Flextool FP212G User manual

FOR MORE INFORMATION

Version 2.0 (October 2022)

OPERATING INSTRUCTIONS

FLEXTOOL SUBMERSIBLE PUMPS

FP212G, FP212A, FP212C

FLEXTOOL OPERATING INSTRUCTIONS FLEXTOOL SUBMERSIBLE PUMPS

1300 353 986 ﬂextool.com.au

FLEXTOOL OPERATING INSTRUCTIONS SUBMERSIBLE PUMPS

1300 353 986 ﬂextool.com.au

CONTENTS

Introduction 2

Applications 2

Functions and controls 2

Accessories 2

Hazards and risks 2-3

Operation 3

Care and preventive maintenance 4

Cleaning and storage 4

Speciﬁcations 4

Service 4

Dismantling 5

Assembling 5

Trouble shooting 6

Spare parts and service 6

INTRODUCTION

APPLICATIONS

Dams, mines, tanks, tankers, swimming pools, pits, trenches,

excavations, construction sites, canal dredging, pile sinking.

Harbour & rescue services, pork producers, abbotoirs,

plumbers, drainers, builders, rural producers, government,

water, sewerage, power & telecommunication authorities.

Industrial plants, maintenance workshops, hire contractors.

The pump is suitable for continuous use at temperatures up to

65oC.

Operation at higher temperatures up to 95oC is permissible

providing immersion is intermittent and is not continuous.

Thank you for your selection of Flextool equipment.

Flextool have specialised in the design and manufacture of quality

products since 1951.

We have taken care in the design, manufacture and testing of this

product. Should service or spare parts be required, prompt and

efficient service is available from our extensive dealer network.

General safety instructions for the operation of power equipment

The goal of Flextool is to produce power equipment that helps the

operator work safely and efficiently. The most important safety device

for this or any tool is the operator. Care and good judgement are the

best protection against injury. All possible hazards cannot be covered

here, but we have tried to highlight some of the important items,

individuals should look for and obey Caution, Warning and Danger

signs placed on equipment, and displayed in the workplace.

Operators should read and follow safety instructions packed with

each product. Learn how each machine works. Even if you have

previously used similar machines, carefully check out each machine

before you use it. Get the “feel” of it and know its capabilities,

limitations, potential hazards, how it operates, and how it stops.

torque from the drive unit to the pump head. Submersible operation

of the pump head ensures that it is self priming and does not

require suction hose.

The pump is designed with wide passages through the strainer,

impeller and body to allow the unobstructed passage of solids. It is

suitable for handling ﬂuids with a high solid content such as sand,

sludge, silt, efﬂuent up to 60% in suspension, oil and water.

The pump is available with general purpose, abrasive resistant

and chemical resistant pump head models. The pump should

be selected with a model that best suits the most common

applications.

Select the shortest standard ﬂexshaft length (6 or 9 m) to suit the

common application/s.

The pump is ﬁtted with a quick action 60 mm (2.36 in) diameter

ﬂexible shaft coupling for operation from a drive unit ﬁtted with a 45

mm (1.75 in) diameter 3-tooth dog drive.

ACCESSORIES

Drive units are available with petrol and diesel motor drives.

Extension ﬂexshafts (6 m) extend the length of an existing pump

ﬂexshaft and are available to enable dewatering of holes to a

depth of 12 metre. A sealed quick-action coupling allows

underwater operation of the coupling.

HAZARDS AND RISKS

NEVER allow any person to operate a machine without adequate

instruction.

ENSURE all operators read, understand and follow the operating

instructions.

SERIOUS INJURY may result from improper or careless use of this

machine. Some models of P212 pumps weigh in excess of 25 kg.

Handling and positioning may require two people of appropriate

strength, along with correct lifting techniques

! MECHANICAL HAZARDS

DO NOT operate the pump with the body removed.

KEEP hands and feet clear of rotating and moving parts as they will

cause injury if contacted.

DO NOT leave the equipment in operation while it is unattended.

ENSURE that the equipment will remain stable and will not move or

fall while in operation.

DO NOT operate the pump without a discharge hose ﬁtted.

ENSURE that the pump hose is securely fastened to the pump

outlet via an appropriately sized coupling and adaptor.

ENSURE that repairs to machinery are carried out by COMPETENT

personnel.

FUNCTIONS AND CONTROLS

The product is a submersible pump. The pump head operates

underwater, driven by a rotating ﬂexible shaft that transmits the

FLEXTOOL OPERATING INSTRUCTIONS FLEXTOOL SUBMERSIBLE PUMPS

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FLEXTOOL OPERATING INSTRUCTIONS SUBMERSIBLE PUMPS

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! FIRE & EXPLOSION HAZARDS

PETROL is extremely ﬂammable and explosive under certain

conditions.

! CHEMICAL HAZARDS

CARBON MONOXIDE exhaust gases from internal combustion

motor driven units can cause death in conﬁned spaces.

! ADDITIONAL HAZARDS

HANDLE IMPELLERS WITH CARE when the pump body is

removed. Pumps that have been subject to extensive use with

abrasive materials may have impellers that are severely worn leaving

sharp, thin or brittle sections.

USE GLOVES when handling and inspecting the ﬂexible shaft outer

casing. Excessive wear of the rubber cover can expose the wire

braided reinforcement, allowing it to project and cause injury.

DO NOT use the pump for handling ﬂammable liquids.

Slip/Trip/Fall is a major cause of serious injury or death.

Beware of excess hose, the ﬂexible shaft and water left on the

walking or work surface.

DO NOT allow waste water to accumulate under foot.

EXERCISE care when working in the vicinity of unprotected holes or

excacations.

Sump pumping is the simplest method of dewatering.

Pumping from ‘open’ sumps is generally used in coarse sands and

gravels. It is difﬁcult to control the migration of ‘ﬁnes’ and should

not be used if soil displacement is a critical factor of consideration

when working near existing structures, roads, etc.

ADDITIONAL INFORMATION

Refer to the drive unit operation instructions for additional safety

and operation information on the appropriate drive unit.

OPERATION

For information on correct starting procedures refer to the engine

manufacturers operation manual.

Do not engage the drive coupling while the motor is rotating.

Before engaging the ﬂexshaft with a petrol drive unit start the motor

using the recoil starter, increase the speed to full throttle and allow

it to warm up for a few minutes.

Stop the motor.

Turn the bell housing trigger 180 degrees. Insert the ﬂexshaft

coupling fully into the housing of the drive unit and release the

trigger. Push the coupling into the housing and twist the ﬂexible

shaft until the drive dogs are fully engaged and the trigger returns to

the horizontal position.

The motor may now be started.

If the pump ﬂexible shaft is ﬁtted with an external movable spring,

it should be positioned to provide support where the shaft passes

over the edge of a trench or obstruction.

When pumping from deep pits or excavations avoid subjecting the

ﬂexshaft to the total weight of the pump and the discharge hose.

Support the weight of the pump by attaching a rope to one of the

pump eye-nuts. Secure the other end of the rope to a support

adjacent to the power unit so that it takes the weight of the pump

off the ﬂexshaft.

Drive units should be operated on a level surface. If the surface is

not level the drive unit should be restrained to ensure that it does

not move due to vibration or the weight of the pump and the hose.

Avoid extended running of the pump without water, or with the

ﬂexible shaft in a tight curve.

Never operate the pump ﬂexible shaft in the reverse direction, as

this will damage the ﬂexible core. If the impeller is fouled, remove

the bearing housing and manually clear the impeller.

HOW TO GET THE BEST PERFORMANCE FROM YOUR

PUMP.

Maximum discharge performance of the pump will only be

obtained when a reinforced discharge hose is used. This minimises

kinking where the hose passes over obstructions and permits the

unobstructed passage of solids.

If there is a tendency for the pump head to bury itself in heavy

sediment, overcome this by improvising an auxiliary strainer.

Remove the top from an empty 20 litre drum and punch openings

around the sides. Place the pump head in the drum below the

water.

Improved head performance will be obtained by increasing the

governed speed of the drive unit motor. It is recommended that

a motor with a minimum output of 5.6 kW (7.5 hp) is used for

continuous running above 3,000 r/min.

PUMPING CLEAN WATER

When there is a need to pump clean water without the sludge, grit

or solids that have collected at the bottom of a stream, dam, tank

or pit, keep the pump off the bottom. This will also minimise wear

from pumping abrasive materials.

In a pit or excavation attach a rope to an eye nut on the pump and

suspend the pump from the rope.

In dams and ponds support the pump from a ﬂoat made from an

empty sealed steel or plastic container or a marine buoy.

PUMPING HEAVY SLUDGE AND SOLIDS

Best results are obtained if the solids on the bottom of the pit or

pond are stirred into the surface liquid. The most effective way

of achieving this is to direct a hose from the submersible pump,

a large volume tap or a second pump, using waste water, into

the tank or pit for a short time until the solids are stirred from the

bottom.

USE A SUITABLE HOSE

Layﬂat hose is lightweight and rolls ﬂat to facilitate handling and

storage, lt is less expensive than reinforced discharge hose.

However, layﬂat hose can kink and impede the ﬂow of the ﬂuid

and solids. For best results when using layﬂat hose, lay it ﬂat on

the ground keeping it free from kinks, bends and twisting where

possible.

A reinforced hose of 50 mm diameter will improve the discharge

performance, while a 75 mm diameter hose will give superior

discharge performance.

QUICK ACTION HOSE FITTINGS

Cam lever-action ﬁttings enable quick connection of hose to the

pump. They save time and eliminate problems with dirty screw

threads and missing washers that are common with nut and tail

screw thread ﬁttings. Joiners are available for coupling separate

hoses.

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CARE AND PREVENTIVE MAINTENANCE

The most critical part of the pump is the seal. This is because the

seal is subject to wear, particularly when the pump is handling

abrasive materials. It is important that the seals and the sleeve are

replaced before they have worn excessively. If the seals and sleeve

are allowed to wear until failure occurs water will enter the spindle

bearings.

Noisy bearings will not be apparent due to the noise level from the

drive motor.

If the pump is operated unchecked in this condition water will

eventually enter the ﬂexshaft. Naturally, the cost of repairing, a

pump which has been allowed to deteriorate in this way will be

greater.

Regular inspection of the pump and the seal will avoid these

problems.

Check the 3-tooth dog on the drive coupling to ensure that it is fully

meshed and not worn.

Check the strainer for missing sections that could allow the entry of

large objects and result in damage or obstruct ion of the impeller or

volute.

Dismantle the pump and the ﬂexible shaft every 500 hours.

Inspect for wear and lubricate before reassembling

Apply a liberal quantity of grease to the core assembly when

inserting it into the casing assembly from the drive coupling end.

If the spindle is worn by the seal/s located in the adaptor and it is

otherwise satisfactory for further use do not remove the existing

worn seal/s from the screwed adaptor. The bore of the adaptor is

deep enough to accommodate additional seal/s which will then be

located on an unworn area of the spindle.

Check the ﬂexible shaft for kinks and external damage by laying it

out straight on a workbench or the ﬂoor. Although it still operates a

badly kinked ﬂexible shaft may result in a broken inner core.

CLEANING AND STORAGE

It is advisable to operate the pump in clean water after use each

day or before storing when it has been used in sludge or water with

a high solid content. This will ensure that mud and sludge do not

dry out and obstruct the body or the impeller.

The three eye nuts can be unscrewed to allow removal of the pump

body and access to the impeller.

Hire operators should check the impeller for rags, solidiﬁed mud

and debris after each hire. While the body is removed check the

spindle bearings for slackness and smooth rotation.

SPECIFICATIONS

General Purpose Model P212G

@ 2,900 r/min

Maximum head 16.5 m

Maximum discharge 63,000 litre/h

@3,700 r/min

Maximum head >26.0 m

Maximum discharge >64,500 litre/h

ABRASION RESISTANT MODEL P212A

CHEMICAL RESISTANT MODEL P212C

@ 2,900 r/min

Maximum head 15.0 m

Maximum discharge 56,400 litre/h

@3,700 r/min

Maximum head 26.0 m

Maximum discharge 64,500 litre/h

Outlet 50 mm (2 in BSP)

Solids Up to 28 mm dia. or up

to 60% in suspension

Flexshaft dia (mm) Std 13 x 32

HD 16 x 38

SERVICE

! CAUTION

Read the operating instructions before servicing this product

and note the safety information.

Exercise care when handling ﬂexible shaft casings. Severe wear

or damage to the rubber cover may allow the internal wire braid

to protrude and cause injury.

Exercise care when handling pump impellers. Extreme wear may

result in thin sections or sharp surfaces and cause injury.

Inspect for wear and lubricate before reassembling

Apply a liberal quantity of grease to the core assembly when

inserting it into the casing assembly from the drive coupling end.

If the spindle is worn by the seal/s located in the adaptor and it is

otherwise satisfactory for further use do not remove the existing

worn seal/s from the screwed adaptor. The bore of the adaptor is

deep enough to accommodate additional seal/s which will then be

located on an unworn area of the spindle.

Check the ﬂexible shaft for kinks and external damage by laying it

out straight on a workbench or the ﬂoor. Although it still operates a

badly kinked ﬂexible shaft may result in a broken inner core.

CLEANING AND STORAGE

It is advisable to operate the pump in clean water after use each

day or before storing when it has been used in sludge or water with

a high solid content. This will ensure that mud and sludge do not

dry out and obstruct the body or the impeller.

The three eye nuts can be unscrewed to allow removal of the pump

body and access to the impeller.

Hire operators should check the impeller for rags, solidiﬁed mud

and debris after each hire. While the body is removed check the

spindle bearings for slackness and smooth rotation.

to 60% in suspension

Flexshaft dia (mm) Std 13 x 32

HD 16 x 38

SERVICE

! CAUTION

Read the operating instructions before servicing this product

and note the safety information.

Exercise care when handling ﬂexible shaft casings. Severe wear

or damage to the rubber cover may allow the internal wire braid

to protrude and cause injury.

Exercise care when handling pump impellers. Extreme wear may

result in thin sections or sharp surfaces and cause injury.

FLEXTOOL OPERATING INSTRUCTIONS FLEXTOOL SUBMERSIBLE PUMPS

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FLEXTOOL OPERATING INSTRUCTIONS SUBMERSIBLE PUMPS

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DISMANTLING

TO REMOVE THE PUMP FROM THE FLEXIBLE SHAFT

Remove the pump body from the housing by unscrewing the

eyenuts.

Unscrew the casing from the adaptor with spanners on the

adaptor spanner ﬂats and ferrule.

Pull the ferrule away from the adaptor to expose the spindle

and the core end.

TO REMOVE THE COUPLING FROM THE FLEXIBLE SHAFT

Unscrew the casing from the coupling using spanners on the

housing spanner ﬂats and ferrule.

Pull the ferrule away from the housing to expose the spindle

and the core end.

TO REMOVE THE CORE FROM THE CASING

Lay the ﬂexible shaft out straight on a long workbench or the

ﬂoor.

Pull the core out by hand ,coil it and lay it on down on clean

newspaper.

Inspect

Casing for kinks, wear and damage.

Core for wear and kinks.

TO DISMANTLE THE PUMP

Unscrew the impeller from the spindle with a lever through

blades and a spanner on the spindle spanner ﬂats.

Hold the housing in a vice.

Unscrew the adaptor from the housing using a spanner on the

spanner ﬂats.

Drain the oil from the housing and support it with the ﬂange

uppermost.

Press the spindle, bearings and spacer out of the housing.

Press the spindle out of the bearings after removing the circlip

Support the housing with the ﬂange down and press the seals

out off the housing.

Support the adaptor with the largest thread down and press

the seals out off the adaptor.

Slide the sleeve off the spindle over the external thread and

remove the o-ring.

Remove the o-rings from the adaptor.

INSPECT

Pump body and plate for wear.

Impeller for wear.

Housing and plate for wear and corrosion

Housing seals and seal sleeve for wear.

Adaptor seals and spindle seal diameter for wear.

Bearings for wear.

Strainer for missing grille segments.

Note: Because the pump seals are subject to wear, particularly

when the pump is handling abrasive materials, it is important

that the seals and sleeve are replaced before they have worn

excessively. If the seals and sleeve are allowed to wear until seal

failure occurs allow water will enter the spindle bearings.

If the pump is operated unchecked in this condition water will

eventually enter the ﬂexshaft. Regular inspection of the pump and

the seal will avoid these problems.

To dismantle the coupling

Unscrew the socket set screw from the housing.

Support the housing with the thread uppermost.

Press the spindle, seal, bearings and space out of the housing.

Support the spindle on the seal with the threaded end

uppermost and press the spindle out of the bearings after

removing the circlip.

Remove the o-ring from the housing.

INSPECT

Spindle dog teeth for wear.

Spindle dog seal diameter and seal for wear.

Bearings for wear.

ASSEMBLING

Clean the pump and coupling parts by washing in safety

solvent.

Clean the core assembly by wiping it with a clean cloth.

Reverse the above assembly procedure.

Ensure that the seals are correctly assembled with the housing

seal lips and the adaptor seal lips facing out when pressed into

position.

Fit the coupling to the same end of the casing that the core

was inserted through.

LUBRICATION

Pump

Apply a grease ﬁlm to o-rings, seal lips, seal sleev e and spindle

seal diameter.

Fill the housing with oil to cover bearing before screwing the

adaptor into the housing.

Coupling

Pack the bearings and the spacer with grease.

Apply a grease ﬁlm to the o-ring, the seal lips and the dog seal

diameter.

FLEXSHAFT

Apply a liberal coating of grease to the core as it is inserted into

the casing.

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TROUBLESHOOTING

SYMPTOM POSSIBLE CAUSES AND CORRECTION

The drive motor is

operating but the pump

is not functioning.

Check that the coupling is fully inserted in the bell housing and secured by the trigger.

Check that the impeller is not obstructed.

Check that a kink in the discharge hose has not created an air lock preventing water from initially

entering the pump.

Check that the pump is sufﬁciently submerged to allow water to cover the impeller.

Check that electric motor rotation is as shown by the direction arrow on the bell housing (anti-clockwise

when viewing its drive dog).

Check that the threaded core ends on the ﬂexible drive core have not unscrewed from the pump or

coupling spindle due to reverse rotation of the motor.

Check that the inner ﬂexible core has not failed.

There is a tendency

for the pump head to

bury itself in the heavy

sediment

Overcome this by improvising an auxiliary strainer. Remove the top from an empty 20 litre drum and

punch openings around the sides. Place the pump head in the drum below the water.

Model

Flexshaft

Length

m (ft)

Operating

Weight

kg (lb)

Shaft

Core Diameter

mm (in)

Shaft Casing

Diameter

mm (in)

Discharge

Diameter

mm (in)

Max

Discharge Head

m (ft)

Max

Discharge

l/h (gal/h)

Solids

Capacity

mm (in)

Product Code

Australia

FP212G-6 6

(19.7)

26.5

(58.4)

(0.5)

(1.3)

(2)

(85.3)

63,000

(16,642)

(1.1) FT201801-UNIT

FP212G-9 9

(29.5)

(83.8)

(0.5)

(1.3)

(2)

(85.3)

63,000

(16,642)

(1.1) FT201803-UNIT

Model

Flexshaft

Length

m (ft)

Operating

Weight

kg (lb)

Shaft

Core Diameter

mm (in)

Shaft Casing

Diameter

mm (in)

Discharge

Diameter

mm (in)

Max

Discharge Head

m (ft)

Max

Discharge

l/h (gal/h)

Solids

Capacity

mm (in)

Product Code

Australia

FP212A-6 6

(19.7)

(75)

(0.6)

(1.5)

(2)

(85.3)

63,000

(16,642)

(1.1) FT201805-UNIT

FP212A-9 9

(29.5)

42.5

(93.7)

(0.6)

(1.5)

(2)

(85.3)

63,000

(16,642)

(1.1) FT201818-UNIT

GENERAL PURPOSE PUMPS

ABRASION RESISTANT PUMPS

Model

Flexshaft

Length

m (ft)

Operating

Weight

kg (lb)

Shaft

Core Diameter

mm (in)

Shaft Casing

Diameter

mm (in)

Discharge

Diameter

mm (in)

Max

Discharge Head

m (ft)

Max

Discharge

l/h (gal/h)

Solids

Capacity

mm (in)

Product Code

Australia

FP212C-6 6

(19.7)

37.5

(82.7)

(0.6)

(1.5)

(2)

(85.3)

63,000

(16,642)

(1.1) FT201817-UNIT

CHEMICAL RESISTANT PUMPS*

*Improved chemical resistance to a wide range of chemicals compared to general purpose pumps.

Parchem Construction Supplies Pty Ltd

1956 Dandenong Road, Clayton VIC 3168, Australia

Phone: 1300 353 986

flextool.com.au

ABN 80 069 961 968

This manual summarises our best knowledge of the product based on the information available at the time of publication. You should read this manual carefully and

consider the information in the context of how the product will be used. Our responsibility for products sold is subject to our standard terms and conditions of sale.

DISCLAIMER:

Any advice, recommendation, information, assistance or service provided by us in this manual is given in good faith and is believed by us to be appropriate and reliable.

However, any advice, recommendation, information, assistance or service provided by us is provided without liability or responsibility PROVIDED THAT the foregoing shall

not exclude, limit, restrict or modify the right entitlements and remedies conferred upon any person or the liabilities imposed upon us by any condition or warranty implied

by Commonwealth, State or Territory Act or ordinance void or prohibiting such exclusion limitation or modification. The product can be expected to perform as indicated