PFT G 5 SUPER User manual

PFT G 5 SUPER Operating Manual Issued 11.2008
Knauf PFT GmbH & Co.KG
1
OPERATING MANUAL
(ltem number of operating manual: 00 01 19 27)
(ltem number of machine – parts list: 00 00 79 40)
Mixer Pump
PFT G 5 SUPER
WE KEEP THINGS MOVING

PFT G 5 SUPER Operating Manual Issued 11.2008
Knauf PFT GmbH & Co.KG
2
It is prohibited to forward this document, even excerpts, without our written authorisation. All
technical specifications, diagrams etc. are subject to copyright law. All rights, errors and
modifications are reserved.
© by Knauf PFT GmbH & Co. KG

PFT G 5 SUPER Operating Manual Issued 11.2008
Knauf PFT GmbH & Co.KG
3
Dear PFT customer
Congratulations on your purchase. You have made a wise choice as you clearly value the quality
that comes with a brand name product from a reputable company.
The PFT G 5 SUPER mixer pump uses state-of-the-art technology. It was functionally designed to
be a reliable aid under rough construction site conditions.
This operating manual should always be stored and kept at hand at the site where the machine is
used. It contains information on the various functions of the machine. Study the operating manual
thoroughly before starting the machine, as we accept no liability for accidents or damage to the
machine caused by incorrect operation.
The PFT G 5 SUPER mixer pump will prove to be a trustworthy aid providing it is operated
correctly and handled with care.
It is prohibited to forward this document, even excerpts, without our written authorisation. All
technical specifications, diagrams etc. are subject to copyright law. All rights, errors and
modifications are reserved.
Initial inspection after delivery:
An important task of all technicians delivering the PFT G 5 SUPER is the inspection of the machine
settings at the end of the first work phase. The factory settings may change during the initial cycle.
If these changes are not corrected in time, immediately after run-in, problems may arise during
operation.
Following receipt of the PFT G 5 SUPER mixer pump and training in regard to it, i.e. after about
two hours of operation, the technician must always carry out the following checks / make the
following settings:
¾Water safety switch
¾Pump pressure, back pressure
¾Pressure relief valve on compressor
¾Air nozzle tube (Spraying pattern)
¾Air safety switch
¾Compressor pressure switch
¾Remote control switch
¾Pressure reducing valve
¾Motor safety switch

PFT G 5 SUPER Operating Manual Issued 11.2008
Knauf PFT GmbH & Co.KG
4
Contents
Dear PFT customer ....................................................................................................................... 3
Contents ........................................................................................................................................ 4
Applications: .................................................................................................................................. 6
Proper use of the machine ............................................................................................................ 6
Description of functions ................................................................................................................. 6
Dangers and warning symbols ...................................................................................................... 7
Basic safety instructions................................................................................................................ 8
Basic safety instructions................................................................................................................ 9
Signs ........................................................................................................................................... 11
Overview of G 5 SUPER: ltem number 00 00 84 05 ................................................................... 13
Overview of CADDY G 5 SUPER: ltem number 00 00 82 15...................................................... 14
Overview of control box G 5 SUPER: ltem number 00 00 71 34................................................. 15
Overview of water / air manifold .................................................................................................. 16
Technical Specifications.............................................................................................................. 17
Caddy Icons ................................................................................................................................ 18
Settings ....................................................................................................................................... 19
Settings ....................................................................................................................................... 19
Mortar pressure ........................................................................................................................... 20
PFT pump components ............................................................................................................... 20
Checking the conveying pressure and back pressure................................................................. 21
Pump System adjustable............................................................................................................. 22
Start-up........................................................................................................................................ 23
Setting the water factor ............................................................................................................... 25
Procedures at the End of Work and Cleaning ............................................................................. 29
Getting Rid of Hose Blocks ......................................................................................................... 31
Measures for Power Failure and Water Supply Failure............................................................... 31
Measures for Water Supply Failure............................................................................................. 32
Measures for Suzero Temperatures............................................................................................ 32
Transport ..................................................................................................................................... 34
Maintenance................................................................................................................................ 34
Accessories ................................................................................................................................. 35
Fault – Cause – Remedy............................................................................................................. 36
Spare parts list for chassis G 5 SUPER: part no. 00008223....................................................... 38
Spare parts list geard motor / mixing tube................................................................................... 40
Spare parts list pump unit / mortar pressure gauge .................................................................... 42
Spare parts list chassis caddy, compressor K2N and manifold box............................................ 44
Spare parts list water manifold G 5 SUPER: part no. 00008260................................................. 46

PFT G 5 SUPER Operating Manual Issued 11.2008
Knauf PFT GmbH & Co.KG
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Spare parts list air manifold G 5 SUPER: part no. 00008261 ..................................................... 50
Sare parts list control box external: part no. 00007134............................................................... 52
Spare parts list control box internal: part no. 00007134.............................................................. 54
List of spraying guns, hoses, tool kits and spraying caps ........................................................... 56
Circuit Diagramm......................................................................................................................... 58
Check list for annual inspection by specialists (master copy) ..................................................... 62
Notes: .......................................................................................................................................... 63

PFT G 5 SUPER Operating Manual Issued 11.2008
Knauf PFT GmbH & Co.KG
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Applications:
For pumpable, ready-mixed dry mortars, such
as:
•Machine-applied gypsum plasters
•Gypsum-lime plasters
•Cement renders
•Lime plasters
•Cement-lime renders
•Masonry mortars
•Insulating plasters
•Slot mortars
•Reinforcing and bonding mortars
•Self-levelling floor screeds
•Fango materials
•... and many more
Proper use of the machine
The PFT G 5 SUPER is a continuously operating mixing pump for pre-mixed machinable mortar
with a particle size of up to 3 mm.
Please observe the processing guidelines of the material manufacturer!
The machine consists of portable individual components of handy dimensions that allow fast,
convenient transport.
The following points should be observed during operation:
1) Connection for worksite distribution board – control box
2) Connection for control box – pump motor
3) Connection for control box – compressor
4) Connection for compressor – air manifold
5) Connection for water supply – water manifold / booster pump
6) Connection for air manifold – air hose
7) Connection for air hose – finishing plaster device
8) Connection for mixing tube – mortar pressure gauge
9) Connection for mortar pressure gauge – mortar hose
10) Connection for mortar hose – finishing plaster device
Description of functions
The PFT G 5 SUPER can be loaded with bagged materials or by means of a delivery hood or injection
hood. The mixing shaft and the pump are driven by a geared motor. The pump motor speed is
approximately 400 rpm. Water is added and mixed into the dry material in the mixing area. The water
flow rate needs to be set manually at the needle valve. The water flow rate may be checked using the
water flow meter. A pressure switch monitors the water flow pressure. If it falls below 1.9 bar, the
machine shuts down automatically. This problem is prevented by installing a booster pump upstream.
The mixed mortar is pumped away by a screw pump installed downstream from the mixing shaft.
A spraying gun can be mounted at the end of the conveying hose. The compressed air required for
spraying is supplied by a compressor.

PFT G 5 SUPER Operating Manual Issued 11.2008
Knauf PFT GmbH & Co.KG
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Dangers and warning symbols
The following terms and symbols are used in this manual for particularly important information:
In order to make the operation of our machines as easy as possible for you, we would like to briefly
inform you of the most important safety instructions. If you comply with these instructions, you will
be able to use our machine in a safe and quality-assuring manner for a long time to come.
Warning – hot surface!
Proper handling:
Hot surfaces should not be touched without protective gloves.
Waste oil!
Proper handling:
Only pour waste oil in the disposal container if it consists purely of oil.
(Do not pour in any mixtures, such as mixed benzine and oil!)
Warning – dangerous area!
Proper handling:
Observe the danger warning and exercise the appropriate caution
(e.g. protective clothing) and prudence.
Warning – dangerously high voltage!
Proper handling:
In work areas with this designation, work may be performed only by those
persons who possess the required expertise (e.g. electricians or persons with
authorisation for electrical work) and who have been assigned this work by the
contractor.
Unauthorised individuals may not enter such designated work areas or open
cabinets with this designation.

PFT G 5 SUPER Operating Manual Issued 11.2008
Knauf PFT GmbH & Co.KG
8
Basic safety instructions
1. Follow all safety instructions and danger warnings on the machine. Ensure that all instructions are kept
legible.
2. Inspect the machine for visible damage and defects at least once every shift. If you notice any safety-
threatening alterations to the machine or its operating behaviour, stop the machine immediately and
notify your supervisor.
3. Do not attempt to modify the machine in any way which may impair its safety without first consulting
your machine dealer. This also applies to the installation of unchecked “safety devices”.
4. Spare parts must comply with the technical requirements of the manufacturer. This is guaranteed for all
original PFT parts.
5. Only trained or instructed personnel should be employed. Clearly define the responsibilities of the
personnel for operation, setup, maintenance and repairs.
6. Personnel undergoing training should only be allowed to operate the machine under the supervision of
experienced persons.
7. All electrical work should be carried out by a qualified electrician or by trained personnel under the
supervision of a qualified electrician and should comply with the respective regulations.
8. Observe the operating instructions when turning the machine on and off. Watch control indicators for signals.
9. When the machine is completely switched off for maintenance and repair work, measures must be
taken to ensure that it cannot be switched back on accidentally (for example, lock the main switch and
remove the key, or attach a warning sign to the main switch).
10. Before cleaning the machine with a water jet, seal all openings through which water could enter and
thereby impair the safety and proper functioning of the machine (electric motors and control boxes).
Remove all covers after cleaning.
11. Only use original fuses of the prescribed amperage.
12. If work has to be carried out on live components, a second person should be present to disconnect the
power in the event of an emergency.
13. Disconnect the machine from all external power sources before you relocate it, even if you are only
moving it a short distance. The machine should be connected properly to the mains before being put
back into operation.
14. Set up the machine on stable ground and secure it against unintentional movements.
15. Lay out the conveying lines safely. Do not bend them over sharp edges.
16. Depressurise all conveying systems before opening conveying lines.
17. When unblocking hoses, stand away from the machine to avoid injury through high-pressure discharges
of mortar. Safety goggles should also be worn. No other persons may be within the immediate vicinity of
the machine during this work.
18. Appropriate noise insulation devices must be provided if the continuous noise level exceeds 85 dB(A).
19. If required, wear the following protective clothing while spraying: safety goggles, safety shoes, safety
clothing, gloves, protective skin cream and respirator mask
Have the machine inspected as required – but at least once a year – by a specialist.

PFT G 5 SUPER Operating Manual Issued 11.2008
Knauf PFT GmbH & Co.KG
9
Basic safety instructions
NOTE:
Special information for running the machine efficiently.
WARNING!
Special instructions, regulations and restrictions for the prevention of damage.
WARNING!
The machine should only be used if it is in flawless technical condition and in compliance with the
regulations. Pay attention to safety and the operating instructions. It is especially important to
immediately correct any faults that could impair safety.
In order to make the operation of our machines as easy as possible for you, we would like to briefly
inform you of the most important safety instructions. If you comply with these instructions, you will
be able to use our machine in a safe and quality-assuring manner for a long time to come.
WARNING!
The following terms and symbols are used in this manual for particularly
important information:
WARNING!
The machine should only be used if it is in flawless technical condition
and in compliance with the regulations. Pay attention to safety and the
operating instructions. It is especially important to immediately rectify all
faults which could impair safety.
In order to make the operation of our machines as easy as possible fo
r
you, we would like to briefly inform you of the most important safety
instructions. If you comply with these instructions, you will be able to use
our machine in a safe and quality-assuring manner for a long time to
come.
WARNING!
If additional parts that are not specified in these operating instructions
are installed for special procedures, it is necessary to adhere to the
utilisation, safety and maintenance regulations.
WARNING!
It is prohibited to use the machine for purposes other than those fo
r
which it is intended.

PFT G 5 SUPER Operating Manual Issued 11.2008
Knauf PFT GmbH & Co.KG
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WARNING!
It is prohibited to use the machine in environments at risk of explosion.
WARNING!
The machine must always be in perfect condition and used in
accordance with these instructions and under observation of the safet
y
instructions and danger warnings. Any damage that could impai
r
operational reliability must be repaired immediately.
WARNING!
The user must be aware of the risks of catching clothing or long hair in
moving parts.
Chains, bracelets and rings can also pose a risk.
WARNING!
The workplace of the user must be clean, tidy and free from objects
which could restrict freedom of movement.
WARNING!
The workplace must be appropriately lit for the respective tasks.
Insufficient or excess lighting can be dangerous.
WARNING!
Special instructions, regulations and restrictions for the prevention o
f
damage.
The machine should only be used as intended in a perfect technical
condition and in compliance with safety regulations and the operating
instructions. It is especially important to immediately correct any faults
that could impair safety.
WARNING!
Please observe the accident prevention regulations for compressors
(VBG 16), in particular sections IIIc “Installation” and IV “Operation”, as
well as VBG 4 “Electrical equipment and tools”.
Modifications to the pumps can only be carried out with factory consent.

PFT G 5 SUPER Operating Manual Issued 11.2008
Knauf PFT GmbH & Co.KG
11
Signs
The following symbols and notices are located in the work area. They refer to the immediate
vicinity in which they are attached.
WARNING!
Danger of injury due to illegible symbols!
Over the course of time, stickers and signs can become
dirty or through other means unreadable.
Therefore:
– Always maintain all safety, warning and operating
notices in legible condition.
– Replace damaged signs or stickers at once.
Running machine
Do not reach into the machine while it is running.
Maximum pressure
Do not exceed the maximum pressure.
Hand injury
Keep hands away from areas displaying this warning
symbol.
There is a risk of hands becoming crushed, drawn in or
otherwise injured.
Automatic startup
Machine starts up automatically.
Electrical voltage
Only electricians may work in areas with this designation.
Unauthorised individuals may not enter such designated
work areas or open cabinets with this designation.
Moving machine parts
Maintenance work on opened machines may only be
performed by specially trained technicians. There is a risk
of injury while the machine is moving.
Compressed air
Warning of the presence of compressed air.

PFT G 5 SUPER Operating Manual Issued 11.2008
Knauf PFT GmbH & Co.KG
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Danger point
Warning of a danger point in work areas.
Protective gloves
for protecting hands from friction, scraping, punctures or
deep injuries as well as from contact with hot surfaces.
Observe the operating manual
Only use the designated object after having read the
operating manual.
Face guard
for protecting eyes and face from flames, sparks or embers
as well as from hot particles or exhaust gases.
Running machine
Do not reach into the machine while it is running.
Safety devices
Use safety devices.
Rotating parts
Do not reach into rotating parts.
No maintenance work
Do not perform any maintenance while the machine is
running.
Touching prohibited
Touching may destroy containers or parts.

PFT G 5 SUPER Operating Manual Issued 11.2008
Knauf PFT GmbH & Co.KG
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Overview of G 5 SUPER: ltem number 00 00 84 05
1. Motor Connection Cable 2. Motor Flange
3. Pump Motor ZF 38 5,5KW 400U/min. 4. Star Wheel
5. Protection Grill + Sack Opener 6. Material Hopper
7. Star Wheel Cable 8. Star Wheel Motor ZFQ 38 0,75KW 28U/min.
9. Pumping System TWISTER 10. Mixing Tube with Suction Flange

PFT G 5 SUPER Operating Manual Issued 11.2008
Knauf PFT GmbH & Co.KG
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Overview of CADDY G 5 SUPER: ltem number 00 00 82 15
1. Controll Box G 5 SUPER 2. Socket for Mains 32A
3. Housing for manifold G 5 SUPER 4. Water Connection from Mains or Tank
5. Water counter 6. Water to Mixing Tube
1
4
3
2
5
6

PFT G 5 SUPER Operating Manual Issued 11.2008
Knauf PFT GmbH & Co.KG
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Overview of control box G 5 SUPER: ltem number 00 00 71 34
1. Display Lamp: Direction of Rotation 2. Main Reversing Switch
3. Display Lamp: Water Pressure 4. Blue Switch: Pump Motor:Reverse
5. Empty: No Material 6. Display Lamp: On / Off
7. Display Lamp: Fault in System 8. Socket: Mixing Pump
9. Socket: Vibrator 16A 10. Socket: Compressor 16A
11. Socket: Star Wheel 16A 12. Schuko-Socket 230V, 16A fuse
13. Socket for Mains 32A 14. Water Flow Button
15. Compressor selector switch 16. Water pump selector switch
17. Star wheel selector switch 18. Remote Control Socket 42V
19. Blind-Plug 4-pin 20. Socket 42V white for Level Sensor
21. Socket: Star Wheel 16A black

PFT G 5 SUPER Operating Manual Issued 11.2008
Knauf PFT GmbH & Co.KG
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Overview of water / air manifold
1. Air from Compressor 2. Air-Pressure Saftey Switch
3. Compressor Switch 4. Air to Spraying Gun
5. High Pressure Pump AV 3 6. Water Saftey Switch
7. Water Inlet Filter 8. Water Connection form Mains or Tank
9. Pre-valve Pressure 10. Pre-valve Pressure
11. Water Outlet 12. Water Outlet
13. Solenoid Valve 14. Water Outlet Valve
15. Water to Mixing Tube 16. Pressure Reducing Valve
17. Water Flow Meter 18. Water counter max. 10bar

PFT G 5 SUPER Operating Manual Issued 11.2008
Knauf PFT GmbH & Co.KG
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Technical Specifications
Description PFT G 5 SUPER Ltem number 00 00 79 40
Drive 400V
50Hz
Pump motor 5,5 kW
Star wheel motor 0,75 kW
Rpm Pump motor Ca.400 rpm
Star wheel motor Ca. 28 rpmn
Current input Pump motor 11,5 A for 400 V
Star wheel motor 2,2 A for 400 V
Power supply 400 V / 3-phase
32 A
Main fuse 3 x 25 A
Generator min. 25 kVA
Water connection 3/4” mind. 2,5 bar
Pump throughput TWISTER D6-3 Z approx. 22 l/min
Variabel 6-85 l/min
Conveying distance max. with 25 mm ∅30 m
max. with 35 mm ∅50 m
Conveying pressure max. 30 bar
Compressor output 0,25 Nm³/min
Dimensions and weight Filling height 880 mm
Hopper capacity 110 Liter
Hopper capacity with extension 240 Liter
Total length 1150 mm
Total width 650 mm
Total height 1520 mm
Motor module 49 kg
Mixing pump module 81 kg
Hopper module 117 kg
CADDY 85 kg
Total weight 283 kg
Sound power level LWA 77±1 dB(A)
Weighted effective acceleration value to which the upper limbs are exposed = < 2.5 m/s²
* Approximate value depending on conveying height, pump status and design, mortar quality, composition
and consistency.

PFT G 5 SUPER Operating Manual Issued 11.2008
Knauf PFT GmbH & Co.KG
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Caddy Icons
Drives
Star Wheelr
Faults
Motor Saftey Switch off
Water Pump
No Material
Compressor
No Water Pressure
Vibrator
Wrong Direction
Instructions
Manual Operation
At Subzero
Temperatures empty
all water
Automatic Operation
Do not insert hand into
operating machine
Water
Maximum Operating
Pressure 40 bar
Air

PFT G 5 SUPER Operating Manual Issued 11.2008
Knauf PFT GmbH & Co.KG
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Settings
Safty switch
Machine on Machine off
Water 2,2 bar 1,9 bar
Air 1,5 bar 1,9 bar
Compressor 2,5 bar 3,1 bar
Compressor Safety Valve
Compressor on Compressor off
Compressor 2,5 bar 3,1 bar
Compressor Safety Valve
4,0 bar against completely closed air pipe (factory setting and secured with
knurled screw)
Pressure reducing valve:
1,9 bar at max. throughput
Gap : Air Nozzle Pipe
The gap between the air nozzle tube and spraying cap should correspond
to the diameter of the spraying cap.
e.g.: 14 mm spraying cap = 14 mm gap.
Direction of rotation of the star wheel motor
The star wheel usually works independently of the direction of rotation. If a
SILOMAT conveying system is being used, we recommend a clockwise
direction of rotation (factory setting). This ensures that the pump motor also
runs in the correct direction.

PFT G 5 SUPER Operating Manual Issued 11.2008
Knauf PFT GmbH & Co.KG
20
Star wheel
Gap, star wheel to hopper floor: factory setting approx. 8 mm
Rule of thumb:
1.5 x diameter of largest dry mortar particle. If required, star wheel space
r
disc (item no. 20 10 19 00) can be installed for coarse plaster.
Mortar pressure
Warning!
The use of a mortar pressure gauge is absolutely imperative according to
the safety regulations of the Builder’s Guild.
PFT mortar pressure gauges monitor the mortar consistency efficiently and
easily.
Some benefits of the mortar pressure gauge:
¾Exact regulation of correct mortar consistency
¾Constant monitoring of the correct conveying pressure
¾Early detection of clogging or overloading of pump motor
¾Establishment of zero pressure
¾Significant contribution to the safety of the operating personnel
¾Durability of the pump components
PFT pump components
Warning!
During installation/removal of the mortar pump, the following must be
observed:
The main switch must be switched off during assembly!
NOTE:
¾New pump components with a conveying hose of 10 m should attain a conveying pressure of
approx. 30 bar and maintain a back pressure of approx. 2/3, before and after the first spraying.
We recommend using the PFT pressure tester with coupling and outlet tap to monitor the
backpressure:
¾A new rotor and new stator need to be run in; actual pressure values can only be determined
after the first spraying cycle.
¾Pump components which neither attain the required conveying pressure nor maintain the
required backpressure are worn out and must be replaced.