PFT G4X Super Operation Manual
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2016-10-17
Operating Manual
Mixing pump G 4 X Super / G 4 X XL
Part 2 EC Declaration of Conformity
Overview - Operation and service
Article number of the operating manual: 00 43 75 47
Article number of the machine: 00 41 41 71
Article number of the machine: 00 42 39 47
Article number of the machine: 00 41 41 89
Article number of the machine: 00 40 67 95
Read the operating manual prior to starting any work!
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Summary of Contents for PFT G4X Super
- Page 1 Table of Contents 2016-10-17 Operating Manual Mixing pump G 4 X Super / G 4 X XL Part 2 EC Declaration of Conformity Overview - Operation and service Article number of the operating manual: 00 43 75 47 Article number of the machine: 00 41 41 71 Article number of the machine: 00 41 41 89 Article number of the machine: 00 42 39 47 Article number of the machine: 00 40 67 95...
- Page 2 © Knauf PFT GmbH & Co. KG P.O. Box no. 60 97343 Iphofen Einersheimer Straße 53 97346 Iphofen Germany Phone: +49 (0) 93 23/31-760 Fax: +49 (0) 0 93 23/31-770 Technical hotline +49 9323 31-1818 info@pft-iphofen.de Internet: www.pft.eu 2016-10-17...
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Page 3: Table Of Contents
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Table of Contents EC Declaration of Conformity ..6 11 Operating modes ......16 Selector switch star wheel ......16 Examination ........7 Selector switch pressure booster pump ..16 Examination by machine operator .... - Page 4 Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Table of Contents Switch on air compressor ......37 21 Operation ........26 Safety26 35 Apply mortar ........37 Open the air tap at the spraying gun ... 38 22 Safety system ........
- Page 5 Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Table of Contents Remove the water hose ....... 52 Safety58 Cleaning the mixing tube ......53 Remove connection cable ......58 Insert the mixing tube cleaner ...... 53 Environmental protection ......
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Page 6: Ec Declaration Of Conformity
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... -
Page 7: Examination
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Examination 2 Examination Examination by machine operator Prior to each shift, the machine operator has to examine the effectiveness of the control and safety devices as well as the proper fitting of the protection devices. -
Page 8: General Information
Part 2 Overview, operation and service (this manual). For safe operation of the device both parts have to be read and observed. Together they form one operating manual. Spare parts lists Spare parts lists for the machine can be found on the Internet at www.pft.eu. 2016-10-17... -
Page 9: Technical Data
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Technical data 4 Technical data General information Detail Value Unit Weight approx. 308 / 320 kg Length 1200 mm Width 720 mm Height 1530 / 1660 mm Individual weights Detail Value Unit... -
Page 10: Power Values Pump Unit D6-3
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Technical data Duration Detail Value Unit Max. operating time at a stretch 8 hours Detail Value Unit Electrical details voltage, three-phase current 50 Hz 400 V Power consumption, max. -
Page 11: Sound Power Level
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Dimension sheet Sound power level Guaranteed sound power level L 95dB (A) Vibrations Weighted effective value of acceleration to which the upper body parts are exposed <2.5 m/s² 5 Dimension sheet 1200 Fig. -
Page 12: Name Plate
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Name plate 6 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... -
Page 13: Assembly
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Assembly 8 Assembly Overview 14 13 12 11 10 Fig. 5: Table of the assembly groups 1. Pump motor 10. Booster pump 2. Motor protection handle 11. -
Page 14: Description Of Assemblies
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Description of assemblies 9 Description of assemblies The mixing pump PFT G 4 X consists of the following main components: Hopper Hopper with frame and protective grille Fig. -
Page 15: Mixing Tube With Motor And Pump
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Description of assemblies Mixing tube with motor and pump 1. Pump motor 5.5 / 7.5 kW 2. Rubber mixing tube with adaptable flange 3. Pump unit D6-3 / D6-4 4. -
Page 16: Connections
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Connections 10 Connections 1. Main terminal 2. Connections material hoses 3. Connection water supply from mains 4. Connection air to spray gun Fig. 11: Connections 11 Operating modes Selector switch star wheel The star wheel can be operated in three operating modes:... -
Page 17: Accessories
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. -
Page 18: Intended Use Control Panel
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Intended use Control panel 13 Intended use Control panel Intended purpose control panel The tool is conceptualised and designed exclusively for the purpose of use specified here. Scope of application: Primary use for water and neutral, non-adhesive liquids. -
Page 19: Intended Use Air Compressor
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Intended use air compressor 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. -
Page 20: Safety Systems Air Compressor
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Intended use air compressor Safety systems air compressor WARNING! Danger of death due to non-functioning safety equipment! Safety equipment ensure highest level of safety in operation. -
Page 21: Description G 4 X Super / G 4 Xxl
The dry mortar it thrown into the mixing chamber via the inclined star wheel. The PFT G 4 X can be started and refilled at any time. The star wheel is powered separately and can be quickly disassembled using a central locking mechanism. -
Page 22: Material
If 30 or 40 bar operating pressure are exceeded the mortar hose length has to be reduced. In order to avoid machine faults and increased wear of the pump motor, pump shaft and the pump itself, only original PFT spare parts such as PFT rotors... -
Page 23: Transport, Packing And Storage
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Transport, packing and storage 19 Transport, packing and storage Safety instructions for transport Improper transport ATTENTION! Damage from improper transport! Improper transport may cause substantial property damage. -
Page 24: Transport Inspection
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Transport, packing and storage Transport inspection On receipt check the delivery immediately for completeness and transport damage. In case of externally visible transport damage, proceed as follows: Do not accept the delivery or under reserve only. -
Page 25: Transport In Individual Parts
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Transport, packing and storage Transport of already running DANGER! machine Risk of injury from discharged mortar! Injuries to face and eyes can occur. Therefore: Before opening the couplings ensure that there is no more pressure on the hoses (observe display at mortar pressure gauge). -
Page 26: Packaging
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Packaging 20 Packaging For packaging The individual packages have to be packed in accordance with the transport conditions to be expected. Only environmentally-friendly materials were used for the packaging. The packaging should protect the individual components until the assembly from transport damage, corrosion and other damage. -
Page 27: Safety System
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Safety system Basic information WARNING! Danger of injury due to incorrect operation! Improper operation may lead to serious damage to persons or property. Therefore: Carry out all operating steps according to the instructions in this user manual. -
Page 28: Preparing The Machine
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Preparing the machine 24 Preparing the machine Prior to operating the machine carry out the following steps for preparing the machine: DANGER! Running star wheel! Risk of injury when reaching into the running star wheel. -
Page 29: Check The Individual Connectors
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Connecting the water supply Check the individual connectors Check connections of fill level sensor (1). NOTE! The sensor prevents the hopper from emptying completely. As soon as no material touches the fill level sensor anymore, the machine switches off. -
Page 30: Connecting The Water Supply
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Connecting the water supply Connecting the water supply 1. Clean the water hose (1) from the water supply and bleed. 2. Connect the water hose (1) to the water inlet (2). NOTE! Use only clean water free of solids. -
Page 31: Switching On The G 4 X
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Switching on the G 4 X 27 Switching on the G 4 X Putting the machine into operation 1. Turn main switch (1) to position "I". 2. -
Page 32: Soaking Of The Mixing Section
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Mortar pressure gauge Soaking of the mixing section NOTE! As a rule, the pump has to be soaked. The soaking process permits an easier start-up of the pump. 1. -
Page 33: Anti-Dust Unit For G 4 Completely
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Feeding dry material to the machine Anti-dust unit for G 4 completely Anti-dust unit G 4 article number 00 53 97 16. Consisting of: 1. -
Page 34: Monitoring The Machine
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Monitoring the machine Feeding with delivery hood: Accessory article number 20 60 05 00 Put the delivery hood instead of the grille cover. DANGER! Risk of injury at the star wheel! Do not open the delivery hood during the operation of the machine. -
Page 35: Mortar Hoses
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Mortar hoses 4. Check consistency of mortar. Fig. 48: Consistency of mortar 5. Switch off the machine, press the red push button (5) control voltage “OFF”. -
Page 36: Connect Mortar Hose
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Compressed air supply Connect mortar hose 1. Connect mortar hose (1) to the pressure flange (2). NOTE! Ensure clean correct connection tightness of the couplings! Dirty couplings and rubber seals are not watertight, and water might leak under... -
Page 37: Connecting The Spraying Gun
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Apply mortar Connecting the spraying gun 1. Connect the compressed air hose (1) at the spraying gun (2). 2. Ensure that the air tap (3) is connected to the spraying gun. 3. -
Page 38: Open The Air Tap At The Spraying Gun
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Apply mortar Open the air tap at the spraying gun 1. Switch on the machine, press the green push button (1) control voltage “ON”. 2. -
Page 39: Interruption Of Work
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Apply mortar Interruption of work NOTE! Always observe the setting time of the material to be processed: Clean the system and mortar hoses depending on the setting time of the material and the length of the interruption (pay attention to outside temperature). -
Page 40: Remote Control
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Remote control 36 Remote control Working with the remote control 1. Remove dummy connector (1) from control cabinet. 2. Connect remote control (2). 3. The G 4 X can be switched on or off using the remote control. Fig. -
Page 41: Measures In Case Of Power Cut
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Measures in case of power cut 38 Measures in case of power cut Relieve mortar pressure 1. Close the air tap at the spraying gun. 2. -
Page 42: Work On Troubleshooting
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Work on troubleshooting NOTE! The G 4 X is equipped with a restart interlock. In case of a power cut, the system has to be started as follows. -
Page 43: Fault Displays
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Work on troubleshooting Fault displays The following installation indicates faults: Pos. Light signal Description Red pilot lamp Lights up on motor protection switch fault. Check motor protection switch Yellow pilot Lights up if there is no water. -
Page 44: Table Of Faults
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Work on troubleshooting Table of faults Fault Possible cause Solution Rectification by Machine does Water pressure too low Check water supply, clean strainer Operator/Service not start screen engineer... - Page 45 ½ minute and then turn "thick-thin" down slowly Water safety switch set incorrectly Adjust or replace water safety switch Service engineer or defective Agitator defective; no original PFT Replace agitator with original PFT Operator agitator agitator Pressure reducer set incorrectly or...
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Page 46: Signs For Hose Blockages
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Work on troubleshooting Fault Possible cause Solution Rectification by Bad mixture in mixing tube Add more water Operator Mortar flow ceases (air Material is clumped and narrows Add more water or clean agitator or Operator bubbles) -
Page 47: Causes For This Can Be
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Removal of blockages in the hose Causes for this can be: Highly worn mortar hoses, badly greased mortar hoses, residual water in mortar hose, clogging of the pressure flange, strong tapering at the couplings, kink in mortar hose,... -
Page 48: Change The Direction Of Rotation Of The
3. Dislodge the blockage by tapping or shaking at the place where the blockage is located. 4. If required, insert a rinsing hose into the mortar hose and flush out the material (PFT rinsing hose art. no. 00113856). Fig. 70: Loosen coupling 2016-10-17... -
Page 49: Switch The Machine Back On After The Blockage Has Been Removed
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Cleaning the machine after work Switch the machine back on after the blockage has been removed 1. Insert dummy connector (1) or remote control. 2. -
Page 50: Plug Level Sensor
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Cleaning the machine after work Plug level sensor Note! For cleaning purposes, pull the plug (1) of the filling level sensor, otherwise the machine will get a leak signal via the level probe and stop. -
Page 51: Decouple Mortar Hose
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Cleaning the machine after work Decouple mortar hose 1. Check at the mortar pressure gauge (1) if the mortar pressure is at "0 bar". DANGER! Overpressure on the machine! When opening machine parts they can open in an... -
Page 52: Remove The Water Hose
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Cleaning the machine after work 4. Remove the fine plaster spraying nozzle (5) from the spraying gun. 5. Loosen the ring screw (6) and pull the air nozzle tube (7) out of the spray head. -
Page 53: Cleaning The Mixing Tube
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Cleaning the machine after work Cleaning the mixing tube 1. Open the quick closure at the motor tilt flange and tilt the motor. 2. Remove the mixing shaft (1) and clean it. Fig. -
Page 54: Insert Agitator
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Cleaning the machine after work 2. Turn main switch (3) to position "I". 3. Press the green push button (4) control voltage “ON” (4). 4. -
Page 55: Changing The Pump / Cleaning The Pump
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Changing the pump / Cleaning the pump 42 Changing the pump / Cleaning the pump Fold up mixing tube 1. Secure the machine against switching on by removing the connection cable. -
Page 56: Switch Off G 4 X
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Switch off G 4 X 43 Switch off G 4 X 1. Switch off the machine, press the red push button (1) control voltage “OFF”. 2. -
Page 57: Blow Dry Water Fitting
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Measures in case of risk of frost 6. Open and empty strainer. Fig. 89: Strainer Blow dry water fitting 1. Connect water/air hose (1) with EWO and Geka coupling to the water inlet (2) and to the outlet of the air fitting (3). -
Page 58: Maintenance
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Maintenance Maintenance Safety Personnel The maintenance works described here can be carried out by the operator, unless marked otherwise. Some maintenance work must only be carried out by specially trained technical personnel or exclusively by the manufacturer. -
Page 59: Environmental Protection
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Maintenance Secure against restarting DANGER! Danger to life from unauthorised restarting! When working with the tool, there is the risk that the energy supply is switched on without authorisation. This poses a danger to life for the persons in danger area. -
Page 60: Maintenance Work
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Maintenance NOTE! Maintenance is limited to a few checks. Thorough cleaning after use is the most important maintenance. Interval Maintenance work To be carried out by monthly Clean/replace filter of compressor. - Page 61 Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Maintenance Plastic screen Implementation by operator. 1. Remove the closure cap (1) from the strainer. 2. Take out the plastic sieve (2) from the strainer (monthly). 3.
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Page 62: Safety Valve Air Compressor
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Maintenance Setting value pressure switch air Switching on the Switching off the machine machine 0.9 bar 1.2 bar Fig. 100: Pressure switch air Setting value pressure switch air compressor Switch on air Switch off air compressor... -
Page 63: Disassembly
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Disassembly 4. Ensure that all used tools, materials and other equipments were removed from the work area. 5. Clean the work area and remove any spilled materials such as liquids, processing material or similar. -
Page 64: Disassembly
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Disposal Electrical system DANGER! Danger of death from electric current! There is danger to life if you come in contact with live parts. Activated electrical components can carry out uncontrolled movements and cause serious injuries. -
Page 65: Index
Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Index 48 Index Accessories ............17 Disassembly............63 Adjust locking lever ..........62 Disposal ..............64 Air compressor K2 N with pressure switch-off..15 Division ..............8 Air filter compressor .......... - Page 66 Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Index Keep the manual for future reference ....8 Remote control ........... 40 Maintenance ............58 Removal of blockages in the hose ..... 47 Maintenance plan ..........59 Remove connection cable ........
- Page 67 Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service Transport inspection ........... 24 Water fitting ............15 Transport with van ..........24 Work on troubleshooting ........42 Transport, packing and storage ......23 Working with the remote control ......40 Vibrations ............
- Page 68 Mixing pump G 4 X Super / G 4 X XL Overview - Operation and service The FLOW OF PRODUCTIVITY Knauf PFT GmbH & Co. KG P.O. Box no. 60 97343 Iphofen Einersheimer Straße 53 97346 Iphofen Germany Phone +49 9323 31-760...
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