ALFRA AHP-L 23190 Installation manual

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ALFRA Hydraulikpumpe AHP-L
Elektrische Hydraulikpumpe
Electric Hydraulic Pump
Pompe hydraulique électrique
Elekrohydrauliczna pompa
Art.-Nr. 23190 / Prod.-No. 23190 / N° de produit 23190 / Artykuł nr. 23190

12
Dear customer,
Thank you for purchasing an ALFRA product. Please read these operation instructions closely before using your
device for the first time and keep them along with the enclosed Product Control Card for later reference.
Safety Instructions
Danger can occur when working with high pressure hydraulic pumps due to improper handling and/or poor
maintenance, which may lead to the destruction of the device and to severe physical injuries. Please observe all
safety instructions of this operation manual and contact our Service Team if you have any questions.
Important:
Caution! Hydraulic oil may become hot in the event of extended use. Risk of injury!
Do not move tools under full pressure to the block or as far as they will go. Failure to do so can
shorten the lifecycle of your tool.
Always...
use the ventilation bolt to let the oil tank breathe
install the sealing plug bolt for transport. Failure to do so can cause oil leakage.
provide sufficient ventilation
check electric and hydraulic connection cables for damage
make sure the mains voltage matches the machine
follow the instructions in these operation instructions
familiarize new users with the safe use of this machine
wear safety goggles and ear protection during work
observe local, country-specific guidelines
store in a dry and well-ventilated place
Never...
modify this machine or remove signs
use unknown or damaged tools
use this pump when damaged or when parts are missing
open couplings under pressure
put non-connected hose couplings under pressure
use this hydraulic pump without having been properly instructed
operate this machine without having read and understood the complete operating manual
store or operate this hydraulic pump at temperatures above 45°C (113°F)
leave this machine running unsupervised
allow the machine to come into contact with corrosive materials
use in an environment where there is a risk of explosion
Specified Conditions of Use
The ALFRA AHP-L hydraulic pump is a single-acting radial piston pump and is destined to be used for single-acting
hydraulic tools with automatic oil return and sufficient pressure stability.

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Technical Data
Prod.-No. and description:
23190 AHP-LHydraulic Pump
Input:
2200 Watt
Load rpm:
2860 1-min
Voltage:
230 V 50 Hz
Imax @700 bar:
9.8 A
Hydraulic medium:
HLP 46 oil
Max. pressure:
700 bar
10150 psi
Max. delivery volume:
1.7 l/min
0.45 gal/min
Tank volume:
3.0 l
0.79 gal
Operating volume:
2.2 l
0.58 gal
Weight:
35 kg
70lbs
Noise emission:
92 dB(A) @ 300 mm distance
from the motor
Vibration on the handle:
AC=3.5 mm/s² and VC=3.2 mm/s
AvailableAccessories Prod.-No.
Extension hose On request
ALFRA Service-Boy transport cart 23160
Hydraulic oil HLP 46 (5 l) 3000

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Description
The single-acting hydraulic pump ALFRA AHP-L is a radial piston pump equipped with a high performance electric
motor (1) and achieves optimum delivery volume with three pump elements. Two stable carrying handles (2) can
be found on both sides of the pump around which the electric feed lines can be wound if necessary.
The mains (4), the connection for the commanding feed (6) and the nameplate (7) are located on the front side.The
pump is put into standby by pressing the main switch (5) and can then be activated via the commanding signals of
the tool. A window (8) next to the carrying handles allows the operator to check the oil level inside the tank at any
time. The incorporated asynchronous motor is smooth-running and equipped with an operating capacitor (12) and a
start capacitor (14). The integrated magnetic valve (16) controls the generated oil flow and maintains the pressure
within the tool when the pause function is activated. If the working pressure inside the tool exceeds the maximum
regulated pressure of the pump, the excess pressure valve (15) opens and guides the oil back into the pump tank.
The oil tank vent (10) is closed by means of the air-pervious ventilation bolt during operation and the sealing plug
bolt (11) during transport.
1) Motor
11) Plug bolt
2) Carrying handles
12) Operating capacitor
3) Connection foroilfeed
13) Starting current limitation
4) Mains
14) Start capacitor
5) Mains switch
15) Excess pressure valve
6) Connection for commanding feed (five pole)
16) Magnetic valve
7) Nameplate
17) Printed circuit board
8) Window for oil level
18) Motor contactor
9) Attachment clip
10) Oil tank vent with ventilation screw

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Start-up
You receive a completely assembled hydraulic pump and a detailed operating manual. Please check the condition
of the goods on receipt for any transport damage, and make sure the delivery is complete. Otherwise contact the
manufacturer or distributor immediately.
Always read the operating manual before using this device for the first time!
1. Check the oil level trough the lateral window and refill new oil (HPL 46) if necessary.
Note:
The oil level of the AHP-L should be between the "Min" - "Max" markings on the side of the pump housing
during standby mode. This ensures that there is sufficient oil during use of the connected tools to fill the
cylinder and to prevent the pump from running dry.
2. Check the cable and connector for damages, and then plug in the power plug.
3. Check the hydraulic hose for pinches or any other damage and connect it to the quick coupling ofthe pump and
the tool.
4. Before using the pump forthe first time be sure to replace the sealing plug bolt (black) on top of the tank with the
air-pervious ventilation bolt (orange). This will allow the air to flow through the oil tank.
5. Connect the control cable of the toolto the 5-pole flange socket.
6. Turn the main switch to the position (I) to switch the pump on and to put it into standby mode.
7. Position the desired material in the tool and ensure a central position according to your application.
Be sure to observe the operation and safety instructions of the connected tool.
Do not use any tool if it is damaged or if you are not familiar with its use.
8. Push the start button on the tool to activate pump motor and magnetic valve. The oil flow is released into the
tool.
Depending on the tool, the operator can use the pause function to interrupt the tool’s operation. Although
the motor will stop during the pause function, the magnetic valve remains activated. Thus, the tool does
not return to its starting position and the pressure inside the system stays constant.
9. After use, push the stop button to deactivate the pump and the magnetic valve. The oil can now flow back out of
the tool and into the pump tank and the tool returns to is starting position.
10.To switch the pump off, turn the main switch into the position (O). Replace the ventilation screw with the plug
bolt before transport to prevent the pump from leaking.

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Positioningthe Pump during Operation
The tank of the AHP pump is closed by the ventilation screw and thus is not sealed. To prevent the hydraulic oil
inside the tank from leaking or overflowing, the pump must not be used at a sharp slope.
When the pump is used frequently, foam can occur on the oil surface which, when the pump is used in a highly
sloped position, can flow out of the ventilation screw into the oil tank vent. It is preferable to align the pump
horizontally.
Oil Change
Regular maintenance of the pump will extend the lifetime of seals and moving parts. If the hydraulic pump is used
frequently, the oil must be completely replacedto eliminate suspended matter and deposits.The first oil change
should be carried out after approximately 50 hours of operation. Be sure to change the hydraulic oil once a year.
Wear safety goggles and ear protection!
1. Disconnect the pump from the mains.
2. Remove the plug bolt and screw the 1/2“ threaded nozzle (2) with the silicon hose (1) into the opening of
the tank.
3. Incline the pump forward and let the oil flow into a collection container.
4. Turn the pump to a horizontal position and remove the threaded nozzle and the silicon hose. Refill the tank
with hydraulic oil type HLP 46 (approx. 3 litres).
Deaerate the pump before using tools and cylinders for the first time!
5. To deaerate the pump, put the coupling piece onto the final coupling of the hose set.

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6. Activate the pump and let the oil flow back into the opened tank. Inclining and tilting the pump slightly will
allow you to remove enclosed air cushions.
7. Let the power unit produce oil for 60-120 seconds.When the oil is flowing out of the hose equally and
without any air bubbles or interruptions, the pump is deaerated sufficiently and ready for further use.
8. Remove the coupling piece from the hose.
9. Check the oil content once again. Close the oil tank vent with ventilation screw if you will continue using the
pump, if not, close it using the plug bolt.
Hydraulic oil is harmful to the environment and must be disposed of correctly in compliance
with local standards and regulations.
Maintenance and Inspection
The user is obliged to maintain and service the Hydraulic Pump in compliance with the specifications in the
operating manual and according to the country-specific standards and regulations.
Maintenance, testing and repair work may only be carried out by qualified electricians according to the regulations
valid in the respective country.
The maintenance intervals are classified according to the frequency with which the maintenance should be carried
out.
Always disconnect the machine from the mains before any maintenance operation and repairs.
Beforeeveryuse…
inspect the pump and hoses for visible signs of damage
check the correct, firm fit of the couplings
check connection cables for damage
Weekly…
use dry compressed air to blow the motor compartment out from the outside
Monthly…
check the markings and labelling on the pump for legibility and damage. Replace them if necessary
check the oil level and fill oil up to "Max" if necessary
Annually…
perform a complete oil change with 3 liters of HPL46 hydraulic oil
Only use original ALFRA spare parts.
View our detailed spare parts list at the end of this operation manual.

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Troubleshooting
Maintenance, testing and repair work may only be carried out by qualified electricians according to the regulations
valid in the respective country.
Error
Control
Cause
Repair
The main switch does not
light up when the pump is
switched on.
Check the power supply
and the mains.
The mains is not or not
correctly plugged in.
Have the electrical
connection checked and
repaired by
a qualified electrician.
Cable break or damaged
mains.
The fuse has triggered
due to fault current.
The motor does not start
or move.
Is the commanding feed of
the tool connected?
The commanding feed is
not or not correctly
plugged in.
Have the electrical
connection checked and
repaired by
a qualified electrician.
Did you choose a suitable
tool and the correct
control?
The pin assignment and
the tool buttons must
match the pump.
Chose a compatible tool
or consult with the
manufacturer.
Did you choose a suitable
hand or foot switch?
The pin assignment and
the tool buttons must
match the pump.
Chose a compatible hand
or foot switch or consult
with the manufacturer.
Did the electrical fuse
protectionofthe power
supply trigger?
The power supply is not
sufficient tothe max.
current demand of the
electric motor.
Connect the motor to a
suitable power supply.
The electrical fuse
protection is not
dimensioned sufficiently.
Use another protection,
circuit breaker 16A type B
Does the PCB work
properly? Is the mains
voltage applied to the
motor cable or the motor
terminal box?
The PCB is defective or
incorrectly connected.
Have the electrical
connection checked and
repaired by
a qualified electrician.
Replace the component or
have the pump repaired
by the distributor or
manufacturer.
Is it possible to move the
motor fan?
Be sure to disconnect the
pump from the mains.
The motor is mechanically
blocked due to overload,
contamination or foreign
matter.
Replace the component or
have the pump repaired
by the distributor or
manufacturer.
The contactor is not
energized.
The contactor is defective,
the connections are burnt.
Replace the component or
have the pump repaired
by the distributor or
manufacturer.
The starting current
limitation is defective on
the side of the motor or is
not conducting anymore
(approx. 5 Ohm resistance
at 25°C body temperature
of the IRC thermistors).
The IRC thermistor is
defective due to overload
or wear.
Replace the component or
have the pump repaired
by the distributor or
manufacturer.
The electric motor rotates
just slightly or does not
deliver full power.
Is an extension cable or
cable reel used to connect
the pump to the power
supply?
The cable is not unrolled
completely.
Unrollthecablecompletely.
Conduction loss
(electrical resistance too
high)
Use a shorter extension
cable or a cable with a
higher cable cross-
section.
AHP-L only

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Is the tool in its final
position?
The capability of the pump
to start against counter-
pressure is limited (appr.
200-300 bar).
Let the tool return to its
starting position or reduce
the pressure on the tool or
inside the hydraulic
system.
Isthe tool under a high
hydraulic pressure?
Check the start capacitor
and the operating
capacitor.
The start capacitor or the
operating capacitor is
defective.
Replace the component or
have the pump repaired
by the distributor or
manufacturer.
The connected tool does
not move.
Is the power supply
ensured?
See above
See above
Doesthemotor turn?
Are the hydraulic
couplings correctly
connected?
The quick couplings are
not engaged completely or
the coupling connection is
not completely twisted
together.
Hydraulic couplings are
self-sealing and open only
if they are plugged
in/screwed in as far as
they will go.
Plug in / screw in the
couplings as far as they
will go.
The hydraulic coupling is
dirty and does not close
correctly.
Clean the couplings and
plug/screw them in as far
as they will go.
Replace the component or
have the pump repaired
by the distributor or
manufacturer.
Is the magnetic valve
energized and does it
conduct the oil flow tothe
tool?
Push the plastic cap of the
valve and feel if there is a
slight movement.
The magnetic valve is
defective or overheated.
Replace the component or
have the pump repaired
by the distributor or
manufacturer.
Check the power supply of
the magnetic valve.
Wrong commanding signal
or defective PCB.
Have the electrical
connection checked and
repaired by
a qualified electrician.
Replace the component or
have the pump repaired
by the distributor or
manufacturer.
The tool does not come
out completely or does not
build up any pressure.
Did you mount the
ventilation screw to the oil
tank?
The oil tank is not aerated
sufficiently.
Screw the ventilation
screw into the oil tank
vent.
Check the oil level inside
the tank.
The oil level inside the
tank is too low.
Fill the tank with a
sufficient quantity of
hydraulic oil HLP46.
The pressure is not built
up completely on the tool.
There is air inside the
hydraulic system.
Deaerate the pump, hoses
and tool.
Try another tool and check
its function.
The toolisdefectice.
Replace or repair the tool.
Is the oil foaming and is
there enough oil inside the
tank?
The suction filter is dirty or
blocked.
Replace the component or
have the pump repaired
by the distributor or
manufacturer.

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Markus A. Döring
(Managing Director)
EC Declaration of Conformity
Herewith we,
Alfra GmbH
2. Industriestr. 10
68766 Hockenheim
declare that the hydraulic pump
ALFRA AHP-L
corresponds to the following directives:
Machinery Directive: 2006/42/EC
Low Voltage Directive: 2006/95/EC
Electro-magnetic compatibility (EMC): 2004/108/EC
RoHs Directive: 2011/65/EU
Following directives or normative documents were applied:
Machinery Directive:
EN 61029-1:2009
Low Voltage Directive:
EN 60204-1:2006+A1:2009
EN 60034-1:2010
EN 60034-5:2001+A1:2007
EMC Directive:
EN 55014-1:2006+A1:2009+A2:2011
EN 55014-2:1997+A1:2001+A2:2008
EN 61000-3-2:2006+A1:2009+A2:2009
EN 61000-3-3:2008
RoHs Directive:
EN 50581:2012
Authorized for the compilation of the documents:
Alfra GmbH
2. Industriestr. 10
68766 Hockenheim, Germany
Hockenheim, 03.04.2017