PFT G4X Super User manual

Table of Contents
2020-01-07
Operating Manual
Mixing pump G 4 X FU 230/400V
Part 2 EC Declaration of Conformity
Overview - Operation
Article number of the operating manual: 00 43 75 45
Article number of the machine: 00 26 06 21 Article number of the machine: 00 42 21 35
Article number of the machine: 00 42 34 08 Article number of the machine: 00 42 39 50
Read the operating manual prior to starting any work!

2 2020-01-07
© 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.net

Mixing pump G 4 X FU 230/400V Overview - Operation
Table of Contents
2020-01-07 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 Spare parts lists....................................... 8
4 Spare part lists.................................... 9
5 Technical data...................................10
5.1 General information ............................... 10
5.2 Power connection .................................. 10
5.3 Operating conditions.............................. 10
5.4 Power values ......................................... 11
5.5 Sound power level ................................. 11
5.6 Vibrations............................................... 11
6 Dimension sheet...............................12
7 Name plate ........................................ 12
8 Quality Control sticker.....................12
9 Assembly...........................................13
9.1 Overview................................................ 13
10 Description of assemblies ............. 14
10.1 Hopper ................................................. 14
10.2 Control cabinet article number 00 25
46 51.................................................. 14
10.3 Mixing tube with motor and pump........ 15
10.4 Water fitting.......................................... 15
10.5 Air compressor DELTA2 230V with
pressure switch-off ............................ 15
11 Connections....................................16
12 Operating modes............................16
12.1 Selector switch star wheel....................16
12.2 Selector switch pump motor.................16
12.3 Selector switch pressure booster
pump ..................................................17
12.4 Voltage 230/400V changing.................17
13 Accessories ....................................17
13.1 Adapter cable .......................................18
14 Intended use Control panel ...........19
14.1 Intended purpose control panel............19
14.2 Intended purpose solenoid valve .........19
14.3 Intended purpose flow meter................19
15 Intended use air compressor.........20
15.1 Intended purpose air compressor ........20
15.2 Safety systems air compressor............21
15.3 Pressure switch-off air compressor......21
15.4 Dry-running air compressor..................21
16 Description PFT Booster pump
(Accessory)....................................22
16.1 Scope of application Booster pump .....22
16.2 Intended use.........................................22
17 Preparation booster pump AV3
(accessory) ....................................23
18 Initial start-up booster pump.........23
18.1 Start-up Booster pump.........................23
19 Description G 4 X FU 230/400V......24
19.1 Functional principle G 4 X FU
230/400V............................................24
19.2 Functional description G 4 X FU
230/400V............................................25
19.3 Fields of application..............................25
20 Material:...........................................25
20.1 Flowability / Flow characteristics..........25
21 Mortar pressure gauge...................26
22 Safety rules .....................................26

Mixing pump G 4 X FU 230/400V Overview - Operation
Table of Contents
4 2020-01-07
23 Transport, packing and storage ....26
23.1 Safety instructions for transport...........26
23.2 Transport inspection.............................27
23.3 Transport..............................................28
23.4 Transport with van................................28
23.5 Transport in individual parts.................29
24 Packaging........................................29
25 Operation.........................................30
25.1 Safety...................................................30
26 Safety system..................................30
27 Preparing the machine ...................31
28 Connecting the power supply
400V................................................31
28.1 Check the individual connectors..........32
28.2 Connecting the water supply................32
28.3 Connection of water from water tank...33
29 Switching on the G 4 X (400V) .......34
29.1 Putting the machine into operation
(400V) ................................................34
29.2 Set water quantity ................................34
29.3 Soaking of the mixing section..............35
30 Mortar pressure gauge ...................35
31 Hazardous dusts.............................35
31.1 Anti-dust unit for G 4 completely..........36
32 Feeding dry material to the
machine..........................................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
(400V) ................................................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 (400V)............ 50
42.2 Change the direction of rotation of the
mixing pump motor in case of
blockages in the hose (230V)............ 51
42.3 Blockage does not dislodge................. 51
42.4 Switch the machine back on after the
blockage has been removed (400V) . 52

Mixing pump G 4 X FU 230/400V Overview - Operation
Table of Contents
2020-01-07 5
42.5 Switch the machine back on after the
blockage has been removed (230V) . 52
43 Connection of power supply
(230V) ............................................. 53
43.1 Voltage 230V ....................................... 53
44 Connecting the power supply
230V................................................53
45 Switching on (230V)........................54
45.1 Putting the machine into operation
(230V)................................................ 54
46 Start the machine in a “flying”
mode 230V .....................................54
47 Cleaning the machine after work ..55
47.1 Empty the mixing tube......................... 55
47.2 Secure against restarting..................... 55
47.3 Cleaning the G 4 X .............................. 56
47.4 Decouple mortar hose ......................... 56
47.5 Clean mortar hose ............................... 56
47.6 Remove the water hose....................... 57
47.7 Cleaning the mixing tube ..................... 57
47.8 Insert the mixing tube cleaner.............. 57
47.9 Close motor tilt flange.......................... 58
47.10 Insert agitator..................................... 58
47.11 Cleaning the hopper ..........................59
48 Changing the pump / Cleaning the
pump ..............................................59
48.1 Fold up mixing tube..............................59
48.2 Clean rubber mixing section.................59
49 Switch off G 4 X ..............................60
50 Measures in case of risk of frost...60
50.1 Blow dry water fitting............................61
50.2 Switch on air compressor.....................61
51 Maintenance....................................62
51.1 Safety ...................................................62
51.2 Remove connection cable....................63
51.3 Environmental protection......................63
51.4 Maintenance plan.................................64
51.5 Maintenance work ................................64
51.6 Adjust locking lever ..............................66
51.7 Measures after effected maintenance..66
52 Disassembly....................................67
52.1 Safety ...................................................67
52.2 Disassembly.........................................68
53 Disposal...........................................68
54 Index ................................................69

Mixing pump G 4 X FU 230/400VX FU 230/400V Overview - Operation
EC Declaration of Conformity
6 2020-01-07
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: 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 FU 230/400V Overview - Operation
Examination
2020-01-07 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.

Mixing pump G 4 X FU 230/400V Overview - Operation
General information
8 2020-01-07
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: 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.
3.4 Spare parts lists
Spare parts lists for the machine can be found on the Internet at
www.pft.eu.

Mixing pump G 4 X FU 230/400V Overview - Operation
Spare part lists
2020-01-07 9
4 Spare part lists
You can find spare part lists for the machine in the Internet under www.pft.net
4.1
Accessories
1
2
3
For recommended accessories/equipment, see PFT
Machine and Equipment Catalog
ue or
www.pft.net

Mixing pump G 4 X FU 230/400V Overview - Operation
Technical data
10 2020-01-07
5 Technical data
5.1 General information
Detail Value Unit
Weight approx. 308 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
cmpl.
81 kg
Weight of hopper module 162 kg
Weight compressor 14 kg
Hopper dimensions
Detail Value Unit
Filling height 910 mm
Hopper volume 145 l
Hopper capacity with attachment 200 l
5.2 Power connection
Fig. 1: Motor protection switch
Power Setting value Designation
Star wheel 0.3 kW 0.95 A Q4
Mixer motor 5.5 kW 11 A Q5
Water pump 0.37 kW 2.5A Q6
Compressor 0.52 kW 3.3A Q6
Water connection
Detail Value Unit
Operating pressure, min. 2.5 bar
Connection 3/4 inch
5.3 Operating conditions
Environment
Detail Value Unit
Temperature range 2-45 °C
Relative humidity, max. 80 %

Mixing pump G 4 X FU 230/400V Overview - Operation
Technical data
2020-01-07 11
Duration
Detail Value Unit
Max. operating time at a stretch 8 hours
Electrical details
Detail Value Unit
voltage, three-phase current 50 Hz 230 / 400 V
Power consumption, max. 18 A
Power input, max. approx. 7,5 kW
Fuse protection, at least (400V) 3 x 25 A
Fuse protection, at least (230V) 1 x 16 A
Speed pump motor approx. 385 rpm
Speed star wheel motor 12 rpm
5.4 Power values
Pump output SD6-3 SLIMLINE
Compressor output DELTA 2
Detail Value Unit
Pump capacity, approx. 17
l/min at
385 rpm
Operating pressure, max. 20 bar
Grain size max. 2 mm
Feed range *, max. at 25 mm ∅15
m
Feed range *, max. at 35 mm ∅20
m
Compressor output 0.25 Nm³/min
* reference value depending on conveying height, pump condition and version,
mortar quality, composition and consistency
5.5 Sound power level
Guaranteed sound power level L WA 95dB (A)
5.6 Vibrations
Weighted effective value of acceleration to which the upper body parts are exposed <2.5 m/s²

Mixing pump G 4 X FU 230/400V Overview - Operation
Dimension sheet
12 2020-01-07
6 Dimension sheet
Fig. 2: Dimension sheet
7 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
8 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
1530
720

Mixing pump G 4 X FU 230/400V Overview - Operation
Assembly
2020-01-07 13
9 Assembly
9.1 Overview
1 2 3
14 13 12 11 10 9
Fig. 5: 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 DELTA 2
7. Carrying handle
8. 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
18. Locking lever
4
5
6
7
8
18
17
16
15

Mixing pump G 4 X FU 230/400V Overview - Operation
Description of assemblies
14 2020-01-07
10 Description of assemblies
The mixing pump PFT G 4 X consists of the following
main components:
10.1 Hopper
Fig. 6: Assembly unit hopper
Hopper with frame and protective grille
10.2 Control cabinet article number 00 25 46 51
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. Pilot lamp operation 400V
5. Pilot lamp operation 230V
6. Main terminal 32A
7. **Schuko socket outlet 230V, controlled for water pump
8. Schuko socket outlet 230V, continuous current for air
compressor
9. Connection for gear motor
10. Dummy connector for remote-controlled power socket
11. Remote control socket.
12. Yellow pilot lamp, for wrong direction of rotation
13. Red pilot lamp, motor protection switch was triggered
14. Selector switch pump motor
15. Operation button machine ON / OFF (control voltage).
16. Selector switch star wheel
**NOTE!
Switch off the water pump in 230V / 16 A operation.
(16A fuses could trigger due to the power consumption
of the machine).
1
2
3
4
5
6
7
8
9
16
15
14
13
12
11
10

Mixing pump G 4 X FU 230/400V Overview - Operation
Description of assemblies
2020-01-07 15
10.3 Mixing tube with motor and pump
Fig. 8: Assembly unit mixing tube with motor
1. Pump motor 5.5kW
2. Mixing tube with rubber mixing section
3. Pump unit SD6-3 SLIMLINE
10.4 Water fitting
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
8. Solenoid valve
9. Water to mixing tube
10.5 Air compressor DELTA2 230V with pressure switch-off
Fig. 10: Air compressor
Air compressor DELTA2 230V with pressure switch-off
1
2
3
4
5
6
9
8
7
1
2
3

Mixing pump G 4 X FU 230/400V Overview - Operation
Connections
16 2020-01-07
11 Connections
Fig. 11: Connections
1. Main terminal
2. Connections material hoses
3. Connection water supply from mains
4. Connection air to spray gun
12 Operating modes
12.1 Selector switch star wheel
Fig. 12: 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 position “1”:
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.
12.2 Selector switch pump motor
Fig. 13: Operating modes pump motor
The pump motor can be operated in three operating modes:
Selector switch position “0”:
The machine is switched off.
Selector switch right (toggle):
The machine starts when the main switch and the control voltage
is switched on:
Selector switch left 230V (momentary contact):
The pump motor runs backwards, thus the pump is relaxed while
all other functions are locked.
Selector switch left 400V (momentary contact):
Change the direction of rotation at the main switch (see chapter
28.1 taking machine into operation)
The pump motor runs backwards, thus the pump is relaxed while
all other functions are locked.
1 2 3 4

Mixing pump G 4 X FU 230/400V Overview - Operation
Accessories
2020-01-07 17
12.3 Selector switch pressure booster pump
Fig. 14: Operating modes water pump
The booster pump can be operated in three different operating
modes:
Selector switch position “0”:
Water pump is switched off, e.g. if the water pressure is
continuously at 2.5 bar.
Selector switch right:
Water pump is running in sync with the mixing pump (automatic
mode).
Selector switch left:
The water pump runs continuously in position “manual” (e.g. for
cleaning the hoses).
12.4 Voltage 230/400V changing
Fig. 15: Voltage selector
Voltage selector 230V / 1 phase or 400V / 3 phase
Delivery state position of voltage selector - 400V.
Change voltage:
Turn main switch to position "0".
Select voltage selector 230V - 400V.
Turn main switch to position "I".
Press the push button control voltage “ON”.
13 Accessories
Fig. 16: 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. 17: Delivery hood
PFT delivery hood with 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.

Mixing pump G 4 X FU 230/400V Overview - Operation
Accessories
18 2020-01-07
Fig. 18: ROTOMIX
ROTOMIX D-pumps cmpl. with 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. 19: ROTOQUIRL
ROTOQUIRL II cmpl. with 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. 20: Water hose/air hose
Water hose/air hose 3/4" x 40m with Geka couplings (article number 20
21 21 00)
Fig. 21: Remote control cable
Remote control cable 25m complete with ON/OFF switch and pilot lamp
(article number 20 45 69 29)
Fig. 22: Power cable
Power cable 5 x 4 mm² 25m with CEE plug and coupling 5 x 32A 6h red
(article number 20 42 39 20)
13.1 Adapter cable
Fig. 23: Adapter cable
Adapter cable reversible plug Schuko/coupling
(Article number 00 22 65 38)
Further accessories can be found at www.pft.eu

Mixing pump G 4 X FU 230/400V Overview - Operation
Intended use Control panel
2020-01-07 19
14 Intended use Control panel
14.1 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.
14.2 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.
14.3 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.

Mixing pump G 4 X FU 230/400V Overview - Operation
Intended use air compressor
20 2020-01-07
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.
15 Intended use air compressor
15.1 Intended purpose air compressor
The tool is conceptualised and designed exclusively for the
purpose of use specified here.
A number of accessories for blowing, cleaning and compressed
air tools can be connected to the compressor.
Carefully read the user manual for technical specifications and
instructions for correct use.
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.