PFT G4X Super User manual

Table of Contents
2016-10-17
Operating Manual
Mixing pump G 4 X Super / G 4 X XL
Part 2 EC Declaration of Conformity
Overvie - Operation and service
Article number of the operating manual: 00 43 75 47
Article number of the machine: 00 41 41 71 Article number of the machine: 00 41 41 9
Article number of the machine: 00 42 39 47 Article number of the machine: 00 40 67 95
Read the operating manual prior to starting any ork!

2 2016-10-17
© Knauf PFT GmbH & Co. KG
P.O. Box no. 60 97343 Iphofen
Einersheimer Straße 53 97346 Iphofen
Germany
Phone: [phone]
Fax: [phone]
Technical hotline [phone]
[email protected]
Internet: www.pft.eu

Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service
Table of Contents
2016-10-17 3
1 EC Declaration of Conformity ........ 6
2 Examination ..................................... 7
Examination by machine operator ................. 7
Periodic inspection ......................................... 7
3 General information ........................ 8
Information regarding the operating
manual .................................................
Keep the manual for future reference ............
Division ..........................................................
Spare parts lists .............................................
4 Technical data ................................. 9
General information ....................................... 9
Power connection .......................................... 9
Operating conditions ...................................... 9
Power values Pump unit D6-3 ..................... 10
Power values pump unit D6-4 ...................... 10
Sound power level ....................................... 11
Vibrations ..................................................... 11
5 Dimension sheet............................ 11
6 Name plate ..................................... 12
7 Quality Control sticker .................. 12
8 Assembly ....................................... 13
Overview ...................................................... 13
9 Description of assemblies ............ 14
Hopper ......................................................... 14
Control cabinet item number 00 25 46 66 ... 14
Mixing tube with motor and pump ................ 15
Water tap ..................................................... 15
Air compressor K2 N with pressure switch-
off ....................................................... 15
10 Connections .................................. 16
11 Operating modes ........................... 16
Selector switch star wheel ............................ 16
Selector switch pressure booster pump ....... 16
12 Accessories ................................... 17
13 Intended use Control panel .......... 18
Intended purpose control panel .................... 1
Intended purpose solenoid valve.................. 1
Intended purpose flow meter ........................ 1
14 Intended use air compressor ....... 19
Intended purpose air compressor................. 19
Safety systems air compressor .................... 20
General positioning of the air compressor ... 20
Hot surface of the air compressor ................ 20
15 Description G 4 X SUPER / G 4 X
XL .................................................... 21
Functional principle G 4 X SUPER / G 4 X
XL ....................................................... 21
Functional description G 4 X SUPER / G 4
X XL .................................................... 21
Fields of application ...................................... 21
16 Material: ......................................... 22
Flowability / Flow characteristics .................. 22
17 Mortar pressure gauge ................. 22
18 Safety rules .................................... 22
19 Transport, packing and storage ... 23
Safety instructions for transport.................... 23
Transport inspection ..................................... 24
Transport ...................................................... 24
Transport with van ........................................ 24
Transport in individual parts ......................... 25
20 Packaging ...................................... 26

Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service
Table of Contents
4 2016-10-17
21 Operation ........................................ 26
Safety26
22 Safety system ................................ 27
23 System monitoring ........................ 27
Idle-running protection ................................. 27
24 Preparing the machine .................. 28
25 Connecting the po er supply
400 V ............................................... 28
Check the individual connectors .................. 29
26 Connecting the ater supply ........ 29
Close water draining cocks .......................... 29
Connecting the water supply ........................ 30
Connection of water from water tank ........... 30
27 S itching on the G 4 X .................. 31
Putting the machine into operation .............. 31
Set water quantity ........................................ 31
Soaking of the mixing section ...................... 32
28 Mortar pressure gauge .................. 32
29 Hazardous dusts ............................ 32
Anti-dust unit for G 4 completely .................. 33
30 Feeding dry material to the
machine .......................................... 33
31 Monitoring the machine ................ 34
32 Putting the machine into
operation ........................................ 34
Check consistency of mortar ........................ 34
Start the machine in a “flying” mode ............ 34
33 Mortar hoses .................................. 35
Prepare mortar hoses .................................. 35
Connect mortar hose .................................... 36
34 Compressed air supply ................. 36
Connect air hose .......................................... 36
Connecting the spraying gun ....................... 37
Switch on air compressor ............................ 37
35 Apply mortar .................................. 37
Open the air tap at the spraying gun ........... 3
Interruption of work ...................................... 39
In case of longer interruption of work/break 39
Switch off air compressor ............................ 39
36 Remote control .............................. 40
Working with the remote control .................. 40
37 Stopping in case of emergency
Emergency-stop s itch................. 40
Emergency-stop switch ................................ 40
38 Measures in case of po er cut ..... 41
Relieve mortar pressure .............................. 41
Relieve mortar pressure .............................. 41
39 Work on troubleshooting .............. 42
Reaction in the event of faults ..................... 42
Fault displays ............................................... 43
Faults 43
Safety43
Table of faults .............................................. 44
Signs for hose blockages:............................ 46
Causes for this can be: ................................ 47
Earlier damage to the mortar hose .............. 47
40 Removal of blockages in the
hose ................................................ 47
Change the direction of rotation of the
mixing pump motor in case of
blockages in the hose ........................ 4
Blockage does not dislodge ......................... 4
Switch the machine back on after the
blockage has been removed ............. 49
41 Cleaning the machine after ork .. 49
Empty the mixing tube ................................. 49
Plug level sensor ......................................... 50
Secure against restarting ............................. 50
Cleaning the G 4 X ...................................... 50
Decouple mortar hose ................................. 51
Clean mortar hose ....................................... 51

Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service
Table of Contents
2016-10-17 5
Remove the water hose ............................... 52
Cleaning the mixing tube ............................. 53
Insert the mixing tube cleaner ...................... 53
Insert the mixing tube cleaner ...................... 53
Insert agitator ............................................... 54
Cleaning the hopper .................................... 54
42 Changing the pump / Cleaning
the pump ........................................ 55
Fold up mixing tube...................................... 55
43 S itch off G 4 X ............................. 56
44 Measures in case of risk of frost.. 56
Blow dry water fitting .................................... 57
Switch on air compressor ............................ 57
45 Maintenance .................................. 58
Safety5
Remove connection cable ............................ 5
Environmental protection .............................. 59
Maintenance plan ......................................... 59
Maintenance work ........................................ 60
Safety valve air compressor ......................... 62
Adjust locking lever ...................................... 62
Measures after effected maintenance .......... 62
46 Disassembly .................................. 63
Safety63
Disassembly ................................................. 64
47 Disposal ......................................... 64
48 Index ............................................... 65

Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service
EC Declaration of Conformity
6 2016-10-17
1 EC Declaration of Conformity
Company: Knauf PFT GmbH & Co. KG
Einersheimer Straße 53
97346 Iphofen
Germany
declares under our sole responsibility that the product:
Type of machine: G 4 X
Type of equipment: Mixing pump
Serial number:
Guaranteed sound po er level: 78 dB 95 dB
is in conformity with the following CE directives:
• Outdoor directive (2000/14/EC),
• Machine directive (2006/42/EC),
• Electromagnetic Compatibility Directive (2014/30/EC).
Operative Conformity Assessment according to Outdoor Directive 2000/14/EC:
Internal production control as per article 14 paragraph 2 in connection with annex V.
This declaration only refers to the machine in the state in which it has been placed on the market. Parts
subsequently added by the user and/or subsequent interventions are not covered. This declaration ceases
to be valid if the product is converted or changed without consent.
Person authorised to compile the relevant technical documentation:
Diploma in industrial engineering (FH) 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
Managing director
Place, date of issue Name and signature Details of signatory

Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service
Examination
2016-10-17 7
2 Examination
Examination by machine operator
 Prior to each shift, the machine operator has to examine the
effectiveness of the control and safety devices as well as the
proper fitting of the protection devices.
 The safe working condition of construction machinery has to be
checked by the machine operator during operation.
 If the safety devices show any defects or if any other defects are
detected that compromise a safe operation, the supervisor has to
be informed immediately.
 In case of defects that cause harm to persons, the operation of the
construction machine has to be stopped to eliminate the defects.
Periodic inspection
 Construction machinery has to be inspected for their safe working
condition in accordance with the operating conditions and the
operational requirements as needed, however at least once a year
by an expert.
 Pressure vessels have to undergo the prescribed expert
inspections.
 The inspection results have to be documented and kept at least
until the next inspection.

Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service
General information
2016-10-17
3 General information
Information regarding the operating manual
This operating manual gives important information on handling the
device. A prerequisite for safe working is the observance of all
stated safety guidelines and instructions.
Furthermore the local accident prevention guidelines and general
safety instructions for the application area of the device are to be
adhered to.
Read the operating manual thoroughly before starting any work! It
is a part of the product and has to be kept near the tool and easily
accessible to the staff at all times.
If the tool is given to third parties, also include the operating
manual.
The figures in this manual are for presentation purposes of facts
not necessarily to scale and may slightly differ from the actual
model of the device.
Keep the manual for future reference
The operating manual has to be available during the whole service
life of the product.
Division
The operating manual is divided into 2 books:
 Part 1 Safety
General safety instructions mixing pumps/feed pumps
Article number: 00 17 27 09
 Part 2 Overview, operation and service (this manual).
For safe operation of the device both parts have to be read and
observed. Together they form one operating manual.
Spare parts lists
Spare parts lists for the machine can be found on the Internet at
www.pft.eu.

Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service
Technical data
2016-10-17 9
4 Technical data
General information
Detail Value Unit
Weight approx. 30 / 320 kg
Length 1200 mm
Width
720
mm
Height
1530 / 1660
mm
Individual eights
Detail Value Unit
Weight pump motor with tilt flange 51 / 63 kg
Weight of mixing pump module 1
kg
Weight of hopper module 152 kg
Weight of air compressor 24 kg
Hopper dimensions
Detail Value Unit
Filling height 910 / 940 mm
Hopper volume 145 l
Hopper capacity with attachment 200 l
Po er connection
Fig. 1: Motor protection switch
Po er Setting value Designation
Star wheel 0.75 kW 2.2 A Q5
Mixer motor 5.5 kW / 7.5 11 A / 15 A Q6
Compressor 0.9 kW 1. A Q2
Water pump 0.5 kW 1.7A Q4
Water connection
Detail Value Unit
Operating pressure, max. 2.5 bar
Connection 3/4 inch
Operating conditions
Environment
Detail Value Unit
Temperature range 2-45 °C
Relative humidity, max. 0 %

Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service
Technical data
10 2016-10-17
Duration
Detail Value Unit
Max. operating time at a stretch hours
Electrical details
Detail Value Unit
voltage, three-phase current 50 Hz 400 V
Power consumption, max. 32 A
Power input, max. 7.7 / 9.7 kW
Fuse protection, at least 3 x 25 A
Speed pump motor approx. 3 5 / 400 rpm
Speed star wheel motor 2 rpm
Po er values Pump unit D6-3
Compressor output K2 N
Detail Value Unit
Pump capacity, approx. 22
l/min at
3 5 rpm
Operating pressure, max. 30 bar
Grain size max. 3 mm
Feed range *, max. at 25 mm ∅ 30 m
Feed range *, max. at 35 mm ∅ 50
m
Compressor output 0.25 Nm³/min
* reference value depending on conveying height, pump condition and version,
mortar quality, composition and consistency
Po er values pump unit D6-4
Particular Value Unit
Pump capacity, approx. 23
l/min at
400 rpm
Operating pressure, max. 40 bar
Grain size max. 3 mm
Feed range *, max. at 35 mm ∅ 65
m
* reference value depending on conveying height, pump condition and version,
mortar quality, composition and consistency