alkitronic X E Series Operating instructions

Operating and
maintenance manual
Electric torque multiplier
E Serie
E (PG)

2
Foreword
Congratulations on your purchase of an alkitronic® electric
torquemultiplier.Thisproduct setsthe highestinternational
standardsforqualityandsafety.Tomaintainthesestandards,
please read and follow the information and instructions
found in the operation and maintenance manual.
Maintenance and repair of the alkitronic®electric torque
multiplier must be performed by alki TECHNIK GmbH or
certied workshops trained and instructed by alki TECHNIK
GmbH.
Improper maintenance may endanger you and damage the
unit. Non-compliance with any of the above items voids all
warranty claims!
The operation and maintenance manual contains all basic
information and instructions. The operator must read, un-
derstand, and observe this material together with the basic
precautions before either using or attempting to maintain
the alkitronic® electric torque multiplier.
The manual must always be available on site.
This operation and maintenance manual applies only to the
alkitronic® electric torque multiplier.
Observe the“Safety information”found in section 2, and all
other special instructions in other sections.
Content Table Page
A Reception Control and Packaging 3
B General Description 3
B1 Model Description 3
1. Technical Data 3
Accessories 3
2. Safety Instructions 4
2.1 Intended use 4
2.2 Operators responsibilities 4
2.3 Possible hazards 4
3. Operation 4
3.1 Placing tool in operation 4
3.2 Preparing for bolting 5
4. Electric Operation 5
4.1 Operating elements 5
4.2 Setting torque value 6
5. Mechanic Operation 6
5.1 Tightening and loosening 6
5.2 Correct tightening and loosening 6
5.3 Working steps 7
6. Ending or Interrupting the Work 7
7. Functional and Operational Tests 7
8. Service / Storage / Taking out of operation /
Maintenance 7
8.1 Accessories change 7
8.2 Storage in original packaging 8
8.3 Taking out of operation 8
8.4 Maintenance intervals 8
9. Technical Notes 8
10. Acoustic Emission and Vibration 8
11. Declaration of Conformity 8
12. Appendix
Technical Data 9
Safety instructions.
Non-compliance may result in personal injury
or death.
Safety instructions.
Non-compliance may result in damage to the
alkitronic® NOVA Hydraulic Power Unit, its func-
tions, or the environment.
Information for proper and safe operation.
Practical advice and information to make work
easier.
Denition of Symbols
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Operation and Maintenance Manual

3
A Reception Control and Packaging
Inspect all components for possible damage.
If shipping damage is found, notify the forward-
ing agent immediately. Return components in
the original package to avoid additional damage.
Therefore, please keep the packaging.
B General Description
The alkitronic® electric torque multiplier is a strength power-
operated torque multiplier for continuously tightening or
loosening heavy duty bolt connections.
The torque multiplier turns itself o on reaching the selected
value or nal torque.
The tool is driven by a single phase alternating current motor
with a large torque range and high working speed . Consistent
torque accuracy is achieved through constant electronic mon-
itoring, combined with an electronic automatic switch-o.
B 1 Model Description
alkitronic® E, torque has ranges up to approx. 10,000 Nm
(7,375 ft.lbs), 2 speeds (Power Gear/Run-Down Gear) and
clockwise/anti-clockwise direction. The 360 degree rotating
handle ensures comfortable and safe operation. The sturdy,
ergonomic housing is made of high impact resistant plastic.
1. Technical Data
Supply voltage : 220 V-240 V
Supply frequency : 50 Hz
Nominal power max. : 0.9 kW
Ambient temperature : -20OC to +50O C / -4OF to +122O F
Repeat shut-o accuracy : ± 4%
Housing: Protection Class II, protection type IP20
Additional handle
alkitronic® STACO
Standard socket
alkitronic®STABI
Standard connector
alkitronic® DMA
Torque reaction arm
alkitronic® accessories for torque multiplier with axial drive.
alkitronic®Accessories
Due to the specic selection of
our wide range of accessories,
the operator can apply these
to a broader workeld.
For individual solutions your
alkitronic®Partner or alki
TECHNIK GmbH will gladly
advise you.
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Eelectric torque multiplier

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Operation and Maintenance Manual
2. Safety Instructions
2.1 Intended use
alkitronic® electric torque multipliers are designed to tighten
or loosen heavy duty bolt connections continuously. Do
not use the torque multiplier for any other purpose than its
stated, intended use. For other applications please consult
alki TECHNIK GmbH.
2.2 Operators responsibilities
The operator must have read and understood the
instructions of this operation and maintenance
manual before using or servicing the alkitronic®
electric torque multiplier. Minimum age of the
operator must be 18 years.
Operation and service may not be performed, if
the concerned person does not understand the
purpose, consequences and precise performance
of each procedure. For questions regarding the
safety measures and areas of application, your
alkitronic® Partner will be pleased to assist you.
Improper operation, incorrect application, abuse
or use by unqualied personnel may be hazardous
to other persons, operator, torque multiplier and
other property.
The operator is responsible to third parties within
the work area. Keep children and bystanders away
while operating the torque multiplier.
Do not operate alkitronic® electric torque multipli-
ers in explosive atmospheres, such as ammable
liquids, gases, or dust. For operation outdoors or
in humid rooms, observe the relevant regulations.
Non-authorized alterations and modications of
the torque multiplier are not permitted.
2.3 Possible hazards
Maintain the alkitronic® electric torque multiplier.
Check for broken parts/accessories, damaged
power supply cord, and any other condition that
may affect the tool operation. In case of dam-
age the torque multiplier must immediately be
inspected by a qualied technician for electrical
safety and mechanical defects. Repairs may only
be performed by authorized personnel. All safety
and mechanical defects must be eliminated before
resuming operations.
To avoid electrical shocks or malfunctions only use
the marked extension cords outside.
3. Operation
Before connecting the electrical power, ensure
the indicated technical data on the tool type plate
as well as in the operation manual corresponds
with the power supply and environmental condi-
tions to avoid malfunctions or severe damages.
The alkitronic® torque multiplier is a protective
insulated tool and is supplied with a 2-wire power
cord. Possible replacement of the mains plug
(due to nationally dierent power grids or plug-in
connections) may only be carried out by trained
specialist personnel.
Local regulations for the working environment
must be complied with. The alkitronic® electric
torque multiplier is not suitable for work in
hazardous areas (gas, varnishes, fertilizers, petrol
stations, etc.)
alkitronic® torque multiplier must not be moist
and should not be operated in a humid environ-
ment. A rain cover must be provided.
Depending on the working environment and the
application, local regulations can order wearing
body protection (e.g. safety shoes, helmet, etc.).
Failure to observe such regulations may result in
severe physical damage (e.g. electric shocks, bruis-
ing, head injury due to ying metal parts).
Wear hearing protection during bolting!
In case of power failure or malfunction, the screw-
driver must be switched o immediately via the
mains switch.
3.1 Placing tool in operation
The alkitronic® torque multiplier must always be prepared
for its dierent applications.
alkitronic® STACO/STABI/STA/DMA (specic nuts, connectors,
adaptors and reaction absorbers) available as accessories, are
needed to accord with a specic bolt joint.
The torque multiplier must be disconnected from
the power source before making any adjustments
or changing accessories.

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Eelectric torque multiplier
Safety check
• Accessories may be placed on the tool drive
side. Make sure every part is placed correctly
and secured (in compliance with item 3.2
Pre-
paring for bolting).
• Replace worn or damaged accessories im-
mediately. For replacement, use the original
alkitronic® accessories only. This will reduce the
risk of malfunction and serious personal injury.
• Put STACO / STABI (2)/(3) on, the square drive (both bore-
holes, adaptor and square must correspond).
• Insert safety pin (7). Secure with rubber ring (6).
• STABI: screw in safety screw (8) completely.
alkitronic® STABI
3
8
alkitronic® STACO
2
6
7
For a DMA without a safety screw, a safety ring DMAR is ob-
tainable as an accessory. The safety ring prevents the DMA
from loosening. It can be put additionally on the toothing
and then screwed together.
1
DMA Safety screw
DMAR Safety ring (accessories)
alkitronic® DMA
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3.2 Preparing for bolting
• Place the alkitronic® torque multiplier on a at surface.
• If the DMA is secured with a safety screw, remove the
safety screw completely (the position of the screw can
vary dependent on type).
• Insert DMA reaction arm (1) in to toothing (4);
• Screw in safety screw completely again - the DMA
is secured.
Schematic drawing assembly
4. Electric Operation
4.1 Operating elements
CW/CCW
direction
lever
(2) Switching lever
Gear I / II
(1) Setting torque
(thumbwheel with 7
position numbers)
Start / Stop
Button

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Operation and Maintenance Manual
Always place STACO/STABI completely on the bolt/
nut. For individual DMA solutions, your alkitronic®
Partner will assist you.
Improper bolting connection or incorrect reaction
support may cause:
- Strain breakage in STACO / STABI adaptors,
bearing or output square drive;
- Bruises or even life-threatening injuries (parts
splintering o);
- “Shut-o“ torque failures.
Non-compliance with any of the above items will
void all warranty claims.
5. Mechanic Operation
5.1 Tightening and loosening
Safety hints
Comply with all applicable local, state and national
electrical and safety regulations.
Always carry out a function inspection and safety
check - no working with damaged parts!
Keep hair, clothing, and gloves away from moving
parts. Loose clothes, jewellery or long hair can be
caught in moving parts (alkitronic® DMA/ STACO/
STABI/STA).
Maintain a safe distance when tightening bolts or
nuts. Do not leave the torque multiplier unattended
during use.
Stand and balance properly to ensure better control
of the torque multiplier in unexpected situations.
5.2 Correct tightening and loosening
Never place your hand or ngers between the DMA
and the support point to avoid injuries.
Bolting direction
Reaction moment
4.2 Setting torque value
The torque setting on the alkitronic® torque multiplier must
be eected by the thumbwheel (1) and the gear selector
lever (3) according to the torque table (A).
The desired torque value is assigned to a position number on
the thumbwheel (1). The selection must be visually centered.
The example shows the setting of the shutdown torque
1060 Nm in the fast speed (Gear II).
Check the gear selector lever (3) is correctly po-
sitioned. Change it only when the motor is not
running to avoid damaging the gear parts.
Gear I / II
(3) Gear selector
lever
(1)
(A) Torque table
Gear II
Gear I
The torque of an interim value (Z)
is to be taken from standard torque
chart/data sheet.
(Z)
(Z)
(Z)
Thumbwheel
Thumbwheel

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Eelectric torque multiplier
5.3 Working steps
• Connect the torque multiplier to the power supply.
• Place the alkitronic® torque multiplier with alkitronic®
STACO/STABI completely on the bolt/nut.
• The DMA or torque-on recipient of the torque multiplier
must be at the same height as the socket/adaptor to take
the reaction moment.
• A sure, stable reaction point (2) must be ensured.
• Always keep the torque multiplier in axis line to the bolt
during the bolting process.
• Press start button (rotation direction CW) and start bolt-
ing process.
• The drive stops when it reaches the desired torque value.
• If the torque multiplier is not removable from the
bolted joint (torsional forces caused):
Press start button (rotation direction CCW!) briey.
This leads to a“run free“ of the reaction absorber DMA.
For your information:
When loosening a bolted connection, up to 20% higher
torque may be required (loosening torque)!
• Place on next bolt/nut and start bolting process.
Make every release with gear I, to avoid the motor
heating up strongly.
incorrect
correct
Correct torque reac-
tion point in marked
area only
incorrect
2
1
6. Ending or Interrupting the Work
alkitronic® electric torque multiplier
- Switch o and disconnect the cord plug from
the power socket.
- Do not misuse the power cord. Never use the
cord for carrying, pulling, or unplugging the
tool. Keep the cord away from heat, oil, sharp
edges or moving parts. Damaged or tangled
cords increase the risk of electric shock.
- Place the torque multiplier on a at and dry
surface. Avoid soiling and/or blocking the
ventilating openings.
7. Functional and Operational Tests
Optical and mechanical inspection
Check for intactness regularly, power cord and
plug, display and operating elements, gear box,
drive element, housing and accessories. Before
further use of the torque multiplier, damaged
parts should be properly repaired or replaced.
Serious damages and many accidents are caused
by poorly inspected tools.
Keep the ventilating openings on the torque
multiplier free to reduce the risk of malfunctions,
electronic and motor damage.
In case of performance loss, strong gear noises or
recognisable heavy damage, repair immediately.
For repairs, the alkitronic® torque multiplier (in
original package) must be sent to the appropri-
ate alkitronic® Partner or directly to alki Technik
GmbH.
Observe the following operation and service requests
strictly!
8. Service / Storing / Maintenance
8.1 Accessories change
Note item “3.2 Preparing for bolting“
Perform the described steps in reverse order.
Never block the Start/Stop button or a proper
operation is not possible any more!
The bolting operation must last at least 3 sec.
Otherwise the shut-o torque is not reached.
Do not retighten the nut. Because the preset
torque is exceeded and it can lead to dam-
age to the torque multiplier or to the screw /
threaded bolt.

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Operation and Maintenance Manual
8.2 Storage in original packaging
The alkitronic ® torque multiplier should be stored
dry, cooled down and dust-free in its alkitronic ®
originalpackaging orin anotherlockablecontainer.
Warmth and humidity may lead to oxidations in
gear parts and in other parts within the tool
housing. Take care that the power cord is neither
clamped nor entangled and damaged in any
manner.Followingtheseruleswill reducetherisk
of malfunctions, electronics and motor damage.
8.3 Taking out of operation
If the alkitronic® electric torque multiplier is to be
stored for a long time:
Store the tool cleaned in a dry room, out of the
reach of children. Avoid excessive exposure to heat
and moisture. Protect moving/rotating tool parts
against oxidation.
Note additionally item 8.2 Storage in original
packaging.
8.4 Maintenance intervals
The alkitronic® electric torque multiplier is an ex-
tremely ecient and robust product. Nevertheless
to ensure lifetime and performance for years, a
regular maintenance is necessary (Performance-
Check, Motor-Check, Safety-Check, Calibration-
Service).
Maintenance periode
The torque multiplier must be inspected at least
once a year. After high stresses/loads or lengthy
hours of operation calibration and servicing must
be carried out more frequently.
Renew the carbon brushes after about 150 hours
of operation.
In the event unusual gear or bearing noises, lubricate
the transmission parts immediately to avoid serious
damage.
For of repairs the alkitronic®torque multiplier must
be sent to the appropriate alkitronic® Partner or
directly to alkiTechnik GmbHin its original package.
11. Declaration of Conformity
On our own responsibility we hereby declare alki Technik
GmbH that the alkitronic® electric torque multipliers identied
by Type E, Serie PG 2 .... and Serial Number: -8116...., -9116....,
-10116...., -11116...., -12116...., meet all relevant requirements
of directives:
2006/42/EC, 2014/30/EU, 2011/65/EU (RoHs),
2014/53/EU and Norms
EN 60745-1:2009+A11:2010, EN 60745-2-1:2010, EN
60745-2-2:2010, EN55014-1:2006+A1:2009+A2:2011,
EN 55014-2:1997+A1:2001+A2:2008, EN 61000-3-
2:2014, DIN EN 61000-3-3:2013, EN 50581:2012 .
2018-04-01
Alexander Kipfelsberger,
Managing Director
Techn. documents at alki Technik GmbH, Unterlettenweg 4,
85051 Ingolstadt / Germany.
Automatic or inverter regulations deliver a con-
stant output voltage as well as a constant output
current regardless of voltage drops, any spikes, the
load or heavy load uctuations. When operating
multiple appliances on one mobile generator at
the same time, the power consumption of all the
appliances must be taken into accounts.
Unregulated output voltage impairs operation
and may damage the electronics of the alkitronic®
torque multiplier extensively or even cause the
equipment to shut down. Additionally in case of
damage, warranty claims are at risk. Consistent
power output without spikes is extremely impor-
tant for safety in operation.
10. Acoustic Emission and Vibration
Sound pressure level at max. idling speed:
alkitronic®E, Model PG2 78 - 82 dB(A)
Sound pressure levels were measured for different work
cycles, with the sensor positioned at a distance of 1 m to the
geometric centre of the machine.
Vibration:
becomes moderate just before to reaching the pre-set torque.
9. Technical Notes
Notes regarding the operation of mobile
generators:
For proper operation ensure the power output of
the mobile generator is in accordance with the
power input of the alkitronic®torque multiplier.
Power output min. 1.5 kW upon operation of one
alkitronic®torque multiplier.
We recommend the use of regulated mobile generators.

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*) When loosening bolts, a higher torque (up to 20 %) may be necessary (release torque). We will be pleased to help you with your choice. **) Torque reaction arm
alkitronic®E Models: PG 2 / 80 PG 2 / 150 PG 2 / 250 PG 2 / 350 PG 2 / 600 PG 2 / 800 PG 2 / 1000
Torque range (approx.) gear 2 * Nm 370 - 580 540 - 915 600 - 1100 650 - 1230 800 - 2330 900 - 2960 960 - 3580
Torque range (approx.) gear 1 * Nm 480 - 890 735 - 1500 1000 - 2500 1180 - 3500 2000 - 6000 2370 - 8000 2900 - 10000
Torque range (approx.) gear 2 * ft.lbs 270 - 425 400 - 675 440 - 810 480 - 910 590 - 1720 665 - 2185 710 - 2640
Torque range (approx.) gear 1 * ft.lbs 355 - 655 540 - 1105 735 - 1845 870 - 2580 1475 - 4425 1750 - 5900 2140 - 7375
Square drive B 3/4 " 3/4 " 1 " 1 1/2 " 1 1/2 " 1 1/2 " 1 1/2"
Diameter (approx.) D1mm 41 41 54 72 72 72 91
Diameter (approx.) D2mm 88 88 88 98 109 133 173
Length (approx.) L mm 480 480 530 550 560 565 590
Weight without DMA (approx.) ** kg 6,5 6,5 8 9,5 12 14,5 24,5
Idle speed gear 2 r/min 46 20 9 6 4 3,4 2,6
Idle speed gear 1 r/min 15 7 3 1,8 1,3 1,1 0,9
©alkitechnik / GBA E/2/09-09-21/4Pdesign/
alki TECHNIK GmbH reserves the right to change specications without prior notice
Technical Data
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Eelectric torque multiplier
12. Appendix

10
Notes
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Operation and Maintenance Manual