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

Mixing pump
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Operating manual
Mixing pump G 4 X Super / G 4 X XL
Part 2 Overview, operation and service
Item no. of the operating manual:
G 4 Super, 400 V, 3 Ph, 50 Hz with AV 1000
G 4 Super, 400 V, 3 Ph, 50 Hz with AV 1000, water hose/air hose
40 m and accessories
G 4 Super, 400 V, 3 Ph, 50 Hz with AV 1000, fine plaster unit
DN25-360° S14 600-30° Geka and accessories
G 4 XL, 400 V, 3 Ph, 50 Hz with AV 1000
Read the operating manual prior to starting any work!
00437547
Item no.: 00414171
Item no.: 00414189
Item no.: 00423947
Item no.: 00406795

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Summary of Contents for PFT G 4 X Super

  • Page 1 Operating manual Mixing pump G 4 X Super / G 4 X XL Part 2 Overview, operation and service Item no. of the operating manual: 00437547 G 4 Super, 400 V, 3 Ph, 50 Hz with AV 1000 Item no.: 00414171 G 4 Super, 400 V, 3 Ph, 50 Hz with AV 1000, water hose/air hose Item no.: 00414189...
  • Page 2 Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service About us About us Publisher Knauf PFT GmbH & Co. KG Postfach 60 ▪ 97343 Iphofen Einersheimer Straße 53 ▪ 97346 Iphofen...

  • Page 3: Table Of Contents

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Table of contents Table of contents 4.5.5 Air compressor......... 1 General information........4.5.6 Mortar pressure gauge..... Information regarding the operating Connections........manual..........
  • Page 4 Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Table of contents 5.13.5 Disconnecting and cleaning the mortar hose........5.13.6 Connecting the water hose....5.13.7 Cleaning the mixing tube....5.13.8 Cleaning the material hopper...

  • Page 5: General Information

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service General information General information Information regarding the operating manual This operating manual provides important information and instruc- tions on the correct use of the machine. A prerequisite for safe working is the observance of all stated safety guidelines and instructions.

  • Page 6: Keep The Manual For Future Reference

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service General information Structure of the safety and warning All safety and warning notices consist of: notices The danger sign and signal word...

  • Page 7: Ec Declaration Of Conformity

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service General information EC Declaration of Conformity Company: Knauf PFT GmbH & Co. KG Einersheimer Straße 53 97346 Iphofen Germany declares under our sole responsibility that the machine:...

  • Page 8: Quality Control Sticker

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service General information Quality Control sticker The following details can be found on the Quality Control sticker: CE confirmed as per EU directives...

  • Page 9: Purpose Of Flowmeter

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service General information 1.8.3 Purpose of flowmeter NOTE Application range! The flowmeter serves for measuring the volume of trans- parent liquid and gas flows in closed pipes. Optionally, the flowmeter can also be used for flow monitoring.

  • Page 10: Purpose Of Air Compressor

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service General information 1.8.5 Purpose of air compressor The air compressor has been designed and constructed only for the intended use described in this document.
  • Page 11 Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service General information 1.8.5.2 General setup of the air compressor The air compressor corresponds to the national and international safety regulations and can therefore also be used in damp rooms or in the open air.

  • Page 12: Technical Data

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Technical data Technical data General information 1.200 Figure 3: Dimension sheet in mm Detail Value Unit Unladen weight G 4 X Super approx.

  • Page 13: Power Connection

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Technical data Material hopper dimensions Detail Value Unit Filling height G 4 X Super Filling height G 4 X XL Material hopper volume...

  • Page 14: Capacity Values, Pump Unit D 6-3

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Technical data Capacity values, pump unit D 6-3 Pump capacity D 6-3 Detail Value Unit Pump capacity, approx. l/min at 385 rpm...

  • Page 15: Transport, Packing And Storage

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Transport, packing and storage Transport, packing and storage Safety instructions for transport Improper transport NOTE Damage from improper transport! Improper transport may cause substantial property damage.

  • Page 16: Transport Inspection

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Transport, packing and storage Transport inspection On receipt check the delivery immediately for completeness and trans- port damage. In case of externally visible transport damage, proceed as follows: Do not accept the delivery or under reserve only.

  • Page 17: Crane Transport

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Transport, packing and storage Crane transport Attachment points Anchor the machine at the anchor points for transport by crane. Observe the following conditions: The crane and lifting equipment have to be designed for the weight of the packages.

  • Page 18: Transporting A Running Machine

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Transport, packing and storage Transporting a running machine CAUTION Danger of injury from discharged mortar! Injuries to face and eyes can occur.

  • Page 19: Description

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Description Description Overview Figure 8: Table of the assembly groups Pump motor Motor protection handle Deflector plate Protective grille with sack opener...

  • Page 20: Operating Principle G 4 X Super / G 4 X Xl

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Description Operating principle G 4 X Super / G 4 X XL The dry section to accommodate the ready-mixed mortar is separated from the mixing and pumping section.

  • Page 21: Description Of Assemblies

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Description Flowability / flow characteristics The pump unit D 6–3 can be used up to 30 bar oper- ating pressure. The pump unit D 6–4 can be used up to 40 bar oper- ating pressure.

  • Page 22: Control Box Item No. 00254666

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Description 4.5.2 Control box item no. 00254666 The master switch is also the emergency-stop switch Water supply button Selector switch booster pump "manual-0-automatic"...

  • Page 23: Mixing Tube With Motor And Pump

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Description 4.5.3 Mixing tube with motor and pump Pump motor 6.05 kW or 7.5 kW Rubber mixing tube with adapter flange Pump unit D 6-3 / D 6-4...

  • Page 24: Air Compressor

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Description 4.5.5 Air compressor Air compressor COMP M-250 with pressure cut-off Figure 15: Air compressor 4.5.6 Mortar pressure gauge PFT mortar pressure gauge...

  • Page 25: Operating Modes

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Description Operating modes Selector switch star wheel The star wheel can be operated in three operating modes: Switch position "0": The star wheel is switched off and thus the material supply to the mixing section is interrupted, e.g.

  • Page 26: Accessories

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Description Accessories Injection hood for G 4, RITMO XL, HM 24 Item no. 20600213 The PFT injection hood is used for feeding dry material to the mixing pump using the PFT SILOMAT pneumatic conveying system.
  • Page 27 Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Description Water hose/air hose DN19 Geka | Geka - 40 m Item no. 20212100 Remote control cable with switch - 25 m Item no.

  • Page 28: Operation

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation Operation Safety Personal protective equipment The following protective equipment has to be worn for all operative work: Protective clothing Protective goggles...

  • Page 29: Monitoring The Machine

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation 5.1.2 Monitoring the machine WARNING Access by unauthorised persons! The machine may only be operated when monitored. 5.1.3 Hazardous dusts WARNING...

  • Page 30: Safety System

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation 5.1.4 Safety system Inclination switch (1) in the terminal box of the geared motor. The inclination switch triggers as soon as the quick closure is opened and the geared motor is tilted on the side.

  • Page 31: Inspection By Machine Operator

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation Inspection by machine operator Prior to each shift, the machine operator has to examine the effec- tiveness of the control and safety devices, as well as the proper fitting of the protection devices.

  • Page 32: Connecting The Power Supply

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation 5.3.3 Connecting the power supply 1. Only connect the machine to three-phase current with 400 V. DANGER Danger to life from electric current!
  • Page 33 Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation 4. Clean the water hose (3) from the water supply and bleed. 5. Connect the water hose (3) to the water inlet (4).

  • Page 34: Switching On The Machine

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation 5.3.5 Switching on the machine 1. Turn the main switch (1) to "ON". Green control lamp (2) lights up NOTE The green control lamp (2) only lights up if the supply line is OK and the tilt switch has not tripped.

  • Page 35: Mortar Hoses

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation 5.3.5.2 Watering the mixing zone NOTE The pump must generally be flushed with water. Flushing with water makes it easier for the pump to start up.

  • Page 36: Compressed Air Supply

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation 5.3.6.2 Connecting the mortar hose 1. Connect the mortar hose (1) to the mortar pressure gauge (2). NOTE Ensure clean and correct connection and tightness of...

  • Page 37: Feeding Dry Material To The Machine

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation 5.3.7.2 Connecting the spray gun 1. Connect compressed air hose (1) to the spray gun (2). 2. Make sure that the air tap (3) on the spray gun is closed.

  • Page 38: Shutdown In Case Of Emergency

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation Feeding with injection hood: Item no. 20600213 Fit the delivery hood instead of the grille cover. WARNING Risk of injury at the star wheel! Do not open the machine during pneumatic conveying.

  • Page 39: Putting The Machine Into Operation

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation Putting the machine into operation 5.5.1 Checking the mortar consistency 1. Connect consistency inspection tube to the mortar pressure gauge. 2. Place a bucket or tray below the consistency inspection tube.

  • Page 40: Remote Control

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation Remote control Working with the remote control 1. Remove dummy plug (1) from control box. 2. Connect remote control (2). 3. The G 4 X can be switched on or off using the remote control.

  • Page 41: Opening The Air Tap On The Spray Gun

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation 5.7.1 Opening the air tap on the spray gun 1. Switch the machine one by pressing the green pushbutton (1) control voltage "ON".

  • Page 42: In Case Of Longer Interruption Of Work / Break

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation 5.8.1 In case of longer interruption of work / break NOTE Always observe the setting time of the material to be...

  • Page 43: Switching Off The Machine

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation 5.10 Switching off the machine 1. Switch off the machine by pressing the red pushbutton (1) control voltage "OFF". 2. Turn the main switch (2) to "OFF".

  • Page 44: Discharging Mortar Pressure

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation 5.11.1 Discharging mortar pressure WARNING Overpressure on the machine! When opening machine parts they can open in an uncon- trolled manner and injure the operator.

  • Page 45: Measures In Case Of Risk Of Frost

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation 1. Close the air tap on spray gun. 2. Turn the main switch (1) to "ON". Green control lamp (2) lights up...

  • Page 46: Blowing The Water Manifold Dry

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation 6. Open and empty strainer. NOTE Make sure that the water fully flows out of the water mani- fold. Figure 63: Strainer 5.12.1...

  • Page 47: Ending Work / Cleaning The Machine

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation 5.13 Ending work / cleaning the machine 5.13.1 Cleaning Clean the machine daily at the end of work and in case of extended breaks.

  • Page 48: Emptying The Mixing Tube

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation 5.13.4 Emptying the mixing tube The machine must be cleaned daily after work and before prolonged pauses: 1. Shortly before the end of work, switch the star wheel selector switch (1) to the "0"...

  • Page 49: Connecting The Water Hose

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation Cleaning the mortar hose NOTE The mortar hoses and spray gun must be cleaned imme- diately at the end of work.

  • Page 50: Cleaning The Mixing Tube

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation 5.13.7 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 51: Cleaning The Material Hopper

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation Cleaning the mixing tube CAUTION Danger of crushing at the motor tilt flange! There is a danger of crushing injuries when closing the motor tilt flange.

  • Page 52: Reaction In The Event Of Faults

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation 5.14 Reaction in the event of faults Reaction in the event of faults The following applies as a general rule: 1. In the event of faults presenting immediate danger to persons or property, activate the emergency OFF function immediately.

  • Page 53: Fault Displays

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation 5.14.3 Fault displays The following installation indicates faults: Pos. Light signal Description Red control lamp Lights up on motor protection switch fault.

  • Page 54: Table Of Faults

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation 5.14.4 Table of faults Fault Possible cause Troubleshooting Rectification by Machine does Water pressure too low Check the water supply, clean...
  • Page 55 Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation Fault Possible cause Troubleshooting Rectification by Pump motor Pump motor defective Replace pump motor Service technician will not start Connection cable defective...

  • Page 56: Hose Blockages

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation Fault Possible cause Troubleshooting Rectification by Rotor too deep in pressure Replace pressure flange Service technician flange No original PFT spare parts...

  • Page 57: Removal Of Clogging In Hoses

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation Possible causes: Heavily worn mortar hoses Badly greased mortar hoses Residual water in mortar hose Clogging of the pressure flange Severe restriction at the couplings...
  • Page 58 Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation 5.14.6.2 Blockage cannot be cleared WARNING Overpressure on the machine! When opening machine parts they can open in an uncon- trolled manner and injure the operator.
  • Page 59 Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Operation 5.14.6.3 Switching on the machine after removing a blockage 1. Turn the main switch (1) to "ON". Green control lamp (2) lights up 2.

  • Page 60: Maintenance

    Mixing pump G 4 X Super / G 4 X XL / Part 2 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 61: Remove Connection Cable

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Maintenance 6.1.1 Remove connection cable Electrical system WARNING Danger to life from electric current! There is danger to life if you come in contact with live parts.

  • Page 62: Maintenance Plan

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Maintenance Maintenance plan The following paragraphs describe the maintenance works required for an optimal 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 63: Air Filter Compressor

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Maintenance 6.4.2 Air filter compressor Implementation by a service technician Remove air compressor from bracket: 1. Loosen air hose (1) from the air compressor.

  • Page 64: Strainer Screen In Pressure Reducer

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Maintenance 6.4.4 Strainer screen in pressure reducer Implementation by a service technician 1. Remove the closure cap (1) from the pressure reducer.

  • Page 65: Pump

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Maintenance 6.4.7.1 Safety valve air compressor 1. Check, if the safety valve at the air compressor opens against a completely closed air circuit at 4.0 bar.

  • Page 66: Adjusting The Locking Lever

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Maintenance Adjusting the locking lever By turning the eccentric bushing (1) with the special wrench (2) in the tool bag, the locking lever (3) can be adjusted.

  • Page 67: Spare Parts Lists

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Maintenance Spare parts lists The spare parts lists for the machine can be found on the Internet at www.pft.net. DOCUMENT CENTRE Open the Document Centre under Service → Downloads.

  • Page 68: Disassembly

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Disassembly Disassembly After the useful service life has been reached, the device has to be dismantled and disposed of in an environment-friendly manner.

  • Page 69: Disassembly

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Disassembly Disassembly When decommissioning, clean the device and dismantle it according to the applicable work safety and environmental protection regula- tions. Prior to starting the disassembly: Switch off device and secure against restarting.

  • Page 70: Disposal

    Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Disposal Disposal Provided no return or disposal agreements have been made, recycle the disassembled parts: Scrap metals. Recycle plastic elements. Dispose of remaining components, sorted according to the type of material.
  • Page 71 Mixing pump G 4 X Super / G 4 X XL / Part 2 Overview, operation and service Disposal page 71 / 72...
  • Page 72 PFT - ALWAYS AT YOUR SITE Knauf PFT GmbH & Co. KG Postfach 60 97343 Iphofen Einersheimer Straße 53 97346 Iphofen Germany Telephone: +49 9323 31-760 Fax: +49 9323 31-770 Technical hotline: +49 9323 31-1818 info@pft.net www.pft.net...

This manual is also suitable for:

G 4 x xl

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