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PFT BOLERO 400V Operating Manual

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Operating manual
Mixing pump BOLERO 400V
Part 2 Overview, operation and service
Item no. of the operating manual:
BOLERO, 400 V, 3 Ph, 50 Hz
00249231
Item no. 00231213
Read the operating manual prior to starting any work!

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  • Page 1 Operating manual Mixing pump BOLERO 400V Part 2 Overview, operation and service Item no. of the operating manual: 00249231 BOLERO, 400 V, 3 Ph, 50 Hz Item no. 00231213 Read the operating manual prior to starting any work!
  • Page 2 Mixing pump BOLERO 400V / Part 2 Overview, operation and service About us About us Publisher Knauf PFT GmbH & Co. KG Postfach 60 ▪ 97343 Iphofen Einersheimer Straße 53 ▪ 97346 Iphofen Germany Document name 00249231_1.0_EN Translation of the original operating manual (DE) Date of first issue 02.2024...

  • Page 3: Table Of Contents

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Table of contents Table of contents 5.1.2 Monitoring the machine....1 General information........5.1.3 Hazardous dusts......Information regarding the operating 5.1.4 Mortar pressure gauge..... manual..........Inspection by machine operator..
  • Page 4 Mixing pump BOLERO 400V / Part 2 Overview, operation and service Table of contents 6.4.2 Gear motor maintenance....6.4.3 Lubricate freewheel on agitator..6.4.4 Adjust clamping of pump....Actions after completed mainte- nance..........Periodic inspection/expert inspec- tion............ Spare parts lists.......

  • Page 5: General Information

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service General information General information Information regarding the operating manual This operating manual provides important information and instruc- tions on the correct use of the machine. A prerequisite for safe working is the observance of all stated safety guidelines and instructions.

  • Page 6: Keep The Manual For Future Reference

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service General information Structure of the safety and warning All safety and warning notices consist of: notices The danger sign and signal word Information on the nature of the hazard...

  • Page 7: Ec Declaration Of Conformity

    – (Dipl. in Industrial Engineering, University of Applied Sciences) Michael Duelli, Einersheimer Straße 53, 97346 Iphofen. The technical documentation is available from: – Knauf PFT GmbH & Co. KG, Technical Department, Einersheimer Straße 53, 97346 Iphofen. Iphofen Dr York Falkenberg...

  • Page 8: Quality Control Sticker

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service General information Quality Control sticker The following details can be found on the Quality Control sticker: CE confirmed as per EU directives Serial no / serial number Controller / signature...

  • Page 9: Technical Data

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Technical data Technical data General information Figure 3: Dimension sheet in mm Detail Value Unit Empty weight approx. Length Width Height 1,500 Individual weights Detail Value Unit Pump motor with protection grille...

  • Page 10: Power Connection

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Technical data Power connection Electrical details Detail Performance Setting value Designation Pump motor 1.9 kW 3.5 A Figure 4: Motor protection switch Operating conditions Environment Detail Value Unit Temperature range 2 - 45 °C...

  • Page 11: Capacity Values, Pump Unit D 4-2

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Technical data Capacity values, pump unit D 4-2 Pump capacity D 4-2 Detail Value Unit Conveying output stage 1, l/min approx. Conveying output stage 2, l/min approx. Operating pressure, maximum...

  • Page 12: Transport, Packing And Storage

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Transport, packing and storage Transport, packing and storage Safety instructions for transport Improper transport NOTE Damage from improper transport! Improper transport may cause substantial property damage. Therefore: When unloading the packages on delivery, as well as transport within the company, pay attention and observe the symbols and instruction on the package.

  • Page 13: Transport Inspection

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Transport, packing and storage Transport inspection On receipt check the delivery immediately for completeness and trans- port damage. In case of externally visible transport damage, proceed as follows: Do not accept the delivery or under reserve only.

  • Page 14: Closing The Motor Tilt Flange

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Transport, packing and storage Closing the motor tilt flange CAUTION Danger of crushing at the motor tilt flange! There is a danger of crushing injuries when closing the motor tilt flange.

  • Page 15: Transport In Individual Parts

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Transport, packing and storage Transport in individual parts To make transport easier, disassemble the machine into its individual components. In the units gear motor with protection grille (1) and material hopper with chassis and control box (2).

  • Page 16: Description

    [10] Protective grille with sack opener Functional description of BOLERO The handy PFT BOLERO is a combined mixing, pumping and spraying machine for small building sites. With anticlockwise running of the mixing shaft the material is mixed continuously. When rotating clockwise, the delivery pump is switched on.

  • Page 17: Fields Of Application

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Description Fields of application For materials such as: Doorframe grout Anchor mortar Adhesive mortar Fire protection mortar Multi-component mortar Bentonite Structural plaster Acoustic plaster Levelling compounds Liquid filler Flowability / flow characteristics The pump unit D4-2 can be used up to 20 bar working pressure.

  • Page 18: Gear Motor With Protection Grille

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Description 4.4.1 Gear motor with protection grille Gear motor with protection grille and motor flange. The gear motor with motor flange can be removed from the mate- rial hopper for transport purposes.

  • Page 19: Control Box

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Description 4.4.4 Control box Pushbutton for control voltage ‘ON/ OFF’ Red control lamp, motor protection switch activated Dummy connector / connection for remote control Connection for pump motor Pump motor selector switch...

  • Page 20: Operating Modes

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Description Operating modes Pump motor selector switch The pump motor has three operating modes: Switch position ‘0’: The machine is switched off. Switch position ‘right’: The machine conveys the material from the material hopper.
  • Page 21 Mixing pump BOLERO 400V / Part 2 Overview, operation and service Description RONDO DN25 hydraulic connection male part | Female part – 5 m Item no. 00021103 RONDO DN25 hydraulic connection V-part | Female part - 10 m Item no. 00021100 RONDO DN25 hydraulic connection V-part | Female part - 15 m Item no.
  • Page 22 Mixing pump BOLERO 400V / Part 2 Overview, operation and service Description Air hose DN12 Ewo male part | Geka – 15 m Item no. 20211601 Remote control cable with switch - 25 m Item no. 20456929 Remote control cable with switch on cable reel – 50 m Item no.
  • Page 23 Mixing pump BOLERO 400V / Part 2 Overview, operation and service Description Extension for remote control cable – 50 m Item no. 20456934 ZARGOMAT pro DN25-360° Item no. 00420058 Spraying set for JETSET pro DN25 Ewo Item no. 00418975 Spraying set for JETSET pro DN25 Ewo Item no.
  • Page 24 Mixing pump BOLERO 400V / Part 2 Overview, operation and service Description Water pump as standalone suction pump AV 1000 with integrated pressure cut-off and flow monitor, 230 V, 1 Ph, 50 Hz, 0.6 kW Item no. 00493686 Inlet strainer complete with stainless steel filter screen Item no.
  • Page 25 Mixing pump BOLERO 400V / Part 2 Overview, operation and service Description Air compressor COMP P-320, 230 V, 1 Ph, 50 Hz Item no. 00746490 Spray nozzle DN19 (¾") Geka Item no. 20215700 Rinsing hose DN10 Geka - 11 m Item no.
  • Page 26 Mixing pump BOLERO 400V / Part 2 Overview, operation and service Description Consistency checking tube 25 female part Item no. 20104301 You can find further accessories on the internet at www.pft.net or from your PFT construction machinery dealer. page 26 / 60...

  • Page 27: Operation

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Operation Operation Safety Personal protective equipment The following protective equipment has to be worn for all operative work: Protective clothing Protective goggles Protective gloves Safety shoes Hearing protection Further protective equipment that is to be worn during particular jobs will be pointed out separately in the warning instructions of this chapter.

  • Page 28: Monitoring The Machine

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Operation 5.1.2 Monitoring the machine WARNING Access by unauthorised persons! The machine may only be operated when monitored. 5.1.3 Hazardous dusts WARNING Danger of damage to health! In the long term, inhaled dust can lead to lung damage or have other adverse health effects.

  • Page 29: Inspection By Machine Operator

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Operation Inspection by machine operator Prior to each shift, the machine operator has to examine the effec- tiveness of the control and safety devices, as well as the proper fitting of the protection devices.

  • Page 30: Setting Up The Machine

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Operation 5.3.2 Setting up the machine Install the machine on stable and even ground and secure it against accidental movements: Do not tilt or roll the machine away. Place the machine where it cannot be hit by any falling objects.

  • Page 31: Mortar Hoses

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Operation 5.3.3.1 Connecting the motor connecting cable WARNING Danger to life from rotating parts! Improper operation may lead to serious damage to persons or property. The respective drive (motors) must be operated only with the control box of the machine.
  • Page 32 Mixing pump BOLERO 400V / Part 2 Overview, operation and service Operation 5.3.4.2 Connecting the mortar hose 1. Connect the mortar hose (1) to the mortar pressure gauge (2). NOTE Ensure clean and correct connection and tightness of the couplings! Dirty couplings and rubber seals are not watertight, and water might leak under pressure inevitably leading to blockages.

  • Page 33: Feeding Dry Material To The Machine

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Operation 5.3.5 Feeding dry material to the machine NOTE Never fill the material hopper when the agitator is stationary. CAUTION Danger of injury at the sack opener! The sharp edges of the sack opener pose a risk of injury.

  • Page 34: Putting The Machine Into Operation

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Operation Putting the machine into operation 5.5.1 Feeding material to the machine NOTE Never fill the material hopper when the agitator is stationary. 1. Turn the main switch (1) to ‘ON’.

  • Page 35: Applying Mortar

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Operation Applying mortar WARNING Danger of injury from discharged mortar! Discharged mortar may lead to injuries to eyes and face. Never look into the spray gun. Always wear protective goggles.

  • Page 36: Switching Off The Machine

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Operation 1. Actuate the on/off switch (1). The machine stops. 2. Close ball valve (2). 3. Then open the ball valve (2) again. 4. Actuate the on/off switch (1).

  • Page 37: Discharging Mortar Pressure

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Operation 5.10.1 Discharging mortar pressure WARNING Overpressure on the machine! When opening machine parts they can open in an uncon- trolled manner and injure the operator. Only open the mortar hoses if the mortar pressure gauge (1) indicates the pressure has fallen to ‘0 bar’.

  • Page 38: Measures In Case Of Risk Of Frost

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Operation 1. Turn the pump motor selector switch (1) to the ‘0’ position. 2. Close the ball valve on the zargomat gluing gun. 3. Turn the main switch (2) to ‘ON’.

  • Page 39: Secure Against Restarting

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Operation 5.12.2 Secure against restarting WARNING Danger to life from unauthorised restarting! When working with the machine there is the risk that the energy supply is switched on without authorisation. This poses a danger to life for the persons in danger area.

  • Page 40: Disconnecting And Cleaning The Mortar Hose

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Operation 5.12.4 Disconnecting and cleaning the mortar hose Disconnecting the mortar hose 1. Check the mortar pressure gauge (1) to determine whether the mortar pressure has fallen to ‘0 bar’.

  • Page 41: Drain Residual Water

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Operation 5.12.6 Drain residual water 1. Remove the cover from the cleaning nozzle (1) and let the residual material drain off. 2. Clean the protective grille and material hopper with a water jet.

  • Page 42: Cleaning The Agitator

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Operation 5.12.8 Cleaning the agitator 1. Open the quick closure (1) and tilt the motor with protection grille. 2. Remove the agitator (2) from the material hopper and clean thor- oughly.

  • Page 43: Safety

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Operation 5.13.1 Safety Personnel The work for rectification of faults described here can be carried out by the operator, unless marked otherwise. Some works must be carried out only by specially trained skilled personnel or exclusively by the manufacturer.

  • Page 44: Table Of Faults

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Operation 5.13.4 Table of faults Fault Possible cause Troubleshooting Rectification by Machine does Power supply not in order Repair power supply Service technician not start current Main switch not activated...

  • Page 45: Hose Blockages

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Operation Fault Possible cause Troubleshooting Rectification by Red control Overload due to the pump Remove mixing pump and clean Service technician lamp, fault getting blocked with dry material lights up...

  • Page 46: Removal Of Clogging In Hoses

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Operation 5.13.6 Removal of clogging in hoses WARNING Danger from discharged material! Never detach hose couplings if the feed pressure has not been fully released! Material to be conveyed can be discharged under pressure and cause injuries particularly to the eyes.
  • Page 47 Mixing pump BOLERO 400V / Part 2 Overview, operation and service Operation 5.13.6.2 Blockage cannot be cleared WARNING Overpressure on the machine! When opening machine parts they can open in an uncon- trolled manner and injure the operator. Only open the mortar hoses if the mortar pressure gauge (1) indicates the pressure has fallen to ‘0 bar’.
  • Page 48 Mixing pump BOLERO 400V / Part 2 Overview, operation and service Operation 5.13.6.3 Switching on the machine after removing a blockage 1. Turn the main switch (1) to ‘ON’. 2. Press the green pushbutton (2) control voltage ‘ON’. 3. Turn pump motor selector switch (3) to the ‘right’ position and switch to stage 1.

  • Page 49: Maintenance

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Maintenance Maintenance Safety Personnel The maintenance works described here can be carried out by the operator, unless marked otherwise. Some maintenance work must only be carried out by specially trained technical personnel or exclusively by the manufacturer.

  • Page 50: Remove Connection Cable

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Maintenance 6.1.1 Remove connection cable Electrical system WARNING Danger to life from electric current! There is danger to life if you come in contact with live parts. Activated electrical components can carry out uncontrolled movements and cause serious injuries.

  • Page 51: Maintenance Plan

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Maintenance Maintenance plan The following paragraphs describe the maintenance works required for an optimal and trouble-free operation. In the event that increased wear is detected during regular checks, the required maintenance intervals have to be shortened according to the actual signs of wear.

  • Page 52: Gear Motor Maintenance

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Maintenance 6.4.2 Gear motor maintenance NOTE The gear motor (1) is filled with approx. 0.9 litres of ISO VG 220 lubricating oil at the factory. The oil must be changed every 1,000 hours and every 3 years at the latest.

  • Page 53: Adjust Clamping Of Pump

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Maintenance 6.4.4 Adjust clamping of pump 1. If the pumping pressure decreases, the stator can be adjusted. 2. Evenly tighten the nuts (1). 3. Do not adjust the tightness of the pump clamping during operation.

  • Page 54: Spare Parts Lists

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Maintenance The documents for the expert inspection can be found on the internet at www.pft.net. DOCUMENT CENTRE Open the Document Centre under Service → Downloads. In this area, select the expert inspection category to access all rele- vant inspection documents.

  • Page 55: Disassembly

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Disassembly Disassembly After the useful service life has been reached, the device has to be dismantled and disposed of in an environment-friendly manner. Safety Personnel Disassembly must be carried out by specially trained technical personnel only.

  • Page 56: Disassembly

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Disassembly Disassembly When decommissioning, clean the device and dismantle it according to the applicable work safety and environmental protection regula- tions. Prior to starting the disassembly: Switch off device and secure against restarting.

  • Page 57: Disposal

    Mixing pump BOLERO 400V / Part 2 Overview, operation and service Disposal Disposal Provided no return or disposal agreements have been made, recycle the disassembled parts: Scrap metals. Recycle plastic elements. Dispose of remaining components, sorted according to the type of material.
  • Page 58 Mixing pump BOLERO 400V / Part 2 Overview, operation and service Disposal page 58 / 60...
  • Page 59 Mixing pump BOLERO 400V / Part 2 Overview, operation and service Disposal page 59 / 60...
  • Page 60 PFT - ALWAYS AT YOUR SITE Knauf PFT GmbH & Co. KG Postfach 60 97343 Iphofen Einersheimer Straße 53 97346 Iphofen Germany Telephone: +49 9323 31-760 Fax: +49 9323 31-770 Technical hotline: +49 9323 31-1818 info@pft.net www.pft.net...

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