Hyundai HY25-4 User manual

PETROL WATER PUMP
HY25-4
HY40-4
User Manual

2
CONTENTS
PAGE NO.S
1
SAFETY
3 - 9
2
PART LOCATIONS
10
3
ASSEMBLY
10
4
STARTING PROCEDURE
12
5
STOPPING PROCEDURE
13
6
MAINTENANCE
14 - 17
7
STORAGE
18 - 19
8
TROUBLE SHOOTING
20 - 21
9
SPECIFICATION
21
10
PART LISITNGS
22 - 25
11
DECLARATIONS OF CONFORMITY
26
12
CONTACT DETAILS
27
INDEX

3
1. SAFETY
1.1 General SafetyNotes.
1.2 The operator of the machine is responsible for,and has a dutyof care in making sure
that the machine is operated safely and in accordance with the instructions in this
user manual. Keep the manual safe and pass it on if the machine is loaned or soldto
another user.
1.3 Please note the following safetypoints.
1.4 The machine should never be left it in a condition which would allow an untrained or
unauthorised person/s to operate thismachine.
1.5 All due care and diligence should be taken by the operator for the safety of and with
regard to those around whilst using themachine.
1.6 Some or all of the following - warning signs, symbols and/or PPE pictograms may
appear throughout this manual. You MUST adhere to their warnings. Failure to do
so may result in personal injury to yourself or those aroundyou.
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.
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 and keep the manual safe and pass it on if the machine is loaned or sold to another user.
You MUST fully understand all instructions to ensure you use and operate the machine safely.
Appropriate Personal Protective Equipment (PPE), MUST be worn at all times when operating or
repairing the machine.

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1.10 Carbon Monoxide (whereapplicable).
1.11 Carbon monoxide is a colourless and odourless gas. Inhaling this gas can cause
death as well as serious long term health problems such as braindamage.
1.12 The symptoms of carbon monoxide poisoning can include but are not limited to the
following;
Headaches, dizziness, nausea, breathlessness, collapsing or loss of consciousness.
1.13 Carbon monoxide poisoning symptoms are similar to flue, food poisoning, viral
infections and simply tiredness. It is quite common for people to mistake this very
dangerous poisoning for somethingelse.
1.14 To avoid carbon monoxide poisoning DO NOT use Petrol/Diesel powered equipment
inside any of the following; Home, garage, tent, camper van, mobile home, caravan
or boat. This is not exhaustive and if you are in any doubt contact yourdealer.
1.15 If you think you have or someone around you has been affected by carbon monoxide
poisoning;
1.16 Get them fresh air immediately, by leaving the affected area or by opening doors and
windows. If safe and practical to do so make sure that the machine is turnedoff.
DO NOT enter a room you suspect of having carbon monoxide present – instead call
the emergency services.
1.17 Contact a Doctor immediately or go to Hospital – let them know that you suspect
carbon monoxidepoisoning.
1.18 DO NOT use in an enclosed area or movingvehicle.
1.20 General Fuel Safety (whereapplicable).
CAUTION
ALL FUELS ARE FLAMABLE
1.21 Fire Hazard – keep fuel away from all sources of ignition for example heaters.
Lamps, sparks from grinding orwelding.
1.22 DO NOT carry out hot work on tanks that have containedfuel.
1.23 ALWAYS keep the work areatidy.
1.24 ALWAYS clean up spills promptly using absorbent granules and a liddedbin.
1.25 ALWAYS dispose of waste fuelscorrectly.

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1.30 Fueling/De-fueling (whereapplicable).
CAUTION
ALL FUELS ARE FLAMABLE
1.31 ALWAYS fuel and defuel in a well ventilated area outside ofbuildings.
1.32 ALWAYS wear correct, suitable and fit for purpose Personal Protective Equipment
(PPE), suggested items are but not limited to safety gloves,overalls.
1.33 When fueling/de-fueling ALWAYS avoid inhalingfumes.
1.34 When de-fueling ALWAYS use a proper fuelretriever.
1.35 ALWAYS carry fuel in the correct and clearly markedcontainer.
1.40 Electrical Safety (whereapplicable).
1.41 Electricity can kill – NEVER work on LIVE/ENERGISEDequipment.
1.42 Prior to carrying out any maintenance work you MUST identify electrical isolation
methods and isolate all electricalsupplies.
1.43 Prior to use and with all electrical supplies isolated, you MUST check all electrical
cables, plugs and connectors for thefollowing;
1.44 Are intact and have no signs of damage, to include but not limited to bare wires,
chaffing, cuts and loosewiring.
1.45 If there are any signs of damage, the damage item MUST be taken out of service
until the damage has been repaired by an electrically competentperson.
1.46 All trailing cables should be routed so as not to cause any kind of triphazard.
1.47 NEVER work on or near electricity with wet hands, wet clothing and wetgloves.

6
1.50 Batteries (wherepresent).
1.51 Batteries present a risk if they become damaged by the possible leaking of
electrolyte. This electrolyte is an acid and can cause serious burn injuries. Care
should be taken when working on or near them. NOTE the electrolyte may be in
a liquid or gelform.
1.52 Should you come in to contact with electrolyte youshould;
1.53 Remove all clothing contaminated with electrolyte. If you cannot remove then
saturate them inwater.
1.54 Get medical assistance as soon as possible. You must advise the medical staff of
the type of acid.
1.55 Lead/acid battery = dilute sulphuricacid.
1.56 Nickel/cadmium = potassium hydroxide alkalielectrolyte.
1.57 Use fresh running water to wash off excess electrolyte, continue this until medical
assistance arrives. Make sure that you do not was the electrolyte to another part of
your body orface.
1.58 If electrolyte comes in to contact with Eyes the electrolyte needs to be immediately
washed away with large amounts of water. Make sure that you do not wash the
electrolyte to another part of your face orbody.
1.59 Gasses from charging batteries are highly flammable and great care should be taken
to charge in well ventilatedareas.
1.59.1 There is an explosion risk if the battery terminals are shortcircuited, when
connecting/disconnecting ALWAYS exercise great care so that the terminals or
battery leads are NOT allowed to touch and cause a spark. ALWAYS use suitable
insulated tools.
1.60 Vibrations (whereapplicable).
1.61 Prolonged use of hand held (operated) machines will cause the user to feel the
effects of/from vibrations. These vibrations can lead to white finger (Raynaud’s
phenomenon) or carpal tunnel syndrome. This condition reduces the ability of the
hand to feel and regulate temperature, causing numbness and heat sensations and
may cause never damage and circulatory tissuedeath.
1.62 Not all factors that lead to white finger disease are known, but cold weather, smoking
and other diseases that affect blood vessels and blood circulation as well as large
and long-lasting impact of shocks are considered factors in the formation of white
finger. Note the following to reduce the risk of white finger and carpal tunnel
syndrome;
1.63 Wear gloves and keep your handswarm.
1.64 Take regularbreaks.
1.65 All of the above precautions may help reduce the risk of white finger disease but not
rule out the carpal tunnel syndrome. Long-term and regular users are therefore
recommended to observe the condition of your hands and fingers. Seek medical
attention immediately if any of the above symptoms shouldoccur.

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1.70 Noise (whereapplicable).
1.71 The operating noise of the machine can damage your hearing. Wear hearing
protection such as earplugs or ear defenders to protect your hearing. Long-term
and regular users are advised to have hearing checked regularly. Be especially
vigilant and cautious when hearing ear protection because your ability to hear alarm
warnings will bereduced.
1.72 Noise emissions for this equipment is unavoidable. Carry out noisy work at approved
times and for certain periods. Limit the working time to a minimum. For your personal
protection and protection of people working nearby it is also advisable for them to
wear hearingprotection.
1.73 See CERTIFICATE of CONFORMITY section for Outdoor Noise declaration of
conformity.
MACHINE SPECIFIC SAFETY
1.80 General MachineSafety.
1.81 Read the owner’s manual carefully to understand how to operate this machine
properly.
1.82 The water pump will need priming with water BEFOREuse.
1.83 Check the water pump over before use, if any problems are found you MUST make
sure they are dealt with by the appropriate person beforeuse.
1.84 Check around and underneath the water pump for signs of oil or fuelleaks.
1.85 Remove any dirt or debris, especially from the engine exhaust and recoilstarter.
1.86 Look for any signs ofdamage.
1.87 Check that all nuts, bolts, screws, hose connectors and clamps aretightened.
1.88 Check the general condition of thehoses.
1.89 Before connecting the hoses to the water pump, make sure that they are in good
condition.
1.90 Remember that the suction hose must be of a reinforced construction to prevent the
hose fromcollapsing.
1.91 Check that the sealing washer in the suction hose is in good condition. If there are
any leaks or a poor connection, the pump will draw in air and notfunction.
1.92 Check that the hose connectors and clamps are securelyinstalled.
1.93 Check that the strainer is in good condition and is secured on the suctionhose.
WARNING
Operating the water pump with a low oil level will damage the pump.
NOTE
Before checking the oil, place the water pump on a flat, level surface.

8
NOTE
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.
1.94 A dirty air filter will restrict air flow to the carburetor, reduce engine performance and
thereby reduce the water pump performance. For this reason, it is important to check
the air filterregularly.
1.95 Undo air filter cover Allen screw/wing nut (1) and removecover.
1.96 Remove air filter cartridge(2).
1.97 Remove, inspect and clean foam element (3) all models. Clean by washing in warm
soapy water, rinse with fresh water and allow to dry fully, soak it in clean engine oil
until it has saturated and then squeeze out excess oil before refitting. Replace dam
aged foam filterelements.
1.98 Paper elements must be have all dust and dirt blown out using a low pressure
air-line. Replace damaged paper filterelements.
1.99 Clean the lower body of the air filter, housing and rubber cushions. It is important to
prevent dust from entering into the path of the oilcarburetor.

9
1.99.1 Fuel level check.
NOTE
Do not add fuel over the fuel strainer shoulder (maximum level (2).
Fuel can damage paint and plastic. Be careful not to spill fuel when filling your fuel
tank.
1.99.2 Before each operation of the water pump, check the fuel level with the water pump
placed on a level ground. Un-screw the fuel tank cap and check the fuel level. If the
level is too low, add fuel, screw on the fuel tank cap and tightenit.
1.99.3 Only use straight, fresh unleaded petrol(3).
1.99.4 Never use stale or contaminated petrol or a mixture of oil and petrol. Avoid getting
dirt or water in the fueltank.
1.99.5 Correct Personal Protective Equipment (PPE) MUST be worn at all times when
operating or repairing this machine. This should include but is not limitedto;

10
2. PART LOCATIONS
3. ASSEMBLY
2.0 Suction Hose
2.1 Place the sealing washer (2) over the suction port(1).
2.2 Offer the hose connector (3) to the sealing washer (2) then put the hose clampring
(4) over the hose connector and tighten in a clockwise direction.
2.3 Take the hose clamp ring (5) over the end of the suction hose (6) then push the
suction hose over the end of theconnector.
Once in place move the hose clamp into position and tighten screw in a clockwise
direction until the hose is secured to prevent air entering the pump and to prevent
water leakage.

11
1 7
2.4 Attach the hose strainer to the other end of the suction hose and secure it with the
hose clamp. The strainer will prevent the pump from becoming clogged or damaged
by anydebris.
NOTE
This machine is shipped dry of oil. Prior to starting the motor you must ensure the
crank case is filled with a quality SAE 10W-30 4 stroke oil.
2.5 Remove the oil fillercap/dipstick.
2.6 Fill the crankcase to the upper level oil level with approx. 0.4l of SAE10W-30 4
stroke oil and replace the oil fillercap/dipstick.
2.7 Do not overfill.
2.8
2.9
2.10
2.11
2.12
2.13
CAUTION
All fuels areflammable. You MUST ensure you have read and
understood the fuel safety guidelines in sections 1.20 and 1.30 before filling with fuel.
Fuelling
Place the water pump on flat levelground.
Remove the fuel fillercap.
Fill with clean, fresh unleaded petrol up to the fuel upper limit, donot overfill.
Be careful not to admit dust, dirt, water or any other foreign objects intothefuel.
Replace the fuel filler cap and secure tightly.

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4. STARTING PROCEDURE
CAUTION
The self-priming pump chamber MUST be completely filled before operation.
Failure to do this may result in seal failure and the pump not operating.
If the unit has been operated dry, stop the machine and allow to cool before adding
priming water.
3.0 Remove the self-priming water filler cap and fill withwater
3.1
3.2
3.3
Turn the fuel valve to the ON position.
Close the choke lever (not required if restarting from a warm
engine). Turn the engine switch to the ON position.

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3.4 Move the throttle lever downwards to just past the idleposition.
3.5 Pull the recoil starter grip lightly until resistance is felt, then pull swiftly until the
engine fires.
NOTE
Do not allow the recoil starter to snap back against the engine. Return it slowly to
avoid and possible damage to the starter.
3.6 As the engine warms up, gradually open the choke until the enginerunssmoothly.
3.7 Set the throttle to the desired runningspeed.
5. STOPPING PROCEDURE
3.7
3.8
3.9
NOTE
In an emergency turn the engine switch to the OFF
position.
Move the throttle lever all the wayup.
Turn the engine switch to the OFF position.
Turn the fuel valve to the OFF position.

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6. MAINTENANCE
WARNING
Shut off the engine before performing any maintenance.
Always carry out maintenance in a clean and well ventilated are and follow all
safety precautions when handling fuels or oil.
Always wear the appropriate Personal Protective Equipment.
NOTE
Use only genuine parts or their equivalent for maintenance or repair.
Substandard replacement parts may damage the pump.
Service more frequently in dusty environments.
This pump should be serviced by an authorised water pump dealer.
4.0 MaintenanceSchedule
Regular Service Period
Month or operating hour interval,
Whichever comes first
Pre-
operation
check
First
month or
20 Hrs
Every 3
months
or 50 Hrs
Every 6
months
or 100
Hrs
Every
year or
300 Hrs
Engine Oil Inspection
●
Change
●
●
Air Cleaner Element Inspection
●
Change
●
Spark Plug Maintenance
●
Tappet Clearance Adjustment
●
Combustion Chamber Cleaning
●
Fuel Tank Cleaning
●
Fuel Line Every 2 Years (replace if necessary)
Impeller Inspection
●
Casing Cover Inspection
●
Inlet valve Inspection
●

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4.1 Changing Oil
NOTE
Drain the engine oil while the engine is still warm to assist with rapid and complete
draining.
Oil capacity 0.4l.
4.2 Remove the oil fillercap/dipstick.
4.3 Place a suitable container beneath the oil drain plug to catch wasteoil.
4.4 Remove the oil drain plug and allow all the oil todrain.
4.5 Replace the oil drainplug.
4.6 Replace the engine oil with a good quality SAE 10W-30 4 strokeoil.
4.7
NOTE
Please dispose of used motor oil in a matter that iscompatible with the
environment.
We suggest taking itina sealed container to your local recycling centre for
reclamation.
Do NOT throw waste oil on to the ground or down drains.
Air FilterService
NOTE
Adirty airfilter will restrict airflow to the carburetor. To prevent carburetor
malfunction, service the air cleaner regularly. Service more frequently when
operating the pump in dusty areas.
WARNING
Never use petrol or low flash point solvents for cleaning the air filter element. This
could result in a fire or explosion.

16
NOTE
Never run the engine without an air filter. Rapid engine wear will result from
contaminants such as dust and dirt being drawn in to the engine.
4.8 Unscrew the wing nut and remove the air filtercover.
4.9 Remove the foam air filter element from thehousing.
4.10
4.11
4.12
Wash the element in a solution of household detergent and warm water or a non-
flammable or high flashpoint solvent until clean, then rinse thoroughly and allow to
dry.
Soak the air filter element inclean engine oiland squeeze out any excess. NOTE
the engine will smoke on start-up if too much oil isleft on the element.
Reinstall the air filter and air filtercover.

17
4.13 Spark Plug Service
WARNING
The exhaust becomes very hot during operation and remains hot for a while after
use. Allow the exhaust to cool before carrying out any maintenance.
NOTE
Recommended spark plug model number: F7TC.
An incorrect spark plug may cause engine damage.
4.14
4.15
4.16
4.17
4.18
4.19
4.20
4.21
Remove the spark plug HTwire.
Remove the spark plug with the spark plug wrench provided.
Visually inspect the spark plug and discard if chipped orcracked.
If the spark plug isto be reused then clean with a soft wire brush and reset the gap
using a feelergauge.
The plug gap should be 0.70 – 0.80mm (0.0280.031inches)
Check the spark plug washer isin good condition.
Thread the spark plug back in to the engine by hand taking care to prevent cross
threading.
Once the spark plug has been installed as tight as you can by hand and is seated
correctly, tighten with a spark plug wrench to compress thewasher.
New Plug: ½ a turn
Re-Used Plug: ⅛ – ½a turn

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7. STORAGE
WARNING
The exhaust becomes very hot during operation and remains hot for a while after
use. Allow the exhaust to cool before transporting or storing the water pump.
WARNING
If transporting the water pump, turn the engine switch and fuel valve to OFF.
Keep the water pump level to prevent fuel spillage.
Fuel vapour or spilled fuel may ignite.
5.0 Be sure the storage area is clean and free of excessive humidity anddust.
5.1 Clean the water pumpinterior.
5.2 Sediment will settle in the pump especially if used in water containing debris, sand or
mud.
5.3 Pump clean water through the pump before shutting down or the impeller may be
damaged whenrestarting.
5.4 After flushing, remove the pump drain plug and drain as much water as possible
from the pumphousing.
5.5 After the pump has been drained and is dry, spray a multi-purpose rust inhibitor in
through the inlet port, outlet port and drain hole, then reinstall the drainplug.
5.6 Always store securely in an uprightposition.
5.7 Draining the fuel system.
WARNING
All fuels are flammable and the proper precautions and procedures must be followed
when handling fuels as they are a source of fire or explosion.
Fuel must always be stored in the proper containers.
WARNING
When working with fuels you must always work in a well ventilated areas and avoid
breathing petrol fumes.

19
5.8
5.9
5.10
5.11
With the fuel valve OFF, remove the carburetor drainscrew.
Drain the fuel from the carburetor into a suitablecontainer.
If the fuel in the fuel tank isto be drained, turn the fuel valve ON and drain the
fuel from the fuel tank in to a suitablecontainer.
Replace the drain screw and turn the fuel valve to the OFF position.
Stoppage Time
Recommended service procedure to prevent hard starting
Less than 1 month
No preparation required
1 to 2 months
Fill with fresh fuel and add a fuel conditioner
2 months to 1 year
Fill with fresh fuel and add a fuel conditioner
Drain the carburetor float bowl
1 year or longer
Drain the fuel tank
Drain the carburetor float bowl
After removal from storage, drain stored fuel into a suitable container
Fill with fresh fuel
Use fuel conditioners that are formulated to extend storage life.
5.12
5.13
5.14
5.15
5.16
Remove the spark plug and pour a tablespoon of clean engine oil into the cylinder
bore. Crank the engine a few revolutions to distribute the oil then reinstall the spark
plug.
Slowly pull the recoil starter handle until resistance is felt. At this point the piston is
coming up on its compression stroke and both intake and exhaust valves are closed.
Storing the engine in this position will help to protect itfrom internalcorrosion.
Change the engineoil.
Check the air filter and clean asnecessary.
Cover the water pump with a sheet to keep out dust.

20
8. TROUBLE SHOOTING
WARNING
Before cleaning, inspecting or repairing your unit, you MUST make sure that the
engine has stopped and allowed to cool.
You MUST disconnect the spark plug lead to prevent any accidental starting.
6.0 Engine
Engine will not start
Cause
Corrective measure
Check controls
Fuel valve OFF
Move fuel lever to ON position
Choke OPEN
Move the choke lever to the
CLOSED position unless the
engine is warm
Engine switch OFF
Turn the engine switch ON
Check fuel
Out of fuel
Refuel
Bad fuel, pump has been
stored without treating or
draining fuel or refuelling with
bad fuel
Drain the fuel tank and
carburetor and refuel with
fresh fuel
Remove and inspect the spark
plug
Faulty spark plug or
improperly gapped
Replace with new spark plug
or adjust the spark plug gap
Spark plug wet with fuel,
flooded engine
Dry the spark plug and
reinstall. Start engine with
throttle lever in FAST
Contact dealer
Fuel filter clogged, carburetor
malfunction, ignition
malfunction, valves stuck etc.
Return to dealer for repair
6.1 Water Pump
No output from pump
Cause
Corrective measure
Check pump chamber
Pump not primed
Prime pump
Check suction hose
Hose collapsed, cut or
punctured
Replace hose
Strainer not completely
underwater
Sink strainer and end of
suction hose completely
underwater
Air leak at connector
Replace sealing washer if
damaged or missing. Tighten
hose connector and clamp
Strainer clogged
Clear debris from strainer
Measure suction and
discharge head
Excessive head
Relocate pump and hose to
reduce head
Check engine Engine lacks power
See engine trouble shooting
above