Operating Guide
Contents
1. Loc AO o EU IDA Total Suction Head Head Bad Placement Discharge Head Total Head Good Placement Fig 3 6 HYUNDAI NOTICE Suction head is the height to which a pump can raise water on the suction side measured from the water level in the sump Discharge head is the vertical distance between the intake level of the wa ter pump and the level at which it discharges water freely to the atmosphere Total head is the sum of the suction head and the discharge head HYUNDAI 3 6 Priming Water NOTICE Prior to running the pump always make sure to prime it with water Priming will create a vacuum that will help to start the water flow 1 Unscrew the primer cap 2 Insert the neck of the water container into the opening and gradually tilt until the reservoir is full Refer to Fig 3 7 3 Tighten the cap back on 4 In case of a dry operation stop the engine immediately and al low it to cool before priming Fig 3 7 Primer Cap WARNING Never run the pump unprimed as doing so will overheat and damage the engine CAUTION Avoid spilling water when filling the storage container HYUNDAI CAUTION Make sure that the priming water and the container are free of any debris 4 OPERATION 4 1 Starting the engine Opening the throttle immediately after starting the pump will not provide enough time for the parts to lubricate 1 Prime the pump Refer to Fi2. REVIEW MANUAL CAREFULLY TO AVOID PERSONAL INJURY Licensed by Hyundai Corporation Korea HYUNDAI PREFACE Thank you for purchasing a Hyundai water pump Please register your product in order for us to ensure your continuous satisfaction with our product This manual covers the safety operation and maintenance proce dures for the HWP552 model All information in this publication is based on the latest product information available at the time of approval for printing No part of this publication may be reproduced without written per mission If a problem should arise please contact us by using the contact information at the end of this manual It is important that this manual be read and fully understood before operating the pump Failure to do so may cause serious injuries or equipment damage HYUNDAI Contents 1 SAFETY PRECAUTIONS 1 1 SAFETY LABELS etd 3 1 2 OPERATION SAFETY eee 3 2 IDENTIFICATION OF COMPONENTS 5 3 BEFORE STARTING 9 1 OIL LEVEL CHECK rte 9 3 2 FUEL LEVEL CHECK u uuu ss 10 3 3 AIR FILTER CHECK tritt 11 3 4 HOSE CONNECTIONS 12 3 5 PUMP PLACEMENTT eem 13 3 6 PRIMING WATER u lu 1 asss 15 4 OPERATION 4 1 STARTING THE ENGINE 16 4 2 STOPPING THE ENGINE 19 5 MAINTENANCE 5 1 IMPORTANCE OF MAINTENANCE 20 5 2 MAINTENAN
3. 1 Disconnect and remove the spark plug using a wrench 2 Inspect the spark plug and clean any dirt or debris from the elec trodes with a wire brush Replace if the electrodes are worn or the insulator is damaged 3 Measure the electrode gap with a spark plug gauge or feelers and adjust as necessary by carefully bending the side electrode The gap has to be between 0 7 0 9 mm Refer to Fig 5 4 4 Install the plug carefully by hand Then tighten it with a spark plug wrench Fig 5 4 lt I Spark Plug lt N UU Side Electrode Spark Plug 0 7 0 9 mm m id Wrench gap distance HYUNDAI 5 6 Fuel Sediment Cup Service 1 Move the fuel valve to the OFF position 2 Unscrew the sediment cup using a wrench and remove the O ring 3 Wash the cup and O ring in non flammable solvent and dry thoroughly 4 Place the O ring in the fuel valve then screw the sediment cup into place and tighten securely 5 Move the fuel valve to the ON position and check for leaks Re place the O ring if there is leakage Fig 5 5 gt U O Ring Sediment Cup 5 7 Fuel Drainage CAUTION Never store fuel in any other all purpose container as the gasoline may be affected HYUNDAI 1 Purchase a proper plastic fuel container from your local gas sta tion or general store 2 Place the container underneath while removing the drain screw from the carburetor 3 Turn the fuel valve to the ON position and s
4. Always disconnect the spark plug wire before performing any maintenance work Always keep the unit as clean as possible Keep it free of loose vegetation mud etc Always be already to stop the unit immediately if it suddenly begins to vibrate or shake Inspect for broken missing or im properly installed parts Never refuel the water pump while the engine is running Gaso line is very flammable and may ignite when in contact with hot engine parts HYUNDAI 2 IDENTIFICATION OF COMPONENTS Oil Dipstick Oil drain screw Discharge Port VQ Verx GY NA Y Nu y Fuel tank starter handle Choke lever Throttle lever Fuel valve Lever Fuel drain screw Engine Switch HYUNDAI Air filter Z N 2 0 FETAN m WA TENN CNN Y MVA BA N S LEA S A C EI mE PL XK J 3 amp s N YAN 4 lt Exhaust Primer opening Block HYUNDAI LABEL PLACEMENT WARNING HYUNDAI LABEL PLACEMENT HYUNDAI 3 BEFORE STARTING In order to maximize the service life of your water pump always do a pre operation inspection before every run 1 Look underneath the water pump to check for any puddles of leaking fluids 2 Inspect the water pump for any signs of physical damage 3 Check whether all nuts screws bolts and clamps are tight and not loose 4 Make sure the hoses which you are using are the reinforced construction type 5 Check engine oil level 6
5. Check air filter 7 Check fuel level Be sure to check the pump on a level surface with the engine stopped Low oil level will cause serious damage to a running engine 3 1 Oil Level Check 1 Remove the oil filler cap and wipe the dipstick clean Refer to Fig 3 0 2 Check the oil level by inserting the dipstick into the filler check without rotating If the level is low fill to the upper limit of the oil filler neck with the recommended oil Refer to Fig 3 1 3 Reinstall the oil filler cap and tighten carefully Oil filler cap Dipstick Fig 3 0 Fig 3 1 WARNING Engine oil is a major factor affecting engine performance and service life Non detergent or vegetable oils are not recommended 3 2 Fuel Level Check A WARNING Gasoline is extremely flammable and explosive under certain conditions Refuel in a well ventilated area with the engine stopped Do not allow smoking a naked flame or electrical sparks to occur during refilling Avoid spillage and wipe up spills immediately Keep stored gasoline out of the reach of children 1 Turn the engine switch to OFF position before filling the fuel tank Refer to Fig 3 2 Fig 3 2 HYUNDAI 2 Remove the fuel cap and check the fuel level Refer Fig 3 3 Fig 3 3 3 Refill the fuel tank if the level is low Refuel carefully to avoid spilling fuel 3 3 Air Filter Check Never run the engine without the air
6. filter Rapid engine wear will result from contaminants such as dust and dirt being drawn into the engine 1 Unscrew the wing nut remove the air filter cover and inspect the air filter sponge Refer to Fig 3 4 Wing 2 Observe the sponge for cleanliness Nut Se Z Lu 3 Clean the sponge with soapy water or inflammable solvent Squeeze dry and then soak in clean engine oil Squeeze out all excess oil and reinstall 4 Replace the sponge if it is damaged 3 4 Hose Connections 1 Insert adapters into one end each of the suction and discharge hoses and attach O rings to the adaptors 2 Tighten the hose clamp around the discharge hose until the con nection is airtight 3 Insert a strainer into the suction hose and tighten the hose clamp around the suction hose until the connection is airtight 4 Screw the adapters into the appropriate pump fittings Avoid sharp bends in the hoses and don t allow heavy objects to com press the hoses Refer to Fig 3 5 Hose Clamp 3 Insert Strainer 1 Connect hose 2 Tighten and Stalfi r Cap Suction Hose Clamp Ring Strainer Cap Coupler 3 5 Pump Placement Water pump placement is an important step for ensuring a more efficient and effective pump 1 Ensure that the suction head is less than the discharge head 2 Increasing the discharge head will decrease water output 3 Make sure the pump is primed to minimize the suction head Refer to Fig 3 6
7. CE SCHEDULE 20 5 3 ENGINE OIL CHANGE AND OIL DRAIN P cl mm 21 5 4 AIR FILTER SERVICE ciiir 22 5 5 SPARK PLUG SERVICE esses 24 5 6 FUEL SEDIMENT CUP SERVICE 26 5 7 FUEL DRAINAGE ee 26 5 8 IMPELLER CLEANING eee 28 5 9 TRANSPORTATION eeee 28 5 10 STORAGE e tret eet edis 29 5 11 EXTERNAL PARTS CLEANING 30 6 TROUBLESHOOTING eee 31 f SPECIFICATIONS un ne 33 8 WIRINGDIAGRAM me 34 9 WARRANTY uu a er eaa 35 10 GLOSSARY ana 38 HYUNDAI 1 SAFETY PRECAUTIONS 1 1 SAFETY LABELS DANGER This symbol warns of harzards which can result in severe or lethal personal injury This symbol refers to a hazardous or unsafe practice which has the potential to result in personal injury or product property damage CAUTION This symbol warns of immediate hazards which may result in severe or lethal personal injury 1 2 OPERATIONS SAFETY The water pump must not be operated by anyone under the age of 16 Never operate the engine when transporting the unit Never operate the water pump if you are tired or if you are under the influence of alcohol drugs medication or any other substance that could affect your ability or judgement Always do a pre operation inspection before each use Operate the water pump according to inst
8. away using the engine switch HYUNDAI 5 MAINTENANCE 5 1 Importance of Maintenance Proper maintenance is important because it will ensure safe eco nomical and trouble free operation lt will also reduce air pollution Improper maintenance may cause the water pump to malfunction and can lead to serious injuries or deaths 5 2 Maintenance Schedule Check condition Spark adjust gap Plug and clean Replace if Engine Oil Alr a if Filter necessary Clean fuel valve Fuel and fuel filter tank filter Replace if necessary Check and adjust when engine is cold HYUNDAI Check fuel hose for cracks or other damage Replace if neces sary Check for leakage Retighten or replace gasket if neces Carbu _ a K retor CHORE operation Check for Cooling rain dam System age Check re an coil starter y operation 5 3 Engine oil Change and Oil Drainage Used motor oil can cause skin cancer if repeatedly left in contact with skin for long periods of time Wash your hands thoroughly with soap and water as soon as possible after handling oil HYUNDAI CAUTION Do nat dispose of used oil by pouring it down the drain or on the ground Pour used motor oil into the container and take it to your local service shop for environmentally friendly disposal 1 Stop the engine 2 Remove the oil filler cap Refer to Fig 5 1 3 Place a pan under the engine 4 Re
9. e box The UPC label is the barcode used to scan at the time of purchase and is located on the bottom right corner of the box To register your pump by mail submit both UPC label and com pleted registration card for the address listed on the card You can also register your pump online at www hyundaipower ca UPC label HYUNDAI must still be mailed to the address listed on the registration card Upon receipt of this registration Midland will record and register your warranty No verification of registration and warranty will be sent to the purchaser NO WARRANTY COVERAGE WILL BE AL LOWED UNLESS YOUR PUMP IS REGISTERED WITH MIDLAND AND UPC LABEL IS PROVIDED Warranty Claim Procedure Warranty service must be performed by one of our authorized ser vice dealers If you feel your pump is malfunctioning due to a defect or misuse simply contact our customer support center for technical advice a warranty claim or general information Do not return your pump to the place of purchase for repair MIDLAND INTERNATIONAL INC SHOULD BE CONTACTED TO PROVIDE A CASE NUMBER BEFORE WARRANTY WORK CAN BEGIN To obtain warranty service Contact our customer support centre Toll free 1 877 528 3772 E mail support Hyundaipower ca Website Hyundaipower ca HYUNDAI Lu 10 GLOSSARY Air Filter lt removes dust from engine intake air Carburetor A device used to properly mix fuel and air in the cor rect proportions and delivering
10. ed service or any other misuse neglect incorporation or use of unsuitable attachments or parts will not be covered under this warranty Under this Warranty we do not have the obligation to bear any transportation fees of any product to from an authorized Warranty Center Unauthorized alteration installation or any cause other than defects in material or workmanship of the product will not be covered under the warranty Exclusions Not Covered by this Limited Warranty 1 Normal engine alternator wear 2 Damage caused by lack of maintenance as described in the Hyundai manuals or negligence by using improper or impure motor oil coolant or fuel 3 Damage caused by accidents improper installation or storage 4 Damage caused by water ingestion submersion or external water damage 5 Damage or non performance caused by operation of the pump in a marine application 6 Damage caused by operation with improper fuel or at speeds loads conditions or modifications contrary to published specifica tions 7 Items not supplied by Hyundai including but not limited to ex ternal wiring fuel lines filters etc refer to exclusions 8 Repairs made during the warranty period without first obtaining a case number from Hyundai Product Registration The warranty registration card must be sent to Midland within 30 days of purchase along with the UPC Universal Product Code label on the box The registration card can be found in th
11. ed warranty is valid for residential or recreational applications only and only when the pump receives all necessary preventative maintenance as de scribed in the Hyundai Water Pump Operation Manual The repair or replacement of a pump will take place within a reasonable period of time during normal business hours All repair and replacement parts shall be warranted for 90 days after the initial date of installation or purchase Limitation of Remedies and Disclaimers Midland International Inc disclaims any responsibility for loss of time or use of the pump in which the pump is installed transpor tation commercial loss or any other incidental or consequential damage Any implied warranties are limited to the duration of this written warranty THE FOREGOING LIMITED WARRANTY IS EXCLUSIVE OF AND IN LIEU OF ALL OTHER WARRANTIES OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE AND OF ANY OTHER WARRANTY WHETHER EXPRESS OR IMPLIED HYUNDAI Consumable parts such as oil or fuel filters fuel cut off valve brushes fuel injection nozzle valve lubricant or ignition plug are not covered under this warranty All expenses incurred in maintain ing and replacing parts for pump shall fall on the purchaser This warranty coverage does not include parts affected by accident and or collision corrosion or rust normal wear incorrect fuel type or fuel contamination use in an application for which the product was not intended unauthoriz
12. g 4 1 1 2 Slide the fuel valve lever to the ON position Refer to Fig 4 1 2 3 Slide the choke lever to the CLOSE position Refer to Fig 4 1 2 4 Adjust the throttle lever to about 74 of the way to the left direction Refer to Fig 4 1 3 5 Turn the engine switch to the ON position Refer to Fig 4 1 4 6 Pull the starter grip gently until resistance is felt Then pull it briskly and the engine should start Repeat the process if the en gine does not start Refer to Fig 4 1 5 7 After the engine warms up above 50 F turn the choke lever to the OPEN position Priming Cap Fig 4 1 1 b HYUNDAI Fig 4 1 2 Fuel Valve Fig 4 1 3 Throttle Lever HYUNDAI CAUTION Return the starter grip gently Do not allow it to snap back or the starter may be damaged NOTICE Set the throttle to the full open position to obtain maximum pump output If necessary the flow rate can be regulated by adjusting the throttle position HYUNDAI 4 2 Stopping the Engine 1 Return the throttle lever to the idle position to the right end Refer Fig 4 1 3 2 Turn the engine switch to the OFF position Refer to Fig 4 1 4 3 Turn the fuel valve to the OFF position Refer to Fig 4 1 2 NOTICE In an emergency the engine can be quickly stopped by simply turn ing the engine switch to the OFF position In case of an emergency do not cut down the throttle but rather switch the engine off right
13. he unit level to prevent spillage Secure the pump to the surface it rests on to prevent unwanted movement during transportation 5 10 Storage Do not store close to extreme heat flames or sparks as the water pump may ignite Do not store in an extremely humid and dusty areas as such environments may damage the components A WARNING Do not store with gasoline in the carburetor and gas tank HYUNDAI 1 Clean the impeller and drain all the water out 2 Drain out the gasoline and store the container in a heat flame and spark free place 3 Change the engine oil by draining the old and replacing it with the new 4 Slide the fuel valve to the OFF position 5 Place the water pump in an appropriate storage area at tempera tures above 0 C 6 Cover the intake and discharge port 7 Cover the entire pump with fabric to protect it from dust 5 11 External Parts Cleaning Keeping the external parts clean can prevent debris build up hard ening and ensure easy access during maintenance periods Never pressure wash the water pump as water may damage electrical components 1 Place the water pump in a well lit area 2 Use a grease oil removing solvent and a cloth to clean areas around the gas tank and the oil dipsticks 3 Using a damp cloth to rub off the remaining residue and any debris 4 Allow the unit to air dry HYUNDAI 6 TROUBLESHOOTING Ifthe engine wont start Cause Ll Action O Engine s
14. lowly remove the fuel drain screw from the carburetor Refer to Fig 5 6 4 Allow the fuel to drain fully and then drive the screw back in Fig 5 6 Fuel Drain Screw HYUNDAI 5 8 Impeller Cleaning Impeller cleaning is important when storing the water pump for a long period of time as well as considered good practice during regular maintenance checks 1 Fill up the pump with fresh water through the primer opening 2 Start the pump and let it run for 5 to 8 minutes or until water evaporates upon contact with the engine block 3 Drain the water through the pump drain outlet 4 Flush the pump with clean water pouring it through the primer opening 5 Drive the drain screw back on S E Water drain screw pump drain outlet 5 9 Transportation Contact with a hot engine or exhaust system can cause serious burns or fires Let the engine cool down before transporting the unit HYUNDAI CAUTION Take care not to drop or strike the pump while transporting Do not place heavy objects on the pump CAUTION Never operate a damaged or defective motor When adjusting or making repairs to your pump disconnect the spark plug wire from the spark plug and place that wire where it cannot contact the spark plug Do not use a garden hose to clean the pump because water can enter the fuel system and cause problems Make sure the engine switch and fuel valve are in the OFF positions Keep t
15. move the oil drain screw and let the oil drain completely into the pan Refer to Fig 5 1 5 Reinstall the drain screw and refill the engine with oil to the up per limit using a funnel Refer to Fig 3 1 6 Reinstall the oil filler cap SER Oil Drain Screw Fig 5 1 Oil Filler Cap 5 4 Air Filter Service Using gasoline or other flammable solvent to clean the filter element can cause a fire or explosion HYUNDAI Never run the water pump without the air filter this will cause rapid engine wear 1 Unscrew the air filter cover Refer to Fig 5 2 2 Remove the filter element and wash well with an inflammable solvent or soap and water then dry 3 Pour a small amount of oil into the filter element and gently squeeze out excess oil Never wring out the filter element as it may tear The engine will smoke if too much oil remains in the filter element Refer Fig 5 3 4 Reinstall the filter element and air filter cover ensuring the air filter cover seals completely Fig 5 2 ill d ing ANN Nut I Filter Cover Filter Element HYUNDAI Fig 5 3 ES NDA 5 5 Spark Plug Service 24 CAUTION Never rinse your spark plug with water as it will damage the spark plug CAUTION Follow the guidelines and do not over tighten the spark plugs CAUTION Tighten turn when installing a new spark plug HYUNDAI
16. opriate length width If there is no water ouput Cause Ooo Acion 00 Incorrect pump place Reposition the pump ment Pump is not primed Prime the pump Pump mechanism is Take the pump to an authorized ser damaged vice dealer HYUNDAI 7 SPECIFICATIONS HYUNDAI JI NSS ag T3A31 HU NOLLISNWAL 109 NOLIN T gt O gt 8 WIRING DIAGRAM HYUNDAI AS ING NE 9 WARRANTY Canadian distribution of Hyundai Water Pumps are distributed by Midland International 26 Huddersfield Rd Unit 2 M9W 5Z6 Canada This product is warranted to be free of defects in material and workmanship for two years from date of purchase This warranty guarantees that any defective parts will be repaired or replaced at no cost including diagnosis and replacement parts Limited Warranty periods Recreational residential use 2 years limited 1st year parts and labor 2nd year parts only Commercial use 6 months limited parts and labor This limited warranty begins at the initial time of retail purchase and covers manufacturer s defects caused by a defect in compo nents or workmanship during the two 2 Year period The warranty coverage is continual from the initial date of purchase and does not restart at anytime under any circumstances This limit
17. ructions for safe and dependable service Before operating the water pump read the user manual care fully Otherwise it may result in personal injuries or equipment damage When operating the water pump keep small children away from the area of operation Make sure the surface underneath the pump is levelled and firm Placing the pump at an angle will cause gasoline leakage HYUNDAI e Do not operate the water pump indoors Make sure the area of operation and maintenance is well ventilated Do not remain near the working water pump for a long time as the water pump emits poisonous carbon monoxide gas Do not use the water pump to work with flammable liquids such as gasoline Donotuse the water pump to work with caustic liquids such as used oil milk or wine Do not pump liquids and or chemical solutions such as sea water which may cause corrosion e Keep the working water pump at least 1 5 meters away from any static objects such as cars or buildings in order to ensure proper ventilation and prevent fire hazards Always stop the engine and allow it to cool before refuelling Avoid overfilling and wipe off any fuel that may have spilled Never place flammable material close to the engine muffler Never overturn the water pump when storing or transporting Overturning will cause leakage of vital liquids Never smoke or light fires near the unit Never make unauthorized attachment installations
18. the mixture into the engine s com bustion chamber Choke Lever It is used to provide proper starting mixture when the engine is cold The choke lever must be pulled out to ON posi tion when starting a cold engine Dipstick It seals off engine oil fill hole and is used for indicating the oil level Fuel Valve It controls flow of fuel from fuel tank to carburetor Impeller Rotating part of a pump which forces a fluid under pres sure in a desired direction Priming introducing water into a pump to improve the seal and start the water flowing Recoil Starter A pull cord is attached to the engine and you pull the T handle attached to the starter cord assembly to spin the fly wheel and start the engine Spark Plug A device screwed into the combustion chamber of a spark ignition engine The plug supplied the spark that ignites the air fuel mixture so that combustion can occur Strainer It prevents any large pieces of debris from entering the hose and damaging the pump mechanism HYUNDAI HYUNDAI HYUNDAI HYUNDAI
19. witch not ON Turn the engine switch to ON posi tion Faulty spark plug Use a wrench to remove the spark plug and remove any dirt or debris on the electrode Fuel line clogged Check the fuel line for any leaks Unclog the fuel line if needed Fuel valve not ON Turn the fuel valve to the ON posi tion Choke valve OPEN Turn the choke lever to the CLOSE position if the engine is cold Wrong fuel type Drain out the fuel and clean the fuel line Carburetor not getting Take the pump to an authorized ser fuel or air vice dealer Dirty air filter Disassemble and clean the air filter Empty fuel tank Fill up the fuel tank Low oil level Add oil and restart the engine Starter not functioning Take the pump to an authorized ser vice dealer If power is low Cause Action O Dirty air filter Clean air filter Throttle lever unadjusted Slide the throttle lever to increase the power output If water output is low Cause Acion O Clogged Strainer Clean the strainer rinse out all debris with water Suction hose blocked Clean out the hose with foreign material HYUNDAI Damaged hoses Purchase new hoses of appropriate length width Impeller clogged Remove obstruction Hose clamps loose Tighten or replace the hose clamps Seal leak Take the water pump to an autho rized service dealer Incorrect pump place Reposition the pump ment Incorrect hose length Replace the hoses with ones of ap width pr
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