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

Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service
Dimension sheet
2016-10-17 11
Sound po er level
Guaranteed sound power level L WA 95dB (A)
Vibrations
Weighted effective value of acceleration to which the upper body parts are exposed <2.5 m/s²
5 Dimension sheet
Fig. 2: Dimension sheet
1200
720
1530 / 1660

Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service
Name plate
12 2016-10-17
6 Name plate
Fig. 3: Name plate
The type plate is located at the right bottom of the hopper and
includes the following information:
Manufacturer
Type
Year of manufacture
Machine number
Permissible operating pressure
7 Quality Control sticker
Fig. 4: 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
Date of control

Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service
Assembly
2016-10-17 13
8 Assembly
Overvie
1 2 3
14 13 12 11 10
9
Fig. : Table of the assembly groups
1. Pump motor
2. Motor protection handle
3. Deflector plate
4. Protective grille with sack opener
5. Hopper
6. Air compressor K2N
7. Carrying handle
. Double stop castor
9. Water sampling valve
10. Booster pump
11. Water tap
12. Connection for mortar hose
13. Mortar pressure gauge
14. Rubber mixing section
15. Castor
16. Power connection at control cabinet
17. Control cabinet
1 . Locking lever
4
5
6
7
1
17
16
15

Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service
Description of assemblies
14 2016-10-17
9 Description of assemblies
The mixing pump PFT G 4 X consists of the following
main components:
Hopper
Fig. 6: Assembly unit hopper
 Hopper with frame and protective grille
Control cabinet item number 00 25 46 66
Fig. 7: Assembly unit control cabinet
 Control cabinet
1. Master switch is also emergency-stop switch
2. Push button water inlet
3. Selector switch water pump manual-0-automatic
4. Yellow pilot lamp, no material
5. Green pilot lamp, lights up only if the supply is ok and if the
inclination switch has not been triggered
6. Main terminal 32A.
7. Connection for fill level sensor in hopper
. CEE socket outlet 4x16A, for air compressor
9. CEE socket outlet 7x16A, for pump motor
10. Schuko socket outlet 230V, continuous current
11. CEE socket outlet 4x16A, controlled for water pump
12. Dummy connector for remote-controlled power socket
13. Remote control socket
14. Yellow pilot lamp, no water
15. Red pilot lamp, motor protection switch was triggered
16. Push button reverse direction of rotation
17. Selector switch star wheel
1 . Operating button machine “ON” / “OFF” (control voltage)
1
2
3
4
5
6
7
9
10
1
17
16
15
14
13
12
11

Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service
Description of assemblies
2016-10-17 15
Mixing tube ith motor and pump
Fig. 8: Assembly unit mixing tube with motor
1. Pump motor 5.5 / 7.5 kW
2. Rubber mixing tube with adaptable flange
3. Pump unit D6-3 / D6-4
4. Mortar pressure gauge
Water tap
Fig. 9: Water tap assembly
1. Water flow meter 150-1500l/h
2. The floater shows the set water factor on the scale of the
plastic tube
3. The water pressure can be adjusted at the pressure reducer
4. Pressure switch water shuts down the machine in case the
water pressure is too low
5. Pressure gauge water / operating pressure
6. Drain tap for frost protection
7. The required water factor is set at the needle valve
. Solenoid valve
9. Water to mixing tube
Air compressor K2 N ith pressure s itch-off
Fig. 10: Air compressor
 Air compressor K2 N with pressure switch-off
1
2
3
4
5
6
9
7
1
2
3
4

Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service
Connections
16 2016-10-17
10 Connections
1 2 3 4
Fig. 11: Connections
1. Main terminal
2. Connections material hoses
3. Connection water supply from mains
4. Connection air to spray gun
11 Operating modes
Selector s itch star heel
Fig. 12: Operating modes star wheel
The star wheel can be operated in three operating modes:
Selector s itch position “0”:
The star wheel is switched off and thus the material supply to the
mixing section is interrupted, e.g. for cleaning the mixing section
using the cleaning shaft or carrying out a pressure test of the
pump.
Selector s itch right:
The star wheel is running in sync with the mixing pump motor and
is switched on and off using the air control or remote control.
Selector s itch left:
The star wheel is running in continuous mode, independent from
the air control. In this position material can be added to the mixing
section if the pump is deactivated.
Selector s itch pressure booster pump
Fig. 13: Operating modes water pump
The pressure booster pump can be operated in three different
operating modes:
Selector s itch position “0”:
Water pump is switched off, e.g. if the water pressure is
continuously at 2.5 bar.
Selector s itch right:
Water pump is running in sync with the mixing pump (automatic
mode).
Selector s itch left:
The water pump runs continuously in position “manual” (e.g. for
cleaning the hoses).

Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service
Accessories
2016-10-17 17
12 Accessories
Fig. 14: Injection hood
PFT injection hood E1 for G 4
(article number 20 60 02 13).
The PFT injection hood is used for feeding dry material to the mixing pump
using the PFT SILOMAT pneumatic conveying system.
Fig. 1 : Delivery hood
PFT delivery hood ith off-load operation protection for G 4
(article number 20 60 05 00)
The PFT delivery hood is used for feeding dry material to the mixing pump
PFT G 4 directly from the silo / container. In case of an empty alarm in the
hopper, the mixing pump is switched of via the remote control socket.
Fig. 16: ROTOMIX
ROTOMIX D-pumps cmpl. ith 35 coupling (article number 20 11 80 00)
Remixer for better decomposition and mixing of the material. Direct drive via
tang of the rotor. Contents approx. 1.2 l
Fig. 17: ROTOQUIRL
ROTOQUIRL II cmpl. ith 35 coupling (article number 20 11 84 00)
Remixer for better decomposition and mixing of the material. Direct drive via
tang of the rotor. Contents approx. 4.2 l
Fig. 18: Water hose/air hose
Water hose/air hose 3/4" x 40m ith Geka couplings (article number 20
21 21 00)
Fig. 19: Remote control cable
Remote control cable 25m complete ith ON/OFF s itch and pilot lamp
(article number 20 45 69 29)
Fig. 20: Power cable
Po er cable 5 x 4 mm² 25m ith CEE plug and coupling 5 x 32A 6h red
(article number 20 42 39 20)
Further accessories can be found at www.pft.eu

Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service
Intended use Control panel
1 2016-10-17
13 Intended use Control panel
Intended purpose control panel
The tool is conceptualised and designed exclusively for
the purpose of use specified here.
Scope of application:
Primary use for water and neutral, non-adhesive
liquids. Also suitable for air and neutral non-
flammable gases.
Maximum operating pressure (inlet pressure) 16
bar.
Outlet pressure infinitely adjustable from 1. to 6
bar.
Smallest possible inlet pressure 2. bar.
Minimum pressure drop (inlet pressure/outlet
pressure) 1 bar.
Maximum media and ambient temperature 7 °C.
Assembly position as desired, preferable vertical.
Intended purpose solenoid valve
Scope of application:
Solenoid valves for liquid and gaseous media,
aggressive or neutral, can be used different
temperature and pressure ranges
Type 6213 is a 2/2 way solenoid valve with straight
passage, normally closed, with a permanently
coupled membrane system. It operates from 0 bar
and can be used universally for liquids. A minimum
pressure differential of 0. bar is required for the
valve to fully open.
Intended purpose flo meter
Scope of application:
The flow meter is used for the volume
measurement of transparent liquid and gaseous
flows in closed pipelines. Optionally the devices
can be used for flow monitoring.

Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service
Intended use air compressor
2016-10-17 19
WARNING!
Danger due to improper use!
Any case of use beyond the specified purpose of
use and/ or any other sort of use of the tool can
lead to dangerous situations.
Therefore:
 Use the tool only for the purpose specified.
 Always adhere to the usage directives of the
material manufacturer.
 Strictly follow all instructions in this operating
manual.
Claims of any kind due to damage caused by improper use will not
be entertained.
The operator of the tool is alone responsible for any damage
arising from improper use.
14 Intended use air compressor
Intended purpose air compressor
The tool is conceptualised and designed exclusively for the
purpose of use specified here.
Attention!
The air compressor is intended exclusively for the
generation of compressed air and is to be used with
connected implement. Any other use or use beyond what
is specified, such as with freely accessible and/or open
hoses and pipelines, is deemed to be not for the intended
purpose. Connected implements or components are to be
designed for the maximum generated pressure of 5.5 bar.
The air compressor is to be used only in technically
perfect condition as well as for its intended use and while
taking into account the safety and hazard information in
the operating instructions!
Particularly malfunctions that may compromise safety
have to be eliminated immediately prior to putting the
compressor back into operation.

Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service
Intended use air compressor
20 2016-10-17
Safety systems air compressor
WARNING!
Danger of death due to non-functioning safety
equipment!
Safety equipment ensure highest level of safety in
operation. Even if work processes become a little
more complicated due to safety equipment, they
must never be decommissioned. The safety is
guaranteed only with intact safety equipment.
Therefore:
 Before starting work, check if the safety
equipment is functioning properly and has been
correctly installed.
 Use safety equipment at all times.
 Do not obstruct access to safety systems such
as emergency stop buttons, pull cords etc.
General positioning of the air compressor
The air compressor complies with the national and international
safety regulations and can therefore also be used in damp rooms
and/or outdoors. Areas with clean and dry air should be preferred.
Ensure that the device can freely suck in the air. This applies in
particular if an installation is intended.
The air compressor should only be set up in such a way that no
dangerous additives, such as solvents, vapours, dusts or other
harmful substances can be sucked in. The device should be
positioned only in rooms where the hazard of a potentially
explosive atmosphere is not given.
Hot surface of the air compressor
General information
WARNING!
Danger of injury due to hot surface!
During operation the compressor can reach a
surface temperature of up to 100 °C. Therefore it
has to be ensured that the device does not get into
contact with bare body pars during use as well as
for some time after use, in relation to the heating
temperature.