Flextool PortaPump PP32 User manual

OPERATING INSTRUCTIONS
PortaPumpTM
PORTABLE PUMP
MODEL PP32
To reduce the risk of injury, all operators and maintenance personnel must read
and understand these instructions before operating, changing accessories, o
r
performing maintenance on this power equipment. All possible situations cannot be
covered in these instructions. However care must be exercised by everyone using,
maintaining or working near this equipment.
WARNING

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Thank you for your selection of Flextool equipment.
Flextool has specialised in the design and manufacture of quality products since 1951. We
have taken care in the assembly and testing of this product. It is covered by a 12-month
warranty. Should service or spare parts be required, prompt and efficient service is available
from our branches. For contact details of our branches, please refer to section Spare Parts &
Service on Page 10 of this manual.
This manual covers the operation and maintenance of the PortaPump. All information in this
manual is based on the latest product information available at the time of printing. Flextool
reserves the right to make changes at any time without notice and without incurring any
obligation.
READ THIS OPERATING INSTRUCTION CAREFULLY. Pay special attention to warnings
highlighted in this manual.
Introduction ................................................................................................................ 3
Applications ............................................................................................................... 3
Assembly ................................................................................................................... 3
Function and Controls ............................................................................................... 4
Hazards and Risks .................................................................................................... 4
Operation ................................................................................................................... 6
Care and Preventive Maintenance ............................................................................ 7
Service ..................................................................................................................... 7
Cleaning and Storage ............................................................................................ 8
Warranty .................................................................................................................. 8
Troubleshooting ...................................................................................................... 8
Specification and Performance ............................................................................. 9
Spare Parts and Servicing.................................................................................... 10
TABLE OF CONTENTS

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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, however we have highlighted 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 this product.
Learn how this machine works. Even if you have previously used similar machines, carefully
check out the machine before you use it. Get the “feel” of it and know its capabilities,
limitations, potential hazards, how it operates, and how it stops.
The PortaPump is a hand held lightweight pump designed to remove low levels of
accumulated dirty water from wall foundations prior to the pouring of concrete.
Unlike other pumps the PortaPump is designed to pick up and discharge the maximum
amount of residual water left in trenches including suspended solids up to 5mm.
It also has many other uses such as clearing water from ponds, bilges, sumps etc.
The PortaPump is to be used for pumping water only and is not suitable for pumping
chemicals or flammable substances. It is not intended for continuous running at full volume
for long periods.
The unit is supplied with the pump and shaft disconnected from the motor unit. To attach the
flexible shaft and pump, place the threaded ferrule end of the flexible shaft approximately 20
mm from the coupling housing. Engage the square end of the flexible shaft core assembly
into the squared seal sleeve adaptor.
The threaded ferrule end of the flexible shaft may now be screwed into the motor adaptor.
Rotate the ferrule end of the flexible shaft in an anti-clockwise direction to engage the left
hand thread. Once tightened by hand use multi-grip pliers to ensure the ferrule is tightened
sufficiently to stop it from working loose and coming detached during operation.
The PortaPump as supplied includes 2 metres of flexible discharge hose attached to the
pump outlet. A standard male Camlok adaptor is fitted to the opposite end of this. It is
recommended that to conduct discharge water further away from the pump a 5 metre
accessory hose including a 1-1/4” female Camlok coupling be used.
A 1 litre container of Honda 10w/30 engine oil is included with the unit. Engine oil capacity is
100 ml. To add oil place the unit on a level surface and remove the oil filler cap. Add oil until
the oil level reaches the edge of the oil filler neck & reinstall the oil filler cap.
Fuel may now be added and the unit is ready for operation.
INTRODUCTION
APPLICATIONS
ASSEMBLY

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Drive Unit
This portable drive unit is designed to power the flexshaft driven pump.
The motor is controlled by an ON/OFF push button which is mounted below the throttle lever
on the handle.
A centrifugal clutch is fitted to the motor which disengages the drive to the pump when the
motor is idling.
The clutch operates automatically and requires no adjustment.
The motor is a 4-stroke unit and must only be used with unleaded petrol.
The pump is driven by a rotating flexible drive shaft that transmits the drive from the drive
unit.
NEVER allow an untrained person to operate 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.
Do not operate this machine in an impaired mental state. You must be able to exercise good
judgement and reactions to maintain a safe working environment.
! MECHANICAL HAZARDS
ENSURE that the engine operation switch is in the OFF position and the spark plug ignition
lead is disconnected before removing the guards or making adjustments.
ENSURE both the pump and the operator are stable by setting up on a level surface. Make
sure the machine does not tip over, slide or fall while in operation or unattended.
DO NOT leave the machine in operation while it is unattended.
Hold the pump by “D” handle attached and use the supplied carry strap to help support the
weight.
Allow the engine to cool before servicing or replacing parts.
BE CAREFUL not to come in contact with the exhaust muffler when the engine is hot, since it
can cause severe burns.
ENSURE that repairs to the engine and machine are carried out by COMPETENT personnel.
HAZARDS & RISKS
FUNCTIONS AND CONTROLS

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! ELECTRICAL HAZARDS
Follow electrical safety procedures when using the water pump in locations where electricity
is present.
! FIRE & EXPLOSION HAZARDS
PETROL is extremely flammable and explosive under some conditions.
ENSURE that petrol is only stored in an approved storage container.
DO NOT refuel the engine while it is in operation or hot. Allow the engine to cool before
refilling.
DO NOT refuel the engine in the vicinity of sparks, naked flames or a person smoking.
DO NOT overfill the fuel tank and avoid spilling petrol when refuelling. Spilled petrol or petrol
vapour may ignite. If spillage occurs, ensure that the machine is dry before starting the
engine.
Motor vibrations can cause an improperly tightened fuel cap to loosen or come off and spill
quantities of fuel. In order to reduce risk of fuel spillage and fire, firmly tighten fuel cap by
hand.
To reduce the risk of serious injury from burns, never attempt to refuel the unit until it has
been stopped and completely removed from the operator.
! CHEMICAL HAZARDS
DO NOT operate or refuel a petrol engine in a confined space without adequate ventilation.
CARBON MONOXIDE exhaust gases from the petrol engine can cause death in confined
spaces.
! NOISE HAZARDS
EXCESSIVE NOISE can lead to temporary or permanent loss of hearing. Wear approved
hearing protection while working in the vicinity of the machine to limit noise exposure, as
required by Occupational Health and Safety regulations.
PROTECTIVE CLOTHING
ALWAYS wear protective clothing and footwear when using the pump.
GOGGLES for eye protection may also be necessary.
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.

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! ADDITIONAL HAZARDS
To reduce the risk of injury from loss of balance, start the motor with the unit on a flat level
surface, and only pick up the unit when the engine is idling. Slip/Trip/Fall is a major cause of
serious injury or death. Beware of water left on the walking or work surface.
Exercise care when working in the vicinity of unprotected holes or excavations.
To start the motor, place the unit on a flat level surface, and only pick up the unit when the
engine is idling.
To start the motor, turn the engine switch to the ON position.
To start a cold engine, move the choke lever to the closed position.
To restart a warm engine, leave the choke lever in the OPEN
position.
Press the priming pump several times until a flow in the fuel return
tube is visually noticed.
Pull the starter grip lightly until you feel resistance while holding the unit
steady, then pull briskly. Return the starter grip gently.
If the choke lever is in the CLOSED position, gradually move it to the
OPEN position as the engine warms up.
The idle-up function helps the engine start by opening the throttle valve
in the carburettor moderately when the engine won’t start.
1. Hold down the throttle interlock.
2. Pull the throttle trigger.
3. Push the idle-knob, then release the throttle trigger and the interlock.
4. Start the engine.
Always operate the unit at full throttle, when pumping this will ensure correct delivery and
avoid damage to the drive mechanism.
OPERATION

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Be careful starting and/or using the throttle on loose gravel surfaces. Loose gravels may be
sucked into the flywheel cooling fins causing damage to the unit.
Carefully identify potential hazards around the intended area of use before you commence
using the pump.
The patented impeller design will pass some vegetable matter but not long fibrous weeds or
sticks of wood. This impeller is self-cleaning and will in most circumstances clear blockages
by the backflush of water already in the discharge hose. For this to occur the engine must be
running at idle speed with some head of water in the hose.
If the impeller becomes entangled and jammed, the pump volute may be removed by
undoing the 5 cross recess head screws attaching it to the aluminium manifold and pulling it
away. Take care not to distort, cut or compress the moulded seal between the manifold and
the volute during removal and reassembly. Clean out all debris and ensure the impeller
rotates freely before reassembly. If the impeller remains locked after all debris has been
cleared, do not attempt to dismantle the pump any further. Return the pump to Flextool
(Aust.) Pty. Ltd.
Keep the unit clean.
Check the oil level in the engine crankcase daily, it should reach the edge of the oil filler
neck. The engine oil capacity is only 100 ml and running the engine with a low oil level will
cause serious engine damage.
The pump head must be handled with care, and be properly maintained in order to avoid
unnecessary breakdowns. Check regularly for signs of wear and rectify any faults
immediately.
The exterior of the flexible drive shaft is subject to abrasion and wear. If the pump is
operated unchecked, water may eventually enter the pump head or the flexshaft. Naturally,
the cost of repairing a pump which has been allowed to deteriorate will be greater. Regular
inspection of the pump head and the flexible shaft will avoid these problems.
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
failure of inner core.
Check the outer casing rubber cover for damage where it enters the ferrule at the pump
head. Damage can be caused by excessive bending of the flexible drive shaft near the pump
head or coupling.
Replace the oil in the motor crankcase with Honda 10W/30 oil after the first month or 10
hours use, then replace once every 6 months or after 50 hours use. Check and replace oil
more frequently when using the engine in harsh conditions.
CARE AND PREVENTIVE MAINTENANCE
SERVICE

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The air cleaner element fitted is a wet foam type. Service the air cleaner element regularly by
washing the element in a non-flammable solvent and let it dry thoroughly. Soak the element
in clean engine oil, squeeze out the excess oil and reinstall the air cleaner element.
A fuel tank strainer is fitted to the unit. A clogged filter may cause poor engine performance
requiring the fuel filter to be removed from the fuel tank and cleaned.
Inspect, clean and/or replace the spark plug regularly.
It is advisable to flush the pump head and wash the flexshaft with clean water after each use
and before storing.
Ensure the cooling fins on the motor are kept unobstructed.
FLEXTOOL products are covered by warranty for a period of twelve (12) months from the
date of purchase against defects in material or workmanship provided that:
• The product has been operated and maintained in accordance with the operating
instructions.
• Has not been damaged by accident, misuse or abuse.
• Has not been tampered with or repaired by any unauthorised person.
The owner is responsible for the cost of transportation to and from the authorised repairer
and the unit is at the owner’s risk while in transit to and from the repairer.
SYMPTOM POSSIBLE CAUSES AND CORRECTION
Engine does not start • Check the ON/OFF switch to make sure that it is switched to
“ON”.
• Check the crankcase oil level.
• Check the spark plug for cleanliness and clearance.
• Check the carburettor jet and bowel to ensure they are
clean.
Engine stops • Check the fuel supply
• Check the condition of the air filter
Engine lacks power • Check the condition of the air filter
• Check impeller for free rotation
Pump does not work • Check strainer for clogging
• Check the pump head for tightness and damage
WARRANTY
CLEANING AND STORAGE
TROUBLESHOOTING

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Specification
Product Part Number F03600
Product Description Portable Pump
Product Model PP32
Inlet and Outlet Diameter 32 mm
Flow Capacity 135 L/min Max. Working Range
Delivery Head 5 m Max. Working Range
Engine
Engine Model HONDA GX35
Engine Type OHV 4-stroke, single cylinder, forced air cooling
Max. Output 1.2 kw
Max. Torque 1.9 N.m
Engine Oil Capacity 100 ml
Fuel Tank Volume 0.65 litre
Fuel Consumption 360 g/kWh
Displacement 35.8 cc
Ignition Type Transistorized magneto
PTO Shaft Rotation Counter-clockwise
Product Net Weight 9.3 kg
Package Dimensions 1210 mm x 250 mm x 270 mm
Performance Curve
Notes: Tested at motor speed 4500RPM
SPECIFICATION & PERFORMANCE

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Flextool (Aust.) Pty. Ltd. ABN 53 116 784 626
Melbourne Head Office
400 Victoria Street, Brunswick VIC 3056, Australia
Tel: [phone] Fax: [phone]
Sydney
Unit 1, 52 Heathcote Road, Moorebank NSW 2179
Tel: [phone] Fax: [phone]
Brisbane
14 Manton St, Morningside QLD 4170
Tel: [phone] Fax: [phone]
Adelaide
68 Daws Road, Edwardstown SA 5039
Tel: [phone] Fax: [phone]
Perth
47 Belmont Avenue, Belmont WA 6104
Tel: [phone] Fax: [phone]
Free Call Tel:[phone] (Outside the above metropolitan areas)
Internet: www.flextool.com.au
Email: [email protected]
CONTACT INFORMATION FOR SPARE PARTS AND SERVICING