alkitronic LEVA User manual

Operation and Maintenance
Manual
Electric Hydraulic Pump LEVA
LEVA

Operation and Maintenance Manual
2
Content Page
A Incoming Inspection and Packaging 4
B General Description 4
1. Technical Data 4
2. Safety Instructions 4
2.1 Intended use 4
2.2 Duties of the user 4
2.3 Dangers with hydraulic components 5
2.4 Dangers with electrics and mechanics 5
3. Commissioning 6
4. Operation 7
4.1 Torque adjustment 7
4.2 Operation with the remote control 7
4.3 Change of direction of rotation / wrench change 7
5. Functional Test 8
5.1 Visual inspection 8
5.2 Check for leaks and contamination 8
5.3 Compliance with time limits 8
5.4 Requirements for hydraulic hoses 8
6. After Operation 8
6.1 Storage 8
6.2 Decommissioning 9
7. Technical Information 9
7.1 Oil temperature 9
7.2 Instructions for operation 9
(Avoiding temperature rise)
8. Disposing of Hydraulic Oil 9
9. Hydraulic Connections 10
10. Troubleshooting Guide 11
Foreword
Congratulations on your purchase of an alkitronic® LEVA
Hydraulic Pump. This product sets the highest interna-
tional standards for quality and safety. To maintain these
standards, please read and follow the information and
instructions found in the operation and maintenance
manual.
Maintenance and repair of the alkitronic® LEVA Hydraulic
Pump must be performed by alki TECHNIK GmbH or cer-
ti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,
understand, and observe this material together with the
basic precautions before, either using or attempting to
maintain the alkitronic® LEVA Hydraulic Pump.
The manual must always be available on site.
This operation and maintenance manual applies only to
the alkitronic® LEVA Hydraulic Pump.
Observe the “Safety information” found in section 2, and
all other special instructions in other sections.
Safety instructions.
Non-compliance may result in personal injury
or death.
Safety instructions.
Non-compliance may result in damage to the
alkitronic® LEVA Hydraulic Pump, its functions,
or the environment.
Information for proper and safe operation.
Practical advice and information to make work
easier.
Denition of symbols

LEVA electric Hydraulic Pump
3
alkitronic® LEVA
LEVA Remote control
For precise, reliable bolting and a wide torque range we
recommend our alkitronic® Hydraulic Wrenches AT and AX.
alkitronic® Accessories
Due to the specic selection of
a wide range of accessories,
you have a broader work ap-
plication eld.
When you need specific, indi-
vidual solutions, your alkitronic®
Partner or alki TECHNIK GmbH
will gladly advise you.

Operation and Maintenance Manual
4
A Incoming Inspection and Packaging
After receipt of the alkitronic® LEVA Hydraulic
Pump all parts must be checked for complete-
ness and possible transport damage. If damage is
found, notify the carrier immediately. For returns,
the original packaging must be used to prevent
damage to the alkitronic® LEVA Hydraulic Pump.
B General Description
The pump is designed for two-hose systems.
Three piston pumps with dierent delivery rates
are controlled by means of solenoid valves via an
electric motor. Hydraulic pressure is built up, which
is transmitted to the user in hydraulic hoses. The
alkitronic® LEVA Hydraulic Pump has been specially
developed for uses of hydraulic tools with hydrau-
lic cylinders that generate a corresponding torque
using a lever.
1. Technical Data
Drive type : electric
Mains voltage : 230 V / 50 Hz
Rated capacity : 0.25 kW
Delivery rate : In the low pressure range
3.2 l/min < 75 bar
in the medium pressure range
0.9 l/min at 75 to 220 bar
in the high pressure range
0.4 l/min to 700 bar
Tank content : approx. 1.8 liters
Weight without
Oil with frame : approx. 18.4 kg
Dimensions
with frame : 330 x 250 x 410 mm
(L x W x H)
Hydraulic oil : HLP 46, HLP 32
(other types of hydraulic oil
or Bio-oil on request)
Emission
Continuous sound pressure level LpA < 83 dB(A).
Measurement according to DIN 45635.
The operator must provide personal protective
equipment (hearing protection).
2. Safety Information
2.1 Intended use
The alkitronic® LEVA Hydraulic Pump may only be used to
run hydraulic torque wrenches which are operated with a twin
line hydraulic system rated for 700 bar pressure with this tool.
No other pneumatic oil grades than those specied in this
manual may be used.
All hydraulic connection equipment must be rated for 700
bar pressure.
Any other use of equipment is not in accordance
with the pump safety requirements.
The use of the pump, especially as a drive unit for all other
hydraulic devices such as presses, lifting cylinders, hydraulic
scissors, spreaders, etc. is not in accordance with the intended
use!
Only the types of hydraulic oil specied in the technical data
(see Section 1) may be used.
2.2 Operator responsibilities
The operator must have read and understood the
instructions in this operation and maintenance
manual before using or servicing the alkitronic®
LEVA Hydraulic Pump. Minimum age of the op-
erator must be 18 years.
Operation and service may not be performed, if the
concerned person does not understand the pur-
pose, 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.
The operator is responsible to third parties within
the work area.
The LEVA Hydraulic Pump must not be used in
explosion-endangered areas. For operation out-
doors or in humid rooms, observe the relevant
regulations.
The LEVA Hydraulic Pump must be protected from
moisture and rain. In case of damage to the unit,
harnesses or the electric connections, stop operat-
ing the Hydraulic Pump.
Improper operation, incorrect application, abuse
or use by unqualied personnel may be hazardous
to other persons, operator, Hydraulic Power Unit
and other property.

LEVA electric Hydraulic Pump
5
Do not extend hydraulic hoses without interme-
diate coupling.
Reversing the couplers for extension results in
reverse ow and reverse control of the hydraulic
tool. Non-compliance with these regulations may
lead to faulty functions and damage to the tool or
serious injuries to the operator.
A uid injection injury must always be treated as
a medical emergency that requires prompt and
accurate diagnosis and treatment.
Possible leaking oil is hazardous to the environ-
ment. It must be safely collected and properly
disposed of.
2.4 General electrical and mechanical risks
The LEVA Hydraulic Pump may only be operated,
if the power supply matches the electric perfor-
mance specications of the unit and all hydraulic
connections to the load (motor, cylinder or hydrau-
lictorquewrench)aretight and non-reversible.The
load should comply with the minimum require-
ments for safe operation.
In case of damage and repair, the Hydraulic Pump
must be separated from the power supply and im-
mediately be checked by a qualied technician for
electrical safety and mechanical defects. All safety
and mechanical defects must be resolved before
resuming operation.
In case of a power failure or malfunction separate
the pump from the power supply and put the
torque wrench in a safe position.
To avoid the risk of tilting or falling, the LEVA Hy-
draulic Pump must always be set-up securely.
When working in high places, it should be secured.
Never remove the transport frame, otherwise sta-
bility is endangered!
2.3 Possible risks with hydraulic components
Correct hose connections see page 10. g. 6a/b
Hazards due to hose failure & oil leakage
Hose assemblies may fail abruptly and unexpect-
edly for a variety of reasons. Hydraulic oil shooting
outathigh pressureand/orat highspeedcan cause
serious personal injury, severe damage to objects,
and environmental pollution.
Examples of potential hazards
• Bursting hose components
• Whipping hose ends
• Oil spray leakage
• Coupling blow-o
Make sure that:
The design and operation of tools and machines
complies with the existing safety regulations.
Inspect hose assemblies for damage and wear at
regular intervals; if possible, before each use.
Inspect hose sets in unpressurised condition; use
implements when necessary.
Defective or damaged hose assemblies must be
replaced immediately. Do not attempt to repair
them. Always use new components.
Never try to locate a leak with your hands!
If leakage occurs, shut down the Hydraulic Pump
immediately. Never try to locate the leak with any
part of the body when the hose set is pressurised.
Use a suitable implement to inspect the hose for
damage.
To avoid hydraulic oil escaping under high pres-
sure, make sure all hydraulic hoses (coupling and
nipple) are properly connected and secured with
the alkitronic® LEVA and the load (hydraulic torque
wrench).
Do not mix alkitronic® products with substitute
copies!
The interface between the coupling and the nipple
is crucial. alkitronics unique tolerances and preci-
sionmustnot be tampered with.An impropersolu-
tion caused by using non-alkitronic devices, may
lead to an incorrect connection, or even worse an
accidentaldisconnection whichresultsinhydraulic
oil shooting out at high pressure.
Unauthorized modications and changes to the
LEVA Hydraulic pump remove any liability from
alki TECHNIK GmbH and lead to the expiry of the
declarationof conformity! In thesecases, the user is
liable for damage caused by the use of the device.

Operation and Maintenance Manual
6
3. Commissioning
g. 1
1. Connect the hydraulic hoses of the hydraulic wrench to
the LEVA Hydraulic Pump (K), see also connection diagram,
point 9, page 10.
It is particularly important toensurethat allcouplings arefully
and securely coupled so that no hydraulic oil escapes and the
oil ow is not impaired.
2. Connect remote control (F)
3. Important safety instructions
Check the oil level in the
sight glass.
The correct oil level must
be displayed in the area
between the maximum
and minimum mark.
If necessary, the hydraulic
oil (grade, see 1. technical
data ) can be relled after
removing the bolt con-
nection (5).
Temperature control
Hydraulic oil
NOTE!
The high-pressure hoses and all couplings, t-
tings and connections must be checked for integ-
rity and cleaned if necessary before each start-up.
Dirt particles in the hydraulic system lead to mal-
functions and breakdowns. The hydraulic hoses
are to be designed with a large radius so that there
is no risk of accidents. Do not kink, step on, drive
over or damage mechanically.
The Hydraulic Pump must not be operated with-
out connected hoses and hydraulic torque tools!
(2) Pressure gauge, (3) Pressure adjustment valve, (4)
Manual solenoid valve (5) Vent valve / screw connec-
tion for oil rell
The hydraulic hoses must be provided in pairs with
plug-in coupling and plug-in nipple, so that the
forward (pressure) and return are unmistakably
applied to the piston or rod side of the hydraulic
cylinder of the hydraulic wrench.
If there is an interruption in the return line, a large
excess pressure on the rod side of the hydraulic
cylinder can form, which can destroy the hydrau-
lic wrench and cause serious physical damage to
people.
In general, when creating bolting connections, the
manufacturers instructions for use of the wrench
must be given equal priority and the regulations
or specications of the corresponding construc-
tion must also be followed with priority.
.
Before bolting with the LEVA Hydraulic Pump
a function check with max. 100 bar operating
pressure (procedure see point 4 and 4.1) must be
carried out.
F
3
2
4
5
K

LEVA electric Hydraulic Pump
7
Setting steps:
Press and hold the white button (1) on the remote
control. The piston of the hydraulic wrench extends.
After reaching the end position, the system pressure
is adjusted accordingly by turning the adjusting knob
on the pressure adjusting valve (3) (pressure increase
clockwise / pressure decrease counter clockwise).
The current operating pressure is displayed on the
pressure gauge (2). Release the white button on the
remote control (1), the piston of the hydraulic wrench
then moves back.
Checking the setting:
Press the white button (1) again to fully extend the
torque wrench piston. Hold until the necessary pres-
sure is reached.
After checking the pressure gauge, readjust the pres-
sure with the adjusting knob if necessary.
As soon as the required pressure is set, the setting is
secured against twisting with the wing nut (3.1).
4.2 Operation with the remote control
When tightening or loosening a bolted connection,
the instructions for use of the hydraulic wrench
must always be given equal priority!
Observe the technical information regarding oil
temperature, point 7, page 9.
Place the hydraulic wrench on the bolt connection.
By pressing and releasing the white button (1) you
can rotate the output. A corresponding torque is the
result. Press button (1) repeatedly until the hydraulic
wrench stops rotating and the set operating pressure
or torque has been reached. Carry out a visual inspec-
tion on the pressure gauge.
Tip:
Press the button (1) once or twice to ensure that the
applied torque is transferred to the bolt connection
and that the hydraulic wrench does not just stop at
the end stop of the hydraulic piston.
Observe the pressure gauge display (2, Fig. 3) on the
hydraulic pump ensure that the previously set operat-
ing pressure has been reached.
(When loosening a bolt connection, this process is
repeated just as often until the bolt connection has
completely loosened, see also point. 4.3)
The LEVAHydraulic Pump switches o by pressing the
black button (2).
4. Operation
Switch on/o
By pressing the button (1) the LEVA
Hydraulic pump is turned on and the
tool piston extends.
The return stroke is triggered
when released.
The Hydraulic Pump
switches o by pressing
the button (2)
g. 3
g. 2
4.1 Torque setting
Check the hose connections of the Hydraulic
Wrench / Hydraulic Pump.
See also point 9, page 10, connection diagram.
Then connect the pump to the mains.
The torque of hydraulic wrenches is proportional to the pres-
sure. The required operating pressure for the corresponding
torque is now determined from the torque table of the hy-
draulic wrench and set on the LEVA Hydraulic Pump.
Do not place the hydraulic wrench on the bolt
or nut yet!
3
3.1
Pressure
adjustment
valve
Pressure
gauge
1
2
ON =
OFF =
2

Operation and Maintenance Manual
8
4.3 Change of direction of rotation / wrench change
Switch o the pump by pressing the black button
(2), see remote control Fig. 2, page 7.
Relieve the pressure on the LEVA
Hydraulic Pump !
Press the manual override
on the top of the solenoid valve.
Disconnect the LEVA Hydraulic pump from the
power supply (pull the plug).
Adjust the hydraulic wrench according to the de-
sired direction of rotation and connect it to the
pump (LOOSEN or TIGHTEN screw connection, see
the instructions for use of the hydraulic wrench).
Reconnect the LEVA Hydraulic Pump to the power
supply. Press the white button (1) on the remote
control to switch it on, Fig. 2, page 7.
When changing a torque wrench, a torque setting accord-
ing to point. 4.1, page 7 is to be achieved.
5. Functional Test
5.1 Visual inspection
Check the connections see point 9,
Fig. 6a / b, page 10 - correct connection diagrams.
5.2 Check for leaks and contamination
The high pressure hoses and all couplings, ttings
and connections must be checked for integrity
and cleaned if necessary.
Dirt particles in the hydraulic system lead to mal-
functions and breakdowns. Check the hydraulic
parts for leaks, defective components must be
replaced professionally.
5.3 Compliance with time limits
To ensure torque precision, an accuracy check of
the pressure gauge must be carried out with the
help of a test pressure gauge for a given occasion,
but no later than annually.
The oil level and oil quality must be checked regu-
larly. In the case of frequent use, we recommend
changing the oil annually (for oil type, see techni-
cal data).
Authorized personnel must also have the LEVA
Hydraulic Pump checked for electrical safety and
mechanical defects at least once a year. With high
loads / stress / operating hours at shorter intervals.
5.4 Requirements for hydraulic hoses
For safety reasons, replace all hydraulic hoses with
normal requirements after 5 years at the latest
(additionally a maximum of 2 years storage time).
With increased requirements (multi-shift opera-
tion, short cycle times, hand-held tools) after only
2 years. Additional regulations from the legislator
(DIN 20 066 / BGR 237) must be observed.
The operating and service requirements specied
in these instructions for use must be observed.
6. After use
After the work has been completed, depressurize the
LEVA Hydraulic Pump and disconnect the pump
from the power supply.
Remove hydraulic hoses and multipliers and keep
all components dry and clean.
(See also the following descriptions)
6.1 Storage
Keep the LEVA Hydraulic Pump dry and clean in
the alkitronic® transport case or in another seal-
able container.
Moisture leads to oxidation on the housing as well
as on internal parts. Consequences can include
malfunctions and further damage.
Hydraulic hoses
When storing, make sure that the hydraulic
hoses are removed and the ends of the hoses
and connecting parts (couplings / nipples) are
closed with the protective caps.
Store in a cool, dry and low-dust condition.
Avoid direct sunlight and UV radiation, ozone-
forming lighting xtures (e.g. uorescent light
sources, mercury vapor lamps) and storage
temperatures below -10 °C.
Hydraulic hoses must not come into contact
with acids, alkali, solvents.
Store tension-free and lying at. When stored
in rings, the minimum bending radius specied
by the manufacturer must not be undercut
•
•
•
•
•
Magnetic
valve

LEVA electric Hydraulic Pump
9
As soon as the hydraulic piston of the multiplier
stops, do not press the button (1) for an unneces-
sarily long time.
As a result, temperature increases due to high mo-
tor strain of the hydraulic pump can be avoided.
6.2 Decommissioning
In the event of prolonged periods without use
the LEVA Hydraulic pump should be cleaned and
stored in a dry, locked room - not accessible to chil-
dren. For further measures see point 6.1, storage.
7. Technical Information
7.1 Oil temperature
Check the oil temperature regularly. If the tem-
perature exceeds 65 °C, interrupt the work to avoid
faulty bolt connections and / or bolt damage.
After the appropriate cooling time, the work can
be continued.
7.2 Instructions for operation
1
Temperatures between +15 °C and +25 °C and a
relative humidity below 65% are recommended
as favorable storage conditions. Ingress of ozone
or other harmful air components can also be pre-
vented by wrapping them in lm.
Temperature control
Hydraulic oil
The used hydraulic oil must be disposed of prop-
erly. Under no circumstances should it permeate
into the ground or get into the sewage system.
8. Disposing of Hydraulic Oil
Oil drain plug
s
Before opening the drain
plug (S) on the left, a suit-
able oil drip pan must be
provided. Bind spilled
hydraulic oil immediately
with suitable material.

Operation and Maintenance Manual
10
Return (R)
Return (R)
HD Hose pair
Hydraulic tool
HD Hose pair
Flow (A)
Flow (A)
alkitronic®LEVA
9. Hydraulic Connections
Correct connection diagram:
Hydraulic pump - HP hose - Hydraulic wrench
Fig. 6a
Fig. 6b
Flow (A)Coupling
Nipple
Nipple
Coupling Return (R)
Connection of
hydraulic pump
Connection of
hydraulic wrench
(A)
(R)

LEVA electric Hydraulic Pump
11
Notes
© alki TECHNIK GmbH/GBA LEVA/1/03.05.20/4Pdesign Technical changes reserved.
10. Troubleshooting
Problem Possible cause Solution
Motor does not start 1. Power cord not connected
2. Mains voltage wrong
3. Power cable defective
- Remote control cable defective
- Remote control defective
4. Hydraulic unit defective
1. Connect the power cord
2. Check the mains voltage and con-
nect to the correct mains
3. Have it replaced by a qualified
electrician
4. Contact alkitronic® Partner
No or insufficient pressure build-up
even though the engine is running
1. Too little or no oil
2. Maximum pressure not set or set too
low
3. Hydraulic unit defective
1. Refill oil
2. Set pressure according to
Chapter 4.1
3. Contact alkitronic® Partner
Multiplier does not move even though
pressure is being built up
1. One or more hose couplings
not closed
1. Unit, hoses and tools
according to - Chapter 9 correct
connection diagrams - connect
Torque wrench works in the wrong
direction of rotation
1. Torque wrench incorrectly connected 1. See chapter 9, correct
connection diagrams and
operating instructions for torque
wrench

EXTRACT FROM OUR PRODUCT RANGE
alki TECHNIK GmbH
Development, production and sales of screw systems
Unterlettenweg 4 – 85051 Ingolstadt/Germany – fon [phone] – fax [phone]
[e-mail] – www.alkitronic.com
Higher quality
First class production
Use of high quality materials
Long product life
Experience in bolting technology since 1984
Made in Germany - worldwide patents
Higher productivity
Fast bolting without reworking
No environmental failure (IP 54, ATEX)
High occupational safety
Simple operation - short familiarization times
Low maintenance and cost-effective
Higher precision
Exact, customer-specic torques
High repeatability
Reliability under continuous load
Bolting documentation
Automatic switch-off
Better service
Technical advice on site
Education and training offers
Factory calibration and certication
Lifecycle support
Spare parts and repair service
YOUR PLUS FOR MORE PERFORMANCE
Hydraulic Torque multipliers and Pumps Manual power wrenches
Electric Torque multiplier Pneumatic Torque Multiplier