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
5
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
6
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
7
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
10
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.