PFT LK 402 IV User manual

74
Contents
2019-01-28
Operating Manual
PFT Air Compressor LK 402 I
Safety
Overview – Operation – Spare Parts Lists
Item number of operating manual: 00 25 52 64
Item number of the machine parts list: 00 23 31 74
Read the operating manual prior to beginning any work!

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© Knauf PFT GmbH & Co.KG
Postfach 0 97343 Iphofen
Einersheimer Straße 53 9734 Iphofen
Germany
Tel.: [phone]
Fax: [phone]
Technical hotline: [phone]
[email protected]
www.pft.net

Contents
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1 General information ..................................... 4
1.1 Information on the safety
instructions........................................... 4
1.2 Keep the manual for later use ............. 4
1.3 Symbols ............................................... 5
1.4 Limitationof liability ..............................
1.5 Copyright protection ............................ 7
1. Spare parts .......................................... 7
1.7 Customer service ................................. 7
2 Safety ............................................................ 8
2.1 Owner responsibility ............................ 8
2.2 Operating personnel ............................ 9
2.3 Proper use of the machine ................ 10
2.4 Personal protective equipment .......... 12
2.5 Special dangers ................................. 13
2. Safety devices ................................... 1
2.7 Dealing with dangerous situations
and accidents..................................... 17
2.8 Signs .................................................. 17
3 Operation .................................................... 20
3.1 Preliminary remark ............................ 20
3.2 Description ......................................... 21
3.3 Proposed scope of application .......... 21
4 General safety standards .......................... 21
4.1 What to do .......................................... 22
4.2 What to refrain from ........................... 22
4.3 Removing the packaging .................... 23
4.4 Disposal of packaging ........................ 23
5 Start-up ........................................................ 24
5.1 Set-up ................................................. 24
5.2 installation .......................................... 24
5.3 Switching on ....................................... 25
5.4 Motor protection switch ...................... 25
5.5 Setting the operating pressure ........... 2
6 Maintenance ................................................ 26
.1 Note .................................................... 2
.2 Check after 50 operating hours .......... 2
.3 Weekly inspection .............................. 27
.4 Monthly inspection or more
frequently............................................ 27
.5 Half-yearly oil change ......................... 28
. Cleaning ............................................. 28
.7 Maintenance program ........................ 28
.8 Electrical data ..................................... 29
7 Solution ....................................................... 30
8 Spare parts diagram ................................... 31
9 Index ............................................................ 33

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1 General information
1.1 Information on the safety instructions
These safety instructions give important notes and instructions on
the correct use of the equipment. Adherence to all defined safety
and handling instructions is a prerequisite for a safe working
environment.
Additionally, the on-site accident prevention regulations and general
safety guidelines for the equipment must be followed at all times.
Read the manual carefully before starting any work! It is an integral
part of the product and must be kept near the machine and
accessible to operators at all times.
Always include the operating manual when transferring the
machine to third parties.
The diagrams and illustrations shown in the manual are intended
for better understanding of tasks and descriptions. They are not
necessarily shown to the correct scale and may vary slightly from
the actual equipment used.
1.2 Keep the manual for later use
The operating manual must be available during the entire service
life of the product.

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1.3 Symbols
Warning symbols Warnings are shown by symbols in this manual. The warnings
themselves open with signal words that express the seriousness of
the danger.
Adhere to these warnings at all times to avoid accidents,
personal injury and equipment damage.
DANGER!
... Indicates an immediate dangerous situation
that will lead to death or serious injury if it is not
avoided.
WARNING!
... Indicates a potentially dangerous situation
that can lead to death or serious injury if it is
not avoided.
CAUTION!
... Indicates a potentially dangerous situation that
can lead to minor or slight injury if it is not avoided.
CAUTION!
... Indicates a potentially dangerous situation that
can lead to material damage if it is not avoided.
Tips and recommendations
NOTE!
... Contains useful tips and recommendations, plus
further information on efficient and problem-free
operation.

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Special safety instructions The following symbols are used in conjunction with safety
instructions in order to illustrate certain types of danger:
DANGER!
Danger of death due to electric current!
... Indicates a potentially life-threatening situation
caused by electricity in the affected area.
Non-compliance with the safety instruction
could lead to death or serious injury.
Work on electrical systems may only be carried
out by specialist electricians.
1.4 Limitationof liability
All specifications and instructions in this manual have been
compiled according to the currently valid norms and instructions,
up-to-date technology and our many years of experience in
the branch.
The manufacturer accepts no liability for damages caused under
the following conditions:
 Failure to follow the instructions
 Non-intended use
 Deployment of untrained personnel
 Unauthorised conversions
 Technical modifications
 Use of non-approved spare parts
The actual scope of delivery may vary from the explanations and
diagrams detailed here due to special models, additional order
options and technological changes.
Additionally, the obligations defined in the delivery contract,
the general terms and conditions, the delivery requirements of
the manufacturer and the valid regulations at the time of contract
conclusion all apply.

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1.5 Copyright protection
Keep the manual and its contents confidential. It is only to be
used by personnel who actively use the machine. Forwarding of
the manual to third-parties without prior written permission from
the manufacturer is not permitted.
NOTE!
The contents, texts, drawings, pictures and other
representations are protected by copyright and are
sub ect to industrial property rights. Any improper
use shall be liable to prosecution.
All forms of reproduction – both in whole and in part – plus the
utilisation or publication of the manual contents are not permitted
without prior written approval by the manufacturer. Violation of
these terms can lead to claims for compensation. We reserve all
other further rights.
1.6 Spare parts
WARNING!
Danger of injury due to incorrect spare parts!
Incorrect or defective spare parts can lead to
damage, improper functionality or complete system
breakdowns. They can also negatively affect
system safety.
Therefore:
– Only use original spare parts from the
manufacturer.
Only purchase spare parts from approved dealers.
1.7 Customer service
Our customer hotline is available in case of technical queries.
Information on the respective contact partners can be found by
telephone, fax, e-mail or on the Internet. The address of
the manufacturer can be found on page 2.
Our employees are always happy to receive new information
resulting from practical operation. This information may be used
for future product improvements.

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2 Safety
This section provides an overview of all important safety aspects.
These offer optimal levels of safety for personnel and safe and
problem-free operation.
Significant danger may result from non-compliance with the
operating steps and safety instructions detailed in this manual.
2.1 Owner responsibility
The equipment is intended for industrial use. The owner of the
equipment is therefore subject to the statutory health and safety
regulations.
Apart from the work safety instructions detailed in this manual,
all valid safety, accident prevention and environmental protection
guidelines for the equipment must be adhered to. This especially
applies to the following:
 The owner must be aware of the valid health and safety
regulations and is responsible for carrying out a hazard analysis
in order to determine additional dangers resulting from the
individual working conditions on the operating site of the device.
These additional dangers must be summarised as operational
instructions for the correct use of the equipment.
 During the entire operation time of the device, the owner is
responsible for coordinating the operating instructions with
the current operational status and for adapting them as required.
 The owner is responsible for clearly allocating and defining
the responsibilities for installation, operation, maintenance
and cleaning.
 The owner must ensure that all employees handling the
device have read and understood the operating manual.
In addition he must train the personnel at regular intervals
and inform them of the dangers associated with equipment use.
The owner is also responsible for the technical functionality
and condition of the equipment. The following rules apply here:
 The owner must ensure that the maintenance intervals detailed
in this operating manual are observed.
 The owner must have all safety devices regularly checked
for functionality and completeness.
 The owner must make the requisite safety equipment available
to personnel.

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2.2 Operating personnel
2.2.1 Requirements
WARNING!
Risk of injury due to lack of qualification!
Improper use of the equipment can lead to
serious personal injury and material damage.
– Only have certain tasks carried out by the
responsible persons detailed in the individual
chapters of this manual.
– Contact specialists in case of doubt.
The following qualifications are specified for various tasks within
this manual:
 Instructed personhas been instructed by the operator about
the tasks assigned to him and possible dangers in the event of
improper behaviour.
 skilled personnelis, due to his technical training, knowledge
and experience as well as knowledge of the relevant
regulations, in a position to carry out the work assigned to
him and to recognise possible dangers independently.
 qualified electricianis able to carry out work on electrical
systems and to recognise possible dangers independently
due to its technical training, knowledge and experience as
well as knowledge of the relevant standards and regulations.
Electricians are specially trained for the work environment in
question and are aware of the relevant standards and
instructions.
Only persons that carry out their work responsibly are permitted
to work with the system. Persons with impaired reactions
(e.g. due to drugs, alcohol or medication) are not permitted.
Observe the specific business and age regulations when selecting
personnel on-site.

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2.2.2 Unauthorised individuals
WARNING! Unauthorised individuals are put
at risk!
Unauthorised individuals who do not fulfil
the requirements here are not fully aware of
the dangers in the work area.
– Keep unauthorised persons away from
the work area.
– In case of doubt, ask the persons involved
and guide them away from the work area.
– Stop operation as long as unauthorised
individuals are found within the work area.
2.2.3 Inspection
The compressor must be inspected by a specialist once a year.
The test must be documented.
This inspection must be carried out once a year by a specialist in
accordance with BGR 183 (German Association for Health and
Safety at Work). As validation of this test, the compressor receives
a test badge. The inspection protocol is to be presented on
demand.
2.3 Proper use of the machine
The equipment has been designed and constructed only
for the intended use described below.
The compressor may only be used as a source of compressed
air, any other application is excluded.

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WARNING!
Danger due to improper use of the machine!
Improper or unauthorised additional use of
the system can lead to dangerous situations.
Therefore:
– Only use the machine as intended.
– Always observe all processing guidelines
from the material manufacturer.
– Adhere to all specifications in this operating
manual to the letter.
– In particular, do not use the device for the
following purposes. They are not considered
as intended:
– Do not use for food or pharmaceutical
industry
– Do not climb on the machine
We accept no responsibility for damages caused by improper
or unauthorised use.
The owner is solely liable for all damage or injury caused by
improper or unauthorised use.

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2.4 Personal protective equipment
In order to minimise negative effects on personal health,
personal protective equipment must be worn during operation.
 Always wear the protective equipment required for the work in
question during work.
 Observe signs for personal protective equipment in
the work area.
Always wear Always wear the following during all work:
Protective work clothing
The protective work clothing is tight-fitting, rips easily if caught,
has narrow sleeves and has no protruding parts. It is primarily
intended as protection from being caught by moving machine parts.
Do not wear rings, chains and other jewellery.
Safety shoes
Protect against heavy falling parts and slipping on slippery surfaces.
Safety goggles
Protect the eyes from flying projectiles and splashing liquids.
Light breathing protection
Protects against dangerous dust.
Ear protection
Protects against damage caused by loud noises.
Safety helmet
Protects against falling and flying parts and materials.
Safety gloves
Protect hands from friction, scraping, punctures or deeper injuries
as well as from contact with hot surfaces.

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Wear for special tasks Special protective equipment is necessary for certain specialist
tasks. These are specially indicated in the individual manual
chapters. These special pieces of equipment are as follows:
Face guard
Protects the eyes and face from flames, sparks or embers as
well as from hot particles or exhaust gases.
2.5 Special dangers
The following section details other elements of risk that can occur
according to the risk assessment.
Pay attention to the safety instructions and warnings in the other
chapters of this manual in order to reduce health risks and avoid
dangerous situations.
Electric current
DANGER!
Danger of death due to electric current!
Contact with live components can lead to death
or serious injury. Damage to electrical insulation
or individual components can be potentially
life-threatening.
Therefore:
– If the insulation is damaged, switch off the
power supply immediately and have it repaired.
– Work on the electrical system must only be
carried out by qualified electricians.
– When carrying out any work on the electrical
system, switch it off and check that it is
voltage-free.
– Before maintenance, cleaning and repair work,
switch off the power supply and secure it
against being switched on again.
– Do not bypass or disable any fuses.
Pay attention to the correct amperage
when replacing fuses.
– Keep moisture away from live parts.
This can lead to a short-circuit.

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Escaping material
DANGER!
Danger of injury due to escaping material!
Escaping material can cause injuries to the eyes
and face.
Therefore:
– Always wear protective goggles
– Always position the machine so that you
cannot be hit should mortar escape.
Noise
WARNING!
Danger of damage to hearing!
The loud noises associated with the work area can
cause serious damage to hearing.
Therefore:
– Always wear ear protection when working.
– Only remain in the danger zone for as long
as absolutely necessary.
Hazardous dust
WARNING!
Danger of health problems due to dust!
Inhaled dust can lead to long-term lung damage
or other health problems.
Therefore:
– Wear light respiratory protection for all work in
the danger area.

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Moving parts
WARNING!
Danger of injury due to moving parts!
Rotating and oscillating parts can cause serious
injuries.
Therefore:
– Do not reach into or handle moving parts
during operation.
– Do not open covers during operation.
– Observe the run-down time:
Before opening covers, ensure that parts are
no longer moving.
– Wear close-fitting protective clothing in
the danger zone.
Dirt and objects lying around
CAUTION!
Risk of tripping due to dirt and obstacles
lying around!
Dirt and other impedances can form a slipping or
tripping hazard, and can lead to significant injuries.
Therefore:
– Always keep the work area clean.
– Remove objects when they are no longer
needed.
– Indicate tripping hazards with yellow
and black tape.

PFT Air Compressor LK 402 IV Overview – Operation – Spare Parts Lists
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2.6 Safety devices
WARNING!
Danger of death due to non-functioning
safety devices!
Safety devices provide the highest possible levels
of operational safety. Even if safety devices make
work processes more complicated, they must never
be disabled. Safety is only assured when the safety
devices are intact.
Therefore:
– Check that the safety devices are functional
and correctly installed before starting work.
– Never disable safety devices.
– Do not obstruct access to safety devices such
as emergency stop buttons, ripcords, etc.
The following safety device is installed:
1
Fig. 1: Main switch
Main switch
The main switch (1) is also designed as an emergency stop switch.
By pressing the main switch, the power supply is switched off
immediately and an emergency stop is triggered.
WARNING!
Danger of death due to uncontrolled
reactivation!
Uncontrolled reactivation can lead to serious injury
or death!
Therefore:
– Before switching the system back on, ensure
that the cause of the emergency stop has been
solved and the safety devices are attached and
fully functional.

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2.7 Dealing with dangerous situations and accidents
Preventative measures  Always be prepared for accidents or fire!
 Keep first aid equipment (first aid kit, blankets, etc.)
and fire extinguishers handy.
 Familiarise personnel with accident reporting, first aid
and rescue equipment.
 Keep access roads clear for rescue vehicles.
In an emergency: Act correctly  Trigger emergency stop immediately.
 Initiate first aid measures.
 Rescue people from the danger zone.
 Inform supervisors at the site.
 Alert doctor and/or fire brigade.
 Clear access roads for rescue vehicles.
2.8 Signs
The following symbols and notices are located in the work area.
They refer to the immediate vicinity in which they are attached.
WARNING!
Danger of injury due to illegible symbols!
Over the course of time, labels and signs
can become dirty or unreadable.
Therefore:
– Always maintain all safety, warning and
operating notices in legible condition.
– Replace damaged signs or stickers at once.

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Running machine
Do not reach into the machine while it is running.
Maximum pressure
Do not exceed the maximum pressure.
Hand injury
Keep hands away from areas displaying this warning symbol.
There is a risk of hands becoming crushed, drawn in or
otherwise injured.
Automatic startup
Machine starts up automatically.
Electrical voltage
Only electricians may work in areas with this designation.
Unauthorised individuals may not enter such designated
work areas or open cabinets with this designation.
Moving machine parts
Maintenance work on opened machines may only be performed by
specially trained technicians. There is a risk of injury while
the machine is moving.
Compressed air
Warns about the presence of compressed air.
Danger point
Warns about a danger point in work areas.
Safety gloves
Protect hands from friction, scraping, punctures or deeper injuries
as well as from contact with hot surfaces.

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Observe the operating manual
Only use the designated object after reading the operating manual.
Face guard
Protects the eyes and face from flames, sparks or embers as well
as from hot particles or exhaust gases.
Running machine
Do not reach into the machine while it is running.
Safety devices
Use safety devices.
Rotating parts
Do not reach into rotating parts.
No maintenance work
Do not perform any maintenance while the machine is running.
Touching prohibited
Touching containers or parts may destroy them.

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3 Operation
3.1 Preliminary remark
This manual is an integral part of the compressor and must be kept with it.
Keep the manual in a suitable place and be careful not to damage it.
If the compressor is sold, the manual must be handed over to the new owner who needs the information it
contains.
Read this manual carefully and familiarise yourself with its contents before operating the compressor.
If you have any questions about operation, please consult the manual immediately.
This manual contains important safety information describing special measures that may result in personal
injury or damage to equipment if not followed. In addition, you will find useful information to facilitate the use
and maintenance of the machine.
If the manual is lost, please request a copy.
Customer service and spare parts service
Only use original spare parts for servicing the compressor.
Non-original spare parts involve risks that may cause personal injury. In order to guarantee a faultless
service, as well as for each request, please always indicate the model, type and identification number
of your compressor. You will find this information on the compressor nameplate.
Product identification
The product you purchase is marked with a CE label providing the following data:
1. Manufacturer data,
2. CE mark – year of construction,
3. TYPE = Designation of the compressor,
CODE = Compressor identification number,
SERIAL N. = Serial number of the acquired
compressor
(Always specify in case of customer service requests).
4. Air generation of the compressor measured in (l/min) and (cfm).
5. Max. Operating pressure (bar and PSI) – Compressor sound pressure dB(A).
6. Electrical data: Supply voltage (V/ph), frequency (Hz), consumption (A) – Power (PS and kW), U./min (Rpm).
7. Any other approval symbols.