alkitronic XP Series Operating instructions

Operating and
maintenance manual
Compact torque multiplier
CL / RCL Series
CL

Operating and maintenance manual
2
Content Page
A Incoming goods inspection and packaging 3
B General description 3
1. Safety instructions 5
1.1 Obligations of the operator 5
1.2 Intended use 5
2. Operation 5
2.1 Commissioning 5
2.2 Preparing for use 5
2.3 Torque adjustment 6
2.4 Operating notes 6
2.5 Operation - Safety measures 7
2.6 Tightening and release - Safety measures 7
2.6.1 alkitronic® CLD, CLS, CLS2 8
2.6.2 alkitronic® RCL 8
2.7 Finishing or interrupting the work 9
3. Service 9
3.1 Changing from standard nut / connector and
DMA (CLD, CLS, CLS2) 9
3.2 Change alkitronic® STA and
support plunger on type RCL 9
3.3 Maintenance 10
4. Technical details 10
4.1 Air lubrication 10
4.2 Noise emission and vibrations 10
5. Declaration of conformity 10
6. Maintenance unit 10
7. Technical data 11
Introduction
We congratulate you on the purchase of a compressed air
powered alkitronic® torque multiplier. You have chosen
a high-quality product that sets new standards around
the world and meets high safety standards. To ensure this
high level, the product requires regular maintenance and
care. We therefore ask you to read these operating and
maintenance instructions carefully and to observe the
following points:
The alkitronic® torque multiplier is only to be repaired or
serviced by employees of alki TECHNIK GmbH, by those
trained by alki TECHNIK GmbH or a certied service pro-
vider.
There could be a risk of damage to health and damage to
the equipment if the product is not properly maintained or
operated. In addition, any warranty claim is then forfeited.
These operating and maintenance instructions contain
basic instructions that must be observed during opera-
tion and maintenance.They must therefore be read by the
operating sta prior to commissioning or maintenance.
They must therefore always be available at the area of ap-
plication of the alkitronic® torque multiplier .
These operating and maintenance instructions refer ex-
clusively to the alkitronic® torque multiplier.
Not only the general safety instructions listed under the
section„Labeling instructions“ need to be observed but
also supplementary regulations, instructions or advice,
depending on the situation.
Safety instructions.
Non-compliance may result in personal injury
or death.
Safety instructions.
Non-compliance may result in damage to the
alkitronic® torque multiplier, its functions, or
the environment.
Information for proper and safe operation.
Practical advice and information to make work
easier.
Denition of Symbols

Pneumatic Torque Multiplier
3
alkitronic®RCL
2 gear radial compact torque
multiplier
For use on protruding screw
ends such as plate heat ex-
changers. Torques up to ap-
prox. 3,390 ft.lbs, 2 gears.
alkitronic®CLS2
2 gear compact torque multiplier
Torques up to approx.
35,855 ft.lbs, 2 gears (overdrive /
power gear), right / left rotation.
Type CLS2
alkitronic®CLS
Compact torque multiplier
Fast rotating assembly mul-
tiplier. A secure support for
the reaction torque must be
ensured!
Torques up to approx. 1,070
ft.lbs, clockwise / anti-clock-
wise rotation.
Type CLS
S = Rigid
Type CLD
R = Rotatable
alkitronic®CLD
Compact torque multiplier
Torque up to approx. 7,225
ft.lbs, clockwise / anti-clock-
wise rotation, optional po-
sitioning of the control unit
thanks to rotatable mounting.
Type RCL
A Incoming goods inspection and packaging
All parts must be visually inspected for possible
transport damage. If damage is found, notify the
carrier immediately. Returns only in original pack-
aging, by doing so damage is avoided. Therefore,
keep the packaging!
B General description
The torque can be regulated via the air supply or via the
pressure regulator of a maintenance unit.The accuracy of the
torque depends on the stability of the air supply. An air pres-
sure of 3-7 bar (4 3-10,000 psi) at a ow rate of approx. 10-15
l/sec ( 122-915 cu.in./min) guarantee optimum working even
in explosion-protected working areas.

Operating and maintenance manual
4
Type CLD, CLS, CLS2
For special bolting the original accessories:
alkitronic®DMA (1)
alkitronic®STACO (2)
alkitronic®STABI (3)
alkitronic®STABI
Standard connector
alkitronic®DMA
reaction arm resp.
Torque reaction absorber
Type RCL
To reduce the wrench size alkitronic® STA (4)
alkitronic® STA
Standard adapter
Support plunger
The maintenance unit ensures
a long service life thanks to the
oiled operating pressure of the
alkitronic® torque multiplier
(see also section E, page 11).
• The water separator extends
the life of the motor blades.
• Accurate adjustment of the
torque is done via the DRV
(pressure control valve).
alkitronic®STACO
Standard nut
Support plunger
1
2 3
4
alkitronic®Accessories
Original accessories for
every type of bolting job

Pneumatic Torque Multiplier
5
2.2 Preparing for use
• Place the alkitronic® CL multiplier on a at surface
• Put support foot / DMA (1) on the gearing (4)
• Fix the standard nut / connector (2) / (3) to the square
shaft (5)
• Insert locking pin (7), secure with rubber ring (6)
or screw in the locking screw (8)
1. Safety instructions
1.1 Obligations of the operator
The user is obliged to read these operating and maintenance
instructions before carrying out any operation or service. al-
kitronic® torque multiplier operations may only be performed
by persons who are familiar with the purpose, consequences
and exact execution.
The user must not be impaired in any way, such as through
drugs, alcohol and medication.
1.2 Intended use
alkitronic® torque multiplier are suitable for continuously ro-
tating tightening and loosening of heavy screw connections.
Any other use, e.g. as a stirring or drilling machine, can cause
damage to the device and the operator. The torque multipli-
ers must not be subjected to external mechanical forces that
could lead to deformation. Other types of use not listed here
require the approval of alki TECHNIK GmbH.
If you have questions about safety measures and areas of ap-
plication, your alkitronic®Partner will be happy to help you.
Incorrect operation, improper use, operation by
unqualied personnel can cause serious personal
injury and property damage.
The user is responsible to third parties in the work
area.
2. Operation
Depending on the work environment and eld of application
for the alkitronic® torque multiplier, local regulations for the
wearing of body protection (eg safety shoes, helmet, etc.)
may apply.
Failure to comply with such regulations can result
in serious bodily injury (e.g. crushing, head inju-
ries from ying metal parts). When operating the
alkitronic® torque multiplier wearing of hearing
protection is mandatory. In continuous operation,
the handle housing cools down greatly. Wearing
gloves is therefore recommended.
2.1 Commissioning
Depending on the eld of applciation, standard nuts / con-
nectors, special torque transducers or adapters are required
for tightening and loosening screw connections (available as
accessories). The standard nuts / connectors are attached to
the output square and secured. Exchange see also Service,
section 3.1.
Before the compressed air is connected, the multiplier must
be prepared for the process:
alkitronic®STABI
Standard connector
3
8
alkitronic®STACO
Standard nut
2
6
7
alkitronic®DMA
Torque reaction absorber
alkitronic®
STACO
Standard
nut
1
2
5
4
• Conducting a security check for correct t of the adapter
• Check for possible damages of the DMAs or adapter
• In case of damage, replace immediately - do not continue
working. Only use original alkitronic® accessories or spare
parts!

Operating and maintenance manual
6
2.3 Torque adjustment
The torque depends on the upcoming air pressure
of the engine. The desired air pressure can be set
via the pressure regulator of the maintenance unit.
The torque setting for the alkitronic® torque multiplier must
be set either on the maintenance unit (appendix E) or on the
air supply in accordance with the enclosed characteristic
data sheet (see sample illustration on the right). For the CLS2
and RCL types, there are 2 gears available (Fig. 1), the fast
and the power gear. The torques (Nm) are listed on a table
and are readable on the upper side of the handle (Fig. 2) of
the alkitronic® multiplier. The torque specications are to be
regarded as adjusting aids. Option: Machine-specic torque
values can be factory determined with our calibration system.
Special connections and larger pressure and / or volume
uctuations in the supply network can lead to deviations. 2.4 Operating notes
During the rst hours of operation (start-up phase)
it is possible that there is a slight leakage of grease
on the housing shells. In this case, remove grease
to avoid slipping during operation or to avoid
contamination.
In the event of loss of performance or other identi-
able damage, send the alkitronic® torque multiplier
to your nearest alkitronic® Partner in the original
packaging as soon as possible or directly to alki
TECHNIK GmbH.
Type alkitronic® CLS2 und alkitronic® RCL:
Change gear (1st gear / 2nd gear) only when the en-
gine is stopped to prevent damage to the multiplier.
alkitronic® torque multiplier are designed for an
ambient temperature of -10 ° C to + 40 ° C. Exceed-
ing or exceeding these temperatures can cause
damage to the multiplier.
alkitronic®CLS2 / RCL
Sample illustration characteristics datasheet
Fig. 1
Fig. 2
I. Gear
II. Gear

Pneumatic Torque Multiplier
7
2.5 Operation - Safety measures
The operation of (Fig. 3) Clockwise / counterclockwise rota-
tion is set via the rocker switch (3) on the pistol grip. The
compressed air is supplied through the coupling on the
compressed air hose (1).
Before connecting the air hose, set the air pres-
sure according to the machine type (see technical
characteristic data sheet). For safety reasons the
maximum operating pressure of approx. 7 bar must
not be exceeded. The consequences are increased
wear with loss of performance or even destruction
of the motor.
Never improperly block the rocker switch (3) (Fig.
3).This will prevent the functions working properly.
An uncontrollable pneumatic multiplier can cause
physical injury and / or property damage.
Manipulating and/or interfering with the motor or
the valves of the alkitronic® torque multiplier lead
to a loss of warranty.
Be careful with high pressure components. Do
not kink hose and check for damage before use.
Damaged hoses or couplings must not be used.
Defective hoses can burst and whip uncontrollably
and cause injury.
The compressed air supplied must be clean and
particle-free, without water and other residues.
Dirt on the hose couplings or aggressive materials
entering the engine via the compressed air hose
can damage the blades.
2.6 Tightening and release - Safety measures
Due to a freely rotating DMA or rotating adapter,
loose clothing, long hair, cables etc. should always
be kept out of the danger / rotation area. When
putting the device into operation, ear protection,
safety shoes and goggles must be worn.
Never leave the alkitronic® torque multiplier unattend-
ed during operation and always be ready to switch it
o. Maintain safety distance of one arm length.
Never reach between the DMA and the support
lcoation. High risk of injury through crushing!
Always t the standard nut / connector or other
adapter completely onto the screw / nut. Improper
connection can lead to fractures due to mate-
rial overload, whereby splintering parts can cause
physical injury or even life-threatening injuries.
Due to the air-oil mixture which escapes from the
multiplier, a respirator mask must be worn, especial-
ly when working overhead or in conned spaces.
Due to the high strain of the alkitronic® pneumatic
motors, it is necessary to ensure an adequate oil
supply. Failure to do so may result in increased
wear of the slats with loss of performance or even
destruction of the motor.
The use of a maintenance unit is strongly recom-
mended in order to maintain a suitable oiled oper-
ating air (see also Service, section 3.3 Maintenance).
2-3 drops per min. is sucient in continuous opera-
tion (see also section 4.1 Air lubrication).
Fig. 3
1
3

Operating and maintenance manual
8
For the correct tightening and loosening of screw connec-
tions, the following steps are to be carried out (Fig. 4):
• alkitronic® CL with standard nut / connector (4), place
fully on screw / nut
• The outrigger (DMA) of the alkitronic® CL must absorb
the reaction moment at the height of the standard nut /
connector (4)
• A secure, stable counter support (5) must be ensured
• Always hold the alkitronic® CL in axis (6) to the bolt dur-
ing the process
• After pressing the rocker switch (3) for clockwise rotation,
the motor stops when the desired torque is reached:
a) Counterforce = Motor power
b) Counter torque = Motor torque
c) Predetermined torque is reached
2.6.1 alkitronic® CLD, CLS, CLS2
During operation, always hold the alkitronic® CL
multiplier in the axial direction (6) towards the nut,
otherwise this increases the risk of deformation /
damage to the standard nut / connector (4) or the
screw / nut which is to be loosened. Furthermore,
a secure counter-support (5) is no longer guaran-
teed. (Fig. 4)
2.6.2 alkitronic® RCL
Insert the support pin (8) completely into the
intended xture (s) of the alkitronic® RCL housing
to prevent damage to the housing.
The tightening and loosening of bolt connections must be
carried out in principle as with multipliers using an axial
downforce. Due to the radial downforce of the alkitronic® RCL
however, the multiplier is to be operated at a 90 degree angle
to the screw axis (6).The output occurs via a xed wrench size
(4). In order to reduce to smaller wrench sizes, alkitronic® STA
(7) should be used. A support pin (8) is used as a torque trans-
ducer. A secure, stable counter support (5) must be ensured
(Fig. 5). (See also application drawing Fig. 6.)
Fig. 4
Fig. 5
3
45
6
correct wrong
Safe support only in the area displayed
wrong
Secure support only with supporting bolts fully inserted in the
housing shells
5
6
7
8
4
Support
Place on next bolt/nut and start bolting process.
If the torque multiplier is not removable from the bolted
joint (torsional forces caused):
• Release the torque multiplier by changing the direction
of rotation
• Briefly press the rocker switch (3, Fig. 4) - counter-
clockwise rotation. In the case of a bolted joint with a
left-hand thread, the direction of rotation is clockwise,
of course.
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)!
• Remove the machine, place on the next bolt / nut
• Repeat the tightening procedure
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.

Pneumatic Torque Multiplier
9
Fig. 6
5
7
8
Handle
Disc
2.7 Finishing or interruption the work (even with
change of accessories)
• Interrupt the air pressure in the machine
• Disconnect the compressed air supply to the maintenance
unit or to the supply system
• By briey switching on the machine, remove any residual air
• Decouple the compressed air hose on the machine
Beware of components exposed to high air pressure:
Unintentional operation of the alkitronic® torque
multiplier may result in injury or property damage.
When removing the compressed air hose from the
machine, always disconnect the air supply rst. An
out of control compressed air hose can cause injury
or property damage.
In the event of prolonged periods without use, oil
must be supplied to the engine via the compressed
air inlet on the pistol grip. This prevents corrosion
damage to the motor lamella (see section 3.3 Main-
tenance and 4.1 Air lubrication).
alkitronic® DMA
Torque reaction absorber
alkitronic®
STACO
Standard
nut
1
2
54
3. Service
Do not use damaged alkitronic® torque multipli-
ers and accessories. Only use original alkitronic®
spare parts / accessories.
3.1 Changing from standard nut, standard connector
and DMA (CLD, CLS, CLS2)
• Interrupt compressed air supply - uncouple the com-
pressed air hose at the machine
• Place the alkitronic® CL on a at surface
• Remove rubber ring (6) and locking pin (7) or locking
screw (8)
• Remove standard nut / connector (2) / (3) towards the
front (Fig. 7.1)
• Pull DMA (1) out of the gearing (4) towards the front (Fig. 7.1)
• Assembly is in reverse order
Fig. 7.1
alkitronic®STACO
Standard nut
alkitronic®STABI
Standard connector
2
6
3
7 8
3.2 Changing the alkitronic® STA (Standard adapter)
and the support plunger for type RCL
alkitronic®STA
Standard adapter
Support plunger
Always insert the support pin and / or standard
adapter completely, otherwise the housing can be
severely damaged during operation.
Support plunger

Operating and maintenance manual
10
5. Declaration of conformity
alki Technik GmbH declares in sole responsibility: The
alkitronic® pneumatic multipliers identied by types CLS ,
CLS 2, CLD, CLV and serial numbers 913001 - 913699, built in
2019, complies with all relevant regulations such as directives /
standards / safety regulations:
2006/42/EG,
DIN EN ISO 12100:2011-03,
DIN EN ISO 4414:2011-04,
DIN EN ISO 13849-2.2013-02,
DIN EN ISO 11148 6:2013-05,
DIN EN ISO 15744:2008-11
January 2019
Alexander Kipfelsberger,
Managing Director
Technical Documents at alki TECHNIK GmbH,
Unterlettenweg 4, 85051 Ingolstadt / Germany.
3.3 Maintenance
Fig. 8
16. Maintenance unit
Art. No. 20350 - Maintenance unit complete
including 5 m hose, bracket and special oil
Pressure control valve Button for lling the oiler by suction
on the lower part of the container
Connection for oil extraction and lling
The alkitronic® torque multipliers are extremely
powerful, robust products. To ensure durability
and performance over many years, regular main-
tenance is required (performance check, engine
check, safety check).
Maintenance periods: Regularly 1x per year or after max.
1000 hours of operation if used properly.
alkitronic® multipliers should only be shipped to your al-
kitronic® Partner or to alki TECHNIK GmbH in the original
packaging to avoid damage.
In the event of prolonged periods without operation, the
motor of the alkitronic® multiplier must be supplied with oil
via the connector (1) of the compressed air supply at the pis-
tol grip (Fig. 8).This prevents corrosion damage to the motor
lamella (see Section 4.1, Air lubrication).
Protect the compressed air supply on the multiplier with a
protective cap to prevent dirt from entering.
Regulator type
diaphragm pressure control valves
Controller function with secondary venting
Pressure supply on one side
Installation position vertical
Ambient temperature min. -10°C /max. +50°C
Operating pressure min./max. 1.5 bar (21.75 PSI) /
16 bar (232 PSI)
Control range min./max. 0.5 bar (7.25 PSI) /
8 bar (116 PSI)
Filter element exchangeable
Container volume Filter 49 cm³ / 2.45 inch³
Drain valve semi-automatic,
depressurised open
Filling type manual oil lling
semi-automatic oil lling
during operation
Container volume Oiler 80 cm³/ 4.9 inch³
4. Technical details
4.1 Air lubrication
Brand/Type Aral /Vitam DE 10
Properties: Resin and acid-free, moisture-
binding, high corrosion- and
wear protection
Specication / Use: SAE 10W
Oil viscosity 40°C: -10 cST,
2-3 drops per min. during
continuous operation
(The manufacturer does not guarantee for other brands)
4.2 Noise emission and vibrations
The sound pressure level measured at maximum engine
power exceeds 85 dB (A). The measurements were carried
out in accordance with the noise measurement method DIN
EN ISO 15744: 2008-11.
Vibration: There are no signicant vibrations.
alkitronic® torque multipliers with lower sound pressure lev-
els (<85 dB (A)) are available as special versions. When tting
with silencer elements, the torque characteristics must be
corrected accordingly.