PFT G4X Super User manual

Table of Contents
2021-08-12
Operating Manual
Mixing pump G 4 X smart
Part 2 EC - Declaration of Conformity
Overview - Operation and service
Article number of the operating manual: 00426926
Article number of the machine: 00257359
Article number of the machine: 00260622
Article number of the machine: 00402116
Article number of the machine: 00403628
Article number of the machine: 00414170 Article number of the machine: 00419620
Article number of the machine: 00414238
Article number of the machine: 00423938
Article number of the machine: 00424067
Article number of the machine: 00425128
Article number of the machine: 00425824
Article number of the machine: 00427200
Article number of the machine: 00430434
Article number of the machine: 00434293
Article number of the machine: 00508766 Article number of the machine: 00510836
Article number of the machine: 00517997
Article number of the machine: 00534352
Article number of the machine: 00541804
Article number of the machine: 00583696
Article number of the machine: 00591126
Article number of the machine: 00593436
Article number of the machine: 00655335
Article number of the machine: 00671959
Read the operating manual prior to starting any work!

2 2021-08-12
© 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]
www.pft.net

Mixing pump G 4 X smart Overview - Operation and service
Table of Contents
2021-08-12 3
1 EC Declaration of Conformity............ 6
2 Examination ........................................ 7
2.1 Examination by machine operator ........... 7
2.2 Periodic inspection................................... 7
3 General information ........................... 8
3.1 Information regarding the operating
manual ................................................. 8
3.2 Keep the manual for future reference ...... 8
3.3 Division .................................................... 8
3.4 Operating Manual .................................... 9
3.5 Spare parts lists ....................................... 9
3.6 Brochures............................................... 10
3.7 Accesories ............................................. 10
3.8 Flip catalog............................................. 10
4 Technical data................................... 11
4.1 General information ............................... 11
4.2 Power connection .................................. 11
4.3 Operating conditions .............................. 11
4.4 Power values Pump unit D6-3 ............... 12
4.5 Output values pump unit D5-2.5 ............ 13
4.6 Output values pump unit D8-2 ............... 13
5 Sound power level............................ 13
6 Vibrations .......................................... 13
7 Dimension sheet............................... 14
8 Name plate ........................................ 14
9 Quality Control sticker ..................... 14
10 Assembly......................................... 15
10.1 Overview .............................................. 15
11 Description of assemblies ............. 16
11.1 Hopper ................................................. 16
11.2 Control cabinet item number
00252527 ...........................................16
11.3 Schaltschrank Artikelnummer
00671960 ...........................................17
11.4 Mixing tube with motor and pump ........17
11.5 Water tap ..............................................17
11.6 Air compressor .....................................18
12 Connections.................................... 18
13 Operating modes ............................ 18
13.1 Selector switch star wheel....................18
14 Accessories .................................... 19
15 Intended use Control panel ........... 20
15.1 Intended purpose control panel............20
15.2 Intended purpose solenoid valve .........20
15.3 Intended purpose flow meter................20
16 Intended use air compressor......... 21
16.1 Intended purpose air compressor ........21
16.2 Safety systems air compressor ............22
16.3 General positioning of the air
compressor.........................................22
16.4 Hot surface of the air compressor ........22
17 Description PFT Booster pump
(Accessory).................................... 23
17.1 Scope of application Booster pump .....23
17.2 Intended use.........................................23
18 Preparation booster pump
(accessory) .................................... 24
19 Initial start-up booster pump ......... 24
19.1 Start-up Booster pump .........................24
20 Description G 4 X smart ................. 25
20.1 Functional principle G 4 X smart ..........25
20.2 Functional description G 4 X smart ......26
20.3 Fields of application..............................26

Mixing pump G 4 X smart Overview - Operation and service
Table of Contents
4 2021-08-12
21 Material: ...........................................26
21.1 Flowability / Flow characteristics.......... 26
22 Mortar pressure gauge ...................27
23 Safety rules......................................27
24 Transport, packing and storage ....27
24.1 Safety instructions for transport ........... 27
24.2 Transport inspection............................. 28
24.3 Packaging ............................................ 29
24.4 Transport.............................................. 29
24.5 Transport in individual parts................. 30
25 Operation .........................................30
25.1 Safety ................................................... 30
26 Safety device ...................................31
26.1 EMERGENCY OFF pushbutton........... 31
26.2 Safety system....................................... 32
27 Preparing the machine ...................32
28 Connecting the power supply 400
V ......................................................32
28.1 Check the individual connectors .......... 33
28.2 Connecting the water supply................ 33
28.3 Connection of water from water tank ... 34
29 Switching on the G 4 X ...................34
29.1 Putting the machine into operation ...... 34
29.2 Set water quantity ................................ 34
29.3 Water the mixing zone ......................... 35
30 Mortar pressure gauge ...................35
31 Hazardous dusts .............................36
31.1 Anti-dust unit for G 4 completely.......... 36
32 Fill the machine with dry material..36
33 Monitoring the machine..................37
34 Putting the machine into
operation ........................................38
34.1 Check consistency of mortar................ 38
34.2 Start the machine in a “flying” mode.... 38
35 Mortar hoses....................................39
35.1 Prepare mortar hoses .......................... 39
35.2 Connect mortar hose ........................... 39
36 Compressed air supply ..................40
36.1 Connect air hose.................................. 40
36.2 Connecting the spraying gun............... 40
36.3 Switch on air compressor .................... 40
37 Apply mortar....................................41
37.1 Open the air tap at the spraying gun ... 41
37.2 Interruption of work .............................. 42
37.3 In case of longer interruption of
work/break ......................................... 42
37.4 Switch off air compressor .................... 42
38 Remote control................................43
38.1 Working with the remote control .......... 43
39 Stopping in case of emergency
Emergency-stop switch.................43
39.1 Emergency-stop switch........................ 43
40 Measures in case of power cut ......44
40.1 Main switch to position “0“ ................... 44
40.2 Relieve mortar pressure ...................... 44
41 Work on troubleshooting................45
41.1 Reaction in the event of faults ............. 45
41.2 Fault displays....................................... 46
41.3 Faults ................................................... 46
41.4 Safety................................................... 46
41.5 Table of faults ...................................... 47
41.6 Signs for hose blockages: ................... 49
41.7 Causes for this can be:........................ 50
41.8 Earlier damage to the mortar hose ...... 50
42 Removal of blockages in the hose 50
42.1 Change the direction of rotation of the
mixing pump motor in case of
blockages in the hose........................ 51
42.2 Blockage does not dislodge................. 51

Mixing pump G 4 X smart Overview - Operation and service
Table of Contents
2021-08-12 5
42.3 Switch the machine back on after the
blockage has been removed ............. 52
43 Cleaning the machine after work .. 52
43.1 Empty the mixing tube ......................... 52
43.2 Secure against restarting..................... 53
43.3 Cleaning the G 4 X .............................. 53
43.4 Decouple mortar hose ......................... 53
43.5 Clean mortar hose ............................... 54
43.6 Remove the water hose....................... 54
43.7 Cleaning the mixing tube ..................... 55
43.8 Insert the mixing tube cleaner.............. 55
43.9 Insert the mixing tube cleaner.............. 55
43.10 Insert agitator..................................... 56
43.11 Cleaning the hopper .......................... 56
44 Changing the pump / Cleaning the
pump .............................................. 57
44.1 Fold up mixing tube ............................. 57
44.2 Adjusting the pump .............................. 58
45 Switch off G 4 X .............................. 58
46 Measures in case of risk of frost... 59
46.1 Blow dry water fitting ............................59
46.2 Switch on air compressor .....................60
47 Maintenance.................................... 60
47.1 Safety ...................................................60
47.2 When working on and in the control
box......................................................61
47.3 Environmental protection......................62
47.4 Maintenance plan .................................63
47.5 Maintenance work ................................63
47.6 Safety valve air compressor .................65
47.7 Adjust locking lever ..............................66
47.8 Measures after effected maintenance..66
48 Disassembly.................................... 67
48.1 Safety ...................................................67
48.2 Disassembly .........................................68
49 Disposal........................................... 68
50 Index ................................................ 69

Mixing pump G 4 X smart Overview - Operation and service
EC Declaration of Conformity
6 2021-08-12
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 power 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/EU).
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 smart Overview - Operation and service
Examination
2021-08-12 7
2 Examination
2.1 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.
2.2 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.
This heading contains test suggestions for the annual inspection by a specialist according to BGR 183 for
the G 4 X.
Knauf PFT - Downloads - Datenblätter
DOCUMENT CENTER
Use our wizard to find specific
downloads
Expert examination
Select your preferred language for
downloads
All languages
Search for downloads
Search
SEARCH RESULT
Designation Status Document type
SP04 G 4 XAug. 2021 Expert examination

Mixing pump G 4 X smart Overview - Operation and service
General information
8 2021-08-12
3 General information
3.1 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.
3.2 Keep the manual for future reference
The operating manual has to be available during the whole service
life of the product.
3.3 Division
The operating manual is divided into 2 books:
Part 1 Safety
General safety instructions mixing pumps/feed pumps
Article number: 00172709
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.

Mixing pump G 4 X smart Overview - Operation and service
General information
2021-08-12 9
3.4 Operating Manual
Operating Manual for the machine can be found on the Internet at:
Knauf PFT - Downloads - Datenblätter
DOCUMENT CENTER
Use our wizard to find specific
downloads
Operating Manual
Mixing pumps
G 4 smart
Select your preferred language for
downloads
German
Search for downloads
Search
3.5 Spare parts lists
Spare parts lists / spare parts posters for the machine can be found on the Internet at:
Knauf PFT - Downloads - Datenblätter
DOCUMENT CENTER
Use our wizard to find specific
downloads
Spare parts lists
Gserie
Select your preferred language for
downloads
German
Search for downloads
Search

Mixing pump G 4 X smart Overview - Operation and service
General information
10 2021-08-12
3.6 Brochures
Brochures for the machine can be found on the Internet at:
Knauf PFT - Downloads - Datenblätter
DOCUMENT CENTER
Use our wizard to find specific
downloads
Brochures
Mixing pumps
G 4 smart
Select your preferred language for
downloads
German
Search for downloads
Search
3.7 Accesories
For recommended accessories / equipment see PFT machine and device catalog or at:
Knauf PFT - Mischpumpe G 4 smart
3.8 Flip catalog
https://www.pft.net/de/service/news/druckfrisch-nuetzlich-markenstark.html

Mixing pump G 4 X smart Overview - Operation and service
Technical data
2021-08-12 11
4 Technical data
4.1 General information
Detail Value Unit
Weight approx.
293
kg
Length
1200
mm
Width
720
mm
Height
1530
mm
Individual weights
Detail Value Unit
Weight pump motor with tilt flange 51 kg
Weight of mixing pump module
81
kg
Weight of hopper module
137
kg
Weight of air compressor
24
kg
Hopper dimensions
Detail Value Unit
Filling height
910
mm
Hopper volume
145
l
Hopper capacity with attachment
200
l
4.2 Power connection
Fig. 1: Motor protection switch
Power Setting value Designation
Star wheel
0.75 / 0.3 kW
2.2 A / 0.95
Q4
Mixer motor
5.5 / 4 kW
11 / 8.3 A
Q5
Compressor
0.9 kW
1.8 A
Q7
Water pump
0.37 kW
1.1 A
Q3
Water connection
Detail Value Unit
Operating pressure, max.
2.5
bar
Connection
3/4
inch
4.3 Operating conditions
Environment
Detail Value Unit
Temperature range 2-45 °C
Relative humidity, max. 80 %

Mixing pump G 4 X smart Overview - Operation and service
Technical data
12 2021-08-12
Duration
Detail Value Unit
Max. operating time at a stretch
8
hours
Electrical details
Detail Value Unit
voltage, three-phase current 50 Hz 400 V
Power consumption, max. 32 A
Power input, max. 7.2 kW
Fuse protection, at least 3 x 25 A
Speed pump motor approx. 385 / 400 rpm
Speed star wheel motor 28 / 12 rpm
4.4 Power values Pump unit D6-3
Pump capacity D6-3 (DE)
Compressor output LK 250
Compressor output K2 N
Detail Value Unit
Pump capacity, approx. 22
l/min at
385 rpm
Operating pressure, max. 30 bar
Grain size max. 2 mm
Feed range *, max. at 25 mm ∅
20
m
Feed range *, max. at 35 mm ∅40 m
Compressor output 0.25 Nm³/min
* reference value depending on conveying height, pump condition and version,
mortar quality, composition and consistency

Mixing pump G 4 X smart Overview - Operation and service
Sound power level
2021-08-12 13
4.5 Output values pump unit D5-2.5
Pump capacity D5-2.5
Detail Value Unit
Pump capacity, approx. 22
l/min at
385 rpm
Operating pressure, max. 25 bar
Grain size max. 3 mm
Feed range *, max. at 25 mm ∅
25
m
Feed range *, max. at 35 mm ∅40 m
* reference value depending on conveying height, pump condition and version,
mortar quality, composition and consistency
4.6 Output values pump unit D8-2
Pump capacity D8-2
Detail Value Unit
Pump capacity, approx. 34
l/min at
385 rpm
Operating pressure, max. 20 bar
Grain size max. 3 mm
Feed range *, max. at 25 mm ∅
25
m
Feed range *, max. at 35 mm ∅40
m
* reference value depending on conveying height, pump condition and version,
mortar quality, composition and consistency
5 Sound power level
Guaranteed sound power level LWA 95dB (A)
6 Vibrations
Weighted effective value of acceleration to which the upper body parts are exposed <2.5 m/s²

Mixing pump G 4 X smart Overview - Operation and service
Dimension sheet
14 2021-08-12
7 Dimension sheet
Fig. 2: Dimension sheet
8 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
9 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
1200
720
1530

Mixing pump G 4 X smart Overview - Operation and service
Assembly
2021-08-12 15
10 Assembly
10.1 Overview
1 2 3
13 12 11 10 9
Fig. 5: Table of the assembly groups
1. Pump motor
2. Motor protection handle
3. Deflector plate (accessory)
4. Protective grille with sack opener
5. Hopper
6. Air compressor
7. Carrying handle
8. Double stop castor
9. Water sampling valve
10.Water tap
11.Connection for mortar hose
12.Mortar pressure gauge
13.Mixing tube
14.Castor
15.Power connection at control cabinet
16.Control cabinet
17.Locking lever
4
5
6
7
8
17
16
15
14

Mixing pump G 4 X smart Overview - Operation and service
Description of assemblies
16 2021-08-12
11 Description of assemblies
11.1 Hopper
Fig. 6: Assembly unit hopper
The mixing pump PFT G4 consists of the following main
components:
Hopper with frame and protective grille
11.2 Control cabinet item number 00252527
Fig. 7: Assembly unit control cabinet
Control cabinet
1. Master switch is also emergency-stop switch
2. Push button water inlet
3. Main terminal 32A
4. CEE socket outlet 4x16A, controlled for water pump
5. CEE socket outlet 4x16A, for air compressor
6. CEE socket outlet 7x16A, for pump motor
7. Schuko socket outlet 230V, continuous current
8. Dummy connector for remote-controlled power socket
9. Remote control socket.
10.Yellow pilot lamp, for wrong direction of rotation
11.Red pilot lamp, motor protection switch was triggered
12.Selector switch star wheel
13.Push button reverse direction of rotation
14.Operating button machine “ON” / “OFF” (control voltage)
1
2
3
4
5
6
7
14
13
12
11
10
9
8

Mixing pump G 4 X smart Overview - Operation and service
Description of assemblies
2021-08-12 17
11.3 Schaltschrank Artikelnummer 00671960
Abb. 8: Baugruppe Schaltschrank
Schaltschrank
1. Hauptwendeschalter, ist gleichzeitig Not-Aus-Schalter
2. Drucktaster Wasservorlauf
3. NOT-HALT-Drucktaster
4. Hauptstromanschluss 32A
5. Blindstecker für Fernsteuersteckdose
6. Kontrolllampe gelb, für falsche Drehrichtung
7. Kontrolllampe rot, Motorschutzschalter hat ausgelöst
8. Wahlschalter Zellenrad
9. Drucktaster Drehrichtung rückwärts
10.Betriebstaster Maschine „EIN“ / „AUS“ (Steuerspannung)
11.4 Mixing tube with motor and pump
Fig. 9: Assembly unit mixing tube with motor
1. Pump motor 5.5kW
Pump motor 4kW
2. Mixing tube G 4 X without adaptable flange
Mixing tube G 4 X with adaptable flange
3. Pump unit D6-3
Pump unit D5-2.5
Pump unit D8-2
11.5 Water tap
Fig. 10: Water tap assembly
1. Water flow meter 100-1000l/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
8. Solenoid valve
9. Water to mixing tube
1
2
3
3
10
9
8
7
6
5
1
2
3
1
2
3
4
5
6
9
8
7

Mixing pump G 4 X smart Overview - Operation and service
Connections
18 2021-08-12
11.6 Air compressor
Fig. 11: Air compressor
Air compressor LK250 with pressure switch-off
Air compressor K2 N with pressure switch-off
12 Connections
1 2 3 4
Fig. 12: Connections
1. Main terminal
2. Connections material hoses
3. Connection water supply from mains
4. Connection air to spray gun
13 Operating modes
13.1 Selector switch star wheel
Fig. 13: Operating modes star wheel
The star wheel can be operated in three operating modes:
Selector switch 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 switch 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 switch 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.

Mixing pump G 4 X smart Overview - Operation and service
Accessories
2021-08-12 19
14 Accessories
Fig. 14: Injection hood
PFT injection hood E1 for G 4
(article number 20600213).
The PFT injection hood is used for feeding dry material to the mixing pump
using the PFT SILOMAT pneumatic conveying system.
Fig. 15: Delivery hood
PFT delivery hood with off-load operation protection for G 4
(article number 20600500)
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. with 35 coupling (article number 20118000)
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. with 35 coupling (article number 20118400)
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 with Geka couplings (article
number 20212100)
Fig. 19: Remote control cable
Remote control cable 25m complete with ON/OFF switch and pilot lamp
(article number 20456929)
Fig. 20: Power cable
Power cable 5 x 4 mm² 25m with CEE plug and coupling 5 x 32A 6h red
(article number 20423920)

Mixing pump G 4 X smart Overview - Operation and service
Intended use Control panel
20 2021-08-12
15 Intended use Control panel
15.1 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 1.5 to 6
bar.
Smallest possible inlet pressure 2.5 bar.
Minimum pressure drop (inlet pressure/outlet
pressure) 1 bar.
Maximum media and ambient temperature 75°C.
Assembly position as desired, preferable vertical.
15.2 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 0.5 bar is required for the
valve to fully open.
15.3 Intended purpose flow 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.