collecting/recycling point.
12.SPECIFICATIONS
13.1.1. See engine manual supplied with machine. Or you can obtain a copy of your manual at -
Model DHY50E DHYC50LE DHY80E DHYT80E
Engine
Displacement (cc)
Fuel tank
capacity (L)
Net installed power @
3600rpm (hp/kw)
Pump
Total head (m)
Suction lift (m)
Max flow l/h
Weight (Kg)
Assembled dimension
L X W X H (mm)
Noise level (dB )
Hyundai D200, 4 stroke single cylinder Hyundai D300, 4 stroke single cylinder
221 221 296 296
3.8/2.8 3.8/2.8 5.5/4.00 5.5/4.00
3.6 3.6 6.7 6.7
Engine oil capacity 0.6 0.6 1.1 1.1
25 35 26 60
8 7 8 7
105 105 109 109
54 51 61 69
570 x 470 x 670 540 x 450 x 540 590 x 490 x 590 590 x 490 x 590
36,000 36,000 60,000 60,000
Aluminium housing
with
a cast iron impeller
Aluminium housing
with
a cast iron impeller
Aluminium housing
with
a cast iron impeller
13.GENPOWER CONTACT DETAILS
13.1.
13.2.
13.3.
13.4.
Postal address;
Genpower Limited, Isaac Way, Pembroke Dock,
Pembrokeshire, SA72 4RW, UK.
Telephone contact number;
Office [phone]
Email contacts;
Technical [email protected]
Web site;
www.hyundaipowerequipment.co.uk
PAGE 20