PFT G 4 X Operating Manual
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PFT G 4 X Operating Manual

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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: 00402116
Article number of the machine: 00414170
Article number of the machine: 00414238
Article number of the machine: 00424067
Article number of the machine: 00425824
Article number of the machine: 00430434
Article number of the machine: 00508766
Article number of the machine: 00517997
Article number of the machine: 00541804
Article number of the machine: 00591126
Article number of the machine: 00655335
Article number of the machine: 00260622
Article number of the machine: 00403628
Article number of the machine: 00419620
Article number of the machine: 00423938
Article number of the machine: 00425128
Article number of the machine: 00427200
Article number of the machine: 00434293
Article number of the machine: 00510836
Article number of the machine: 00534352
Article number of the machine: 00583696
Article number of the machine: 00593436
Article number of the machine: 00671959
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  • Page 1 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...
  • 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.net www.pft.net 2021-08-12...

  • Page 3: Table Of Contents

    Mixing pump G 4 X smart Overview - Operation and service Table of Contents 11.2 Control cabinet item number 1 EC Declaration of Conformity .... 6 00252527 ........... 16 11.3 Schaltschrank Artikelnummer 2 Examination ........7 00671960 ........... 17 2.1 Examination by machine operator ... 7 11.4 Mixing tube with motor and pump ..
  • Page 4 Mixing pump G 4 X smart Overview - Operation and service Table of Contents 21 Material: ........... 26 34.2 Start the machine in a “flying” mode ..38 21.1 Flowability / Flow characteristics ..26 35 Mortar hoses ........39 22 Mortar pressure gauge ....
  • Page 5 Mixing pump G 4 X smart Overview - Operation and service Table of Contents 42.3 Switch the machine back on after the 46.1 Blow dry water fitting ......59 blockage has been removed ..... 52 46.2 Switch on air compressor ..... 60 43 Cleaning the machine after work ..

  • Page 6: Ec Declaration Of Conformity

    Mixing pump G 4 X smart Overview - Operation and service EC Declaration of Conformity 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:...

  • Page 7: Examination

    Mixing pump G 4 X smart Overview - Operation and service Examination 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.

  • Page 8: General Information

    Mixing pump G 4 X smart Overview - Operation and service General information 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.

  • Page 9: Operating Manual

    Mixing pump G 4 X smart Overview - Operation and service General information 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...

  • Page 10: Brochures

    Search for downloads downloads downloads Search Brochures German Mixing pumps G 4 smart 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 2021-08-12...

  • Page 11: Technical Data

    Mixing pump G 4 X smart Overview - Operation and service Technical data 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...

  • Page 12: Power Values Pump Unit D6-3

    Mixing pump G 4 X smart 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 13: Output Values Pump Unit D5-2.5

    Mixing pump G 4 X smart Overview - Operation and service Sound power level 4.5 Output values pump unit D5-2.5 Detail Value Unit Pump capacity D5-2.5 22 l/min at Pump capacity, approx. 385 rpm Operating pressure, max. 25 bar Grain size max.

  • Page 14: Dimension Sheet

    Mixing pump G 4 X smart Overview - Operation and service Dimension sheet 7 Dimension sheet 1200 Fig. 2: Dimension sheet 8 Name plate The type plate is located at the right bottom of the hopper and includes the following information:...

  • Page 15: Assembly

    Mixing pump G 4 X smart Overview - Operation and service Assembly 10 Assembly 10.1 Overview Fig. 5: Table of the assembly groups 1. Pump motor 10. Water tap 2. Motor protection handle 11. Connection for mortar hose 3. Deflector plate (accessory) 12.

  • Page 16: Description Of Assemblies

    Mixing pump G 4 X smart Overview - Operation and service Description of assemblies 11 Description of assemblies 11.1 Hopper The mixing pump PFT G4 consists of the following main components: Hopper with frame and protective grille  Fig. 6: Assembly unit hopper 11.2 Control cabinet item number 00252527...

  • Page 17: Schaltschrank Artikelnummer 00671960

    Mixing pump G 4 X smart Overview - Operation and service Description of assemblies 11.3 Schaltschrank Artikelnummer 00671960 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.

  • Page 18: Air Compressor

    Mixing pump G 4 X smart Overview - Operation and service Connections 11.6 Air compressor Air compressor LK250 with pressure switch-off  Air compressor K2 N with pressure switch-off  Fig. 11: Air compressor 12 Connections 1. Main terminal 2. Connections material hoses 3.

  • Page 19: 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 20: Intended Use Control Panel

    Mixing pump G 4 X smart Overview - Operation and service Intended use Control panel 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.

  • Page 21: Intended Use Air Compressor

    Mixing pump G 4 X smart 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 22: Safety Systems Air Compressor

    Mixing pump G 4 X smart Overview - Operation and service Intended use air compressor 16.2 Safety systems air compressor WARNING! Danger of death due to non-functioning safety equipment! Safety equipment ensures highest level of safety in operation. Even if work processes become a little more complicated due to safety equipment, they must never be decommissioned.

  • Page 23: Description Pft Booster Pump (Accessory)

    Mixing pump G 4 X smart Overview - Operation and service Description PFT Booster pump (Accessory) 17 Description PFT Booster pump (Accessory) 17.1 Scope of application Booster pump The PFT booster pump is mainly used as booster pump for interposing at the mortar mixer and mortar mixing pumps with insufficient water pressure.

  • Page 24: Preparation Booster Pump (Accessory)

    19 Initial start-up booster pump Fill the PFT booster pump with water prior to initial start-up to let the air escape from the pump housing. Fill water through the water inlet (1).

  • Page 25: Description G 4 X Smart

    The dry mortar it thrown into the mixing chamber via the inclined star wheel. The PFT G 4 X smart 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 26: Functional Description G 4 X Smart

    Material: 20.2 Functional description G 4 X smart The new mixing pump G 4 X smart with 400V three-phase drive was specially developed for pumping, spraying and applying of dry mortar, pasty materials for machine use and much more up to 2 mm grain size.

  • Page 27: Mortar Pressure Gauge

    Mixing pump G 4 X smart Overview - Operation and service Mortar pressure gauge 22 Mortar pressure gauge Caution! mortar pressure gauge recommended for safety-related reasons. PFT mortar pressure gauge Some advantages of the mortar pressure gauge: Exact adjustment of the correct mortar consistency.

  • Page 28: Transport Inspection

    Mixing pump G 4 X smart Overview - Operation and service Transport, packing and storage Suspended loads WARNING! Danger of death due to suspended loads! Falling or swinging parts can pose a fatal hazard when heavy loads are lifted. Therefore: Never step underneath suspended loads.

  • Page 29: Packaging

    Mixing pump G 4 X smart Overview - Operation and service Transport, packing and storage 24.3 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.

  • Page 30: Transport In Individual Parts

    Mixing pump G 4 X smart Overview - Operation and service Operation 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 ...

  • Page 31: Safety Device

    Mixing pump G 4 X smart Overview - Operation and service Safety device 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 ...

  • Page 32: Safety System

    Mixing pump G 4 X smart Overview - Operation and service Preparing the machine 26.2 Safety system Inclination switch (1) in the terminal box of the geared motor. The inclination switch triggers as soon as the quick closure is ...

  • Page 33: Check The Individual Connectors

    Mixing pump G 4 X smart Overview - Operation and service Connecting the power supply 400 V 28.1 Check the individual connectors Switch on booster pump (1).  NOTE! The booster pump is necessary should the water pressure be less than 2.5 bar when the machine is running.

  • Page 34: Connection Of Water From Water Tank

    Mixing pump G 4 X smart Overview - Operation and service Switching on the G 4 X 28.3 Connection of water from water tank Fig. 39: Filter screen NOTE! When working from the water tank, the strainer with filter screen (article number 00136619) has to Fig.

  • Page 35: Water The Mixing Zone

    Mixing pump G 4 X smart Overview - Operation and service Mortar pressure gauge 2. At the same time adjust the expected amount of water required at the needle valve (2). 3. The water flow can be seen at the inspection glass (3) of the water flow meter and the level of the floater (4).

  • Page 36: Hazardous Dusts

    Mixing pump G 4 X smart Overview - Operation and service Hazardous dusts 31 Hazardous dusts Warning! In the long term, inhaled dust can lead to lung damage or have other adverse health effects. NOTE! The machine operator or the person working in the...

  • Page 37: Monitoring The Machine

    Mixing pump G 4 X smart Overview - Operation and service Monitoring the machine Feeding with delivery hood: Accessory article number 20600500  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 38: Putting The Machine Into Operation

    Mixing pump G 4 X smart Overview - Operation and service Putting the machine into operation 34 Putting the machine into operation 34.1 Check consistency of mortar 1. Connect consistency test tube at the mortar pressure gauge. 2. Place a bucket or pan under the consistency test tube.

  • Page 39: Mortar Hoses

    Mixing pump G 4 X smart Overview - Operation and service Mortar hoses 35 Mortar hoses 35.1 Prepare mortar hoses 1. Connect the cleaner coupling (1) at the water extraction valve (2). 2. Connect mortar hose (3) and water. 3. More mortar hose and cleaner coupling again and separate.

  • Page 40: Compressed Air Supply

    Mixing pump G 4 X smart Overview - Operation and service Compressed air supply 36 Compressed air supply 36.1 Connect air hose 1. Connect compressed air hose (1) at the air fitting. DANGER! Never loosen the hose couplings as long as the compressed air hose is not depressurised.

  • Page 41: Apply Mortar

    Mixing pump G 4 X smart Overview - Operation and service Apply mortar 37 Apply mortar DANGER! Risk of injury from discharged mortar! Discharged mortar may lead to injuries to eyes and face. Never look into the spraying device. ...

  • Page 42: Interruption Of Work

    Mixing pump G 4 X smart Overview - Operation and service Apply mortar 37.2 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 43: 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. 66: Remote control 39 Stopping in case of emergency Emergency-stop switch 39.1 Emergency-stop switch...

  • Page 44: Measures In Case Of Power Cut

    Mixing pump G 4 X smart Overview - Operation and service Measures in case of power cut 40 Measures in case of power cut 40.1 Main switch to position “0“ 1. Close the air tap at the spraying gun. 2. Turn the main switch (1) to position "0".

  • Page 45: Work On Troubleshooting

    7. Switch on the machine, press the green push button (4) control Fig. 70: Restart interlock voltage “ON”. 8. The G 4 X starts again as soon as the air tap at the spray gun is opened again. NOTE! In case of a longer power cut, the G 4 X and the material hoses have to be cleaned immediately.

  • Page 46: Fault Displays

    Mixing pump G 4 X smart Overview - Operation and service Work on troubleshooting 41.2 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...

  • Page 47: Table Of Faults

    Mixing pump G 4 X smart Overview - Operation and service Work on troubleshooting 41.5 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 48 Mixing pump G 4 X smart Overview - Operation and service Work on troubleshooting Fault Possible cause Solution Rectification by Pump motor defective Exchange pump motor Service engineer Pump motor does not start Connection cable defective Change connection cable Service engineer...

  • Page 49: Signs For Hose Blockages

    Mixing pump G 4 X smart 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...

  • Page 50: Causes For This Can Be

    Mixing pump G 4 X smart Overview - Operation and service Removal of blockages in the hose 41.7 Causes for this can be: Highly worn mortar hoses, badly greased mortar hoses, residual water in mortar hose, clogging of the pressure flange,...

  • Page 51: Change The Direction Of Rotation Of The Mixing Pump Motor In Case Of Blockages In The Hose

    Mixing pump G 4 X smart Overview - Operation and service Removal of blockages in the hose 42.1 Change the direction of rotation of the mixing pump motor in case of blockages in the hose 1. Turn main switch (1) to position "0".

  • Page 52: Switch The Machine Back On After The Blockage Has Been Removed

    Mixing pump G 4 X smart Overview - Operation and service Cleaning the machine after work 42.3 Switch the machine back on after the blockage has been removed 1. With the main switch (1) in position “0”, push the metal bracket (2) into the opposite direction.

  • Page 53: Secure Against Restarting

    Mixing pump G 4 X smart Overview - Operation and service Cleaning the machine after work 43.2 Secure against restarting DANGER! Danger to life from unauthorised restarting! When working with the machine there is the risk that energy supply switched without authorisation.

  • Page 54: Clean Mortar Hose

    Mixing pump G 4 X smart Overview - Operation and service Cleaning the machine after work 43.5 Clean mortar hose NOTE! Mortar hoses and spraying device have to be cleaned immediately after finishing work. 1. Connect the cleaner coupling (1) at the water extraction valve (2).

  • Page 55: Cleaning The Mixing Tube

    Mixing pump G 4 X smart Overview - Operation and service Cleaning the machine after work 43.7 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.

  • Page 56: Insert Agitator

    Mixing pump G 4 X smart 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. Let the machine run for about 5 - 10 seconds until the mixing tube has been cleaned.

  • Page 57: Changing The Pump / Cleaning The Pump

    DANGER! Danger to life from unauthorised restarting! When working with the G 4 X, there is a risk of the power supply being switched on without authorization. There is a risk to life for the people in the danger area.

  • Page 58: Adjusting The Pump

    DANGER! Danger to life from unauthorised restarting! When working with the G 4 X, there is a risk of the power supply being switched on without authorization. There is a risk to life for the people in the danger area.

  • Page 59: Measures In Case Of Risk Of Frost

    Mixing pump G 4 X smart Overview - Operation and service Measures in case of risk of frost 46 Measures in case of risk of frost ATTENTION! Damage by frost! Water that expands inside the machine during frost can cause severe damage.

  • Page 60: Switch On Air Compressor

    Mixing pump G 4 X smart Overview - Operation and service Maintenance 2. Turn main switch (4) to position "I". 3. Turn the star wheel (5) of the booster pump to position “0”. Fig. 95: Dry water fitting 46.2 Switch on air compressor 1.

  • Page 61: When Working On And In The Control Box

    Mixing pump G 4 X smart Overview - Operation and service Maintenance 47.2 When working on and in the control box Implementation by an electrician or a person trained in electrical engineering:  1. Turn the main reversing switch to the “0” position.

  • Page 62: Environmental Protection

    Mixing pump G 4 X smart Overview - Operation and service Maintenance Basic information WARNING! Danger of injury due to improperly performed maintenance work! Improper maintenance can lead to serious injuries or equipment damage. Therefore: Ensure there is adequate space for assembly before ...

  • Page 63: Maintenance Plan

    Mixing pump G 4 X smart Overview - Operation and service Maintenance 47.4 Maintenance plan The following paragraphs describe the maintenance works that are require for an ideal and trouble-free operation. In the event that increased wear is detected during regular checks, the required maintenance intervals have to be shortened according to the actual signs of wear.
  • Page 64 Mixing pump G 4 X smart Overview - Operation and service Maintenance 8. Replace filter cover. NOTE! Opening of the filter cover is at the bottom. Fig. 101: Opening filter cover 47.5.2 Plastic screen Implementation by operator.  1. Remove the closure cap (1) from the strainer.

  • Page 65: Safety Valve Air Compressor

    Mixing pump G 4 X smart Overview - Operation and service Maintenance 47.5.4 Setting value pressure switch water Switching on the Switching off the machine machine Water 2.2 bar 1.9 bar Fig. 104: Pressure switch water 47.5.5 Setting value pressure switch air...

  • Page 66: Adjust Locking Lever

    Mixing pump G 4 X smart Overview - Operation and service Maintenance 47.6.1 47.7 Adjust locking lever NOTE! By turning the eccentric bushing (1) with the special wrench (2) in the tool bag, the locking lever (3) can be adjusted.

  • Page 67: Disassembly

    Mixing pump G 4 X smart 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 68: Disassembly

    Mixing pump G 4 X smart 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 69: Index

    Mixing pump G 4 X smart Overview - Operation and service Index 50 Index Accesories ............10 Dimension sheet ..........14 Accessories ............19 Disassembly............68 Adjust locking lever ..........66 Disassembly............67 Adjusting the pump ..........58 Disposal ..............68 Air compressor ........... 18 Division ..............
  • Page 70 Mixing pump G 4 X smart Overview - Operation and service Index Intended purpose solenoid valve ....... 20 Preparation booster pump (accessory) ....24 Intended use ............23 Prepare mortar hoses ........39 Intended use air compressor ......21 Preparing the machine ........32 Intended use control panel ........
  • Page 71 Mixing pump G 4 X smart Overview - Operation and service Index Switch off air compressor ........42 Transport inspection ...........28 Switch off G 4 X ..........58 Transport with van ..........30 Switch on air compressor ......40, 60 Transport, packing and storage ......27 Switch the machine back on after the blockage Verhalten bei Störungen ........45...
  • Page 72 Mixing pump G 4 X smart Overview - Operation and service PFT - ALWAYS AT YOUR SITE Knauf PFT GmbH & Co. KG P.O. Box no. 60 97343 Iphofen Einersheimer Straße 53 97346 Iphofen Germany Phone +49 9323 31-760 Fax +49 9323 31-770 Technical hotline +49 9323 31-1818 info@pft.net...

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