HT125KM, FA3TM, FA6TE - Fairfield Industrial Sales Manuals/Equalizer/Flang… · Equalizer International Ltd cannot be responsible for damage or injury resulting from unsafe product

HT125KM, FA3TM, FA6TEFLANGE ALIGNMENTTOOLS

Operator Instruction Manual

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www.equalizerinternational.com

INNOVATION IN ITS MOST FUNCTIONAL FORM

FLANGE ALIGNMENT TOOLSOPERATOR INSTRUCTION MANUAL PAGE 1

SECTION CONTENTS PAGE NO.

1 INTRODUCTION 2

2 SAFETY INFORMATION 3-4

3 TECHNICAL DATA 5

4 FLANGE MISALIGNMENT DETERMINATION PROCEDURE 6

4.1 LATERAL MISALIGNMENT 64.2 ROTATIONAL (TWIST) MISALIGNMENT 7

5 HT125KM HAND ALIGNMENT TOOL 8-13

5.1 KIT COMPONENTS 8

5.2 HOW THE HT125KM WORKS 8

5.3 INSTALLATION AND OPERATION 9-10

5.4 EXAMINATION, MAINTENANCE AND STORAGE 11

5.5 PARTS LIST 12

5.6 WEIGHTS AND DIMENSIONS 12

5.7 RANGE OF APPLICATION 13

6 FA3TM MECHANICAL FIXED FLANGE AND ROTATIONAL ALIGNMENT TOOL 14-21


6.2 HOW THE FA3TM WORKS 14



6.5 PARTS LIST 19


6.7 TROUBLESHOOTING 21


7 FA6TE HYDRAULIC FIXED FLANGE AND ROTATIONAL ALIGNMENT TOOL 23-31


7.2 HOW THE FA6TE WORKS 23



7.5 PARTS LISTS 27-28


7.7 TROUBLESHOOTING 30-31


INDEX

FAT IM REV 0228.02.08


The Equalizer HT125KM, FA3TM and FA6TE are aids for use in normal maintenance and installation procedures, and enable the realignment of misaligned flanges within their respective working capacities. For example, all of the tools can be used to assist in the replacement of ring and other types of flange joint. The use of these instructions will promote safe use, and maximize the service life of the tools. It is recommended that the operator read the relevant sections of this instruction manual for the particular flange alignment tool to be used.

1. INTRODUCTION


2. SAFETY INFORMATION

The operator MUST read this manual prior to using the tools.

Failure to comply with the following cautions and warnings could cause equipment damage and personal injury; read the manual fully!

Read all the following instructions, warnings and cautions carefully. Follow all safety precautions to avoid personal injury or property damage during system operation.

Equalizer International Ltd cannot be responsible for damage or injury resulting from unsafe product use, lack of maintenance or incorrect product and/or system operation. Contact Equalizer International Ltd when in doubt as to the safety precautions and applications. To protect your warranty, use only good quality hydraulic oil of the grade 32cSt.

Only people competent in the use of mechanical and hydraulic equipment should use these tools.

In all installations the site safety requirements must be adhered to. ALSO the safety of the operator, and when present, any assisting personnel, is of paramount importance along with the safety of others including, when present, the general public.

These instructions are only to cover the safe operation of THE EQUALIZER HT125KM, FA3TM AND FA6TE FLANGE ALIGNMENT TOOLS, during normal maintenance/installation operations. All other safety aspects must be controlled by the operation supervisor.

CAUTION:

1. The tools must not be attached to a pressure vessel nozzle2. The tools must not be attached to a flange joint prior to misalignment


A CAUTION is used to indicate correct operating or maintenance procedures and practices to prevent damage to, or destruction of equipment or other property.

A WARNING indicates a potential danger that requires correct procedures or practices to avoid personal injury.A DANGER is only used when your action or lack of action may cause serious injury or even death.

IMPORTANT: Operator must be competent in the use of hydraulic equipment. The operator must have read and understood all instructions, safety issues, cautions and warnings before starting to operate the Equalizer equipment.

WARNING: To avoid personal injury and possible equipment damage, make sure all hydraulic components are rated to a safe working pressure of 700 bar (10,000 psi)

WARNING: Do not overload equipment. Over-loading causes equipment failure and possible personal injury. The risk of overloading can be avoided by using the Equalizer Hand Pump, which has its safety valve set to 700 bar by the factory. If alternative pumps are used, ensure they are rated at a safe working pressure of 700 bar (10,000 psi).

CAUTION: Make sure that all system compo-nents are protected from external sources of damage, such as excessive heat, fl ame, mov-ing machine parts, sharp edges and corrosive chemicals.

CAUTION: Avoid sharp bends and kinks that will cause severe back-up pressure in hoses. Bends and kinks lead to premature hose failure.Do not drop heavy objects onto hoses. A sharp impact may cause internal damage to hose wire strands; applying pressure to a damaged hose may cause it to rupture. Do not place heavy weights on the hoses, or allow vehicles to roll over the hoses; crush damage will lead to pre-mature hose failure.

WARNING: Immediately replace worn or damaged parts with genuine Equalizer parts. Equalizer parts are designed to fi t properly and withstand rated loads. For repair or maintenance service contact your Equalizer distributor or service centre.

DANGER: To avoid personal injury keep hands and feet away from the tool and workpiece during operation.

WARNING: Always wear suitable clothing and Personal Protective Equipment (PPE).

DANGER: Do not handle pressurised hos-es. Escaping oil under pressure can pen-etrate the skin, causing serious injury. If oil is injected under the skin, seek medical attention immediately.

WARNING: Never pressurize unconnected couplers. Only use hydraulic equipment in a connected system.

IMPORTANT: Do not lift hydraulic equip-ment by the hoses or couplers. Use the car-rying handle or other means of safe trans-port.

CAUTION: Do not operate the equipment without lubricating all moving parts as in section 5.4, 6.4 & 7.4. Use only high pres-sure molybdenum disulphide grease.


3. TECHNICAL DATA

Tool Description Aligning Force

HT125KM Hand Alignment Tool

125 kg (275 lbs)Mechanical Advantage 5 to 1

FA3TM Mechanical Fixed Flange and Rotational Alignment Tool

3.3 T (33kN) from 50 ft/lbs (67.8 Nm) of torque

FA6TE Hydraulic Fixed Flange and Rotational Alignment Tool

6 T (60 kN) from 10,000 psi (700 bar) of hydraulic pressure


4. FLANGE MISALIGNMENT DETERMINATION PROCEDURE

The tool being used must not be attached to a flanged joint prior to the misalignment procedure being carried out.

4.1 LATERAL MISALIGNMENT

1. Slacken and remove every second bolt around the flange , continue with this until misalignment occurs. A flanged joint, once broken down, may spring out of alignment at any point, or in any direction around its circumference. Misalignment may not occur until only a few bolts remain.

2. At this point the direction of any misalignment should become obvious. The alignment tool being used should be attached at the maximum point of misalignment (point A or B in the examples shown below) as shown in sections 5.3, 6.3 & 7.3.

POINT A

POINT B POINT A

POINT B


4.2 ROTATIONAL (TWIST) MISALIGNMENT

If the outer circumference of the flanges are in alignment but the operator is unable to fit the bolt into any two corresponding bolt-holes then rotational misalignment may have occured.

In this case the alignment tool can be attached to the most accessible point as misalignment occurs at all bolt-holes to the same degree.

1. Attach the alignment tool at the most accessible/convenient point (as shown in sections 5.3, 6.3 & 7.3) and use it to push the flanges out of alignment until one pair of bolt-holes becomes parallel.

2. Insert the bolt into the aligned bolt- hole and release the alignment tool. The load will transfer onto the bolt.

3. Repeat steps 1 and 2 at other points around the flange until all of the remaining bolt-holes are parallel and the rest of the bolts can be inserted.

PARALLELBOLT-HOLES

BOLT

ALIGNMENTTOOL

ALIGNMENTTOOL


5. HT125KM HAND ALIGNMENT TOOL

5.1 KIT COMPONENTS

1 x HT125KM Tool3 x Adaptor Bushes1 x Instruction Manual

Product Code: HT125KGSTD

5.2 HOW THE HT125KM WORKS

1. The HT125KM is secured to the lower of the two flanges by fully inserting the lift pin into the bolt-hole which is parallel with the bolt-hole on the opposite flange. This is where the misalignment is at its greatest point.

2. The counter-balance is adjusted to the desired distance and the butterfly nut is tightened at the top.

3. The flange can now be levered up into alignment and the bolts inserted.


5.3 INSTALLATION AND OPERATION

LIFT MODE:

1. Carry out the Flange Misalignment Determination Procedure (see section 4) to determine the points of maximum misalignment. In this example the points of maximum misalignment are at the top and bottom of the joint.

2. From the three bushes, select the one which best fits the bolt-hole of the flange requiring alignment.

3. Attach the selected bush onto the lift pin.

4. Insert the bush/lift pin into the bolt- hole on the lower flange. Adjust the lifting assembly or the counter-balance and tighten the butterfly nuts.

POINT OF MAX. MISALIGNMENT


BUSH

LIFT PIN

COUNTER-BALANCE

LIFTINGASSEMBLY

BUTTERFLYNUT


5. Lift up on the handle and the counter-balance will push down on the higher flange bringing the joint into alignment.

PUSH MODE:

By removing the handle from the lifting assembly and counter-balance, the handle can be re-inserted from the opposite side. Align the joint by pushing down on the handle.

Care should be taken not to drop any of the component parts when removing them from the flange joint. This action will prevent injuries to either the operator’s lower limbs, or to passers-by.

HANDLE

In this example the joint was being aligned from the top. However if access were limited at the top the alignment could be rectified from the bottom of the joint


• On return from each job and before allocation against subsequent work the completeness of the Equalizer HT125KM kit must be established and items examined to ensure that they are serviceable

• Any missing or damaged items are to be replaced as soon as possible and prior to the tool being used again

• Store the HT125KM in a cool dry place and ensure all machined surfaces are greased

• Grease all moving parts regularly

• Ensure the roller remains grit free

5.4 EXAMINATION, MAINTENANCE AND STORAGE


5.5 PARTS LIST

5.6 WEIGHTS AND DIMENSIONS

01

02

04

05

06

07

08

0910

1011

12

13

*

*

**

* 03 01 each 01 each01 set of 201 each01 each01 each01 each01 each01 each01 set of 201 each01 each01 each

201201-01200102-01200901-02200202-01200302-01201102-01200502-01200601-01200402-01201001-02200801-01200701-01201401-01

HANDLE SLEEVE-BLUEMAIN BARBUTTERFLY NUTLIFTING ASSEMBLYCOUNTER-BALANCEROLL PIN 3/4”ROLLERBUSH ABOLT-HOLE LEVER“O” RINGBUSH CBUSH BROLL PIN 1/2”

010203*040506*07080910*111213*

ITEM PART No. DESCRIPTION QUANTITY

*Repair Kit Part No: 201301-01 with Items 03, 06, 10 & 13

33.0 mm(1.30")

465 mm(18.25")

88 mm(3.46")

230 mm(9.00")

MINIMUM EXTENSION MAXIMUM EXTENSION

TOOL WEIGHT = 2.0 kg (4.4 lbs)


5.7 RANGE OF APPLICATION

DN PN

6

10

16

25

40

64

100

160

pressure(psi)

150

300

400

600

900

1500

2500

Pin Only = Ø 17.0 mm (.669”) Bush A = Ø 21.3 mm (.836”)Bush B = Ø 24.4 mm (.957”)Bush C = Ø 27.4 mm (1.07”)

Pin Only = Ø 17.0 mm (.669”) Bush A = Ø 21.3 mm (.836”)Bush B = Ø 24.4 mm (.957”)Bush C = Ø 27.4 mm (1.07”)

TABLE A: RANGE OF APPLICATION on ANSI, BS & API FLANGES

TABLE B: RANGE OF APPLICATION on DIN FLANGES

+

+

1/2

3/4

+

+

+

1

+

+

+

1 1/4

+

+

+

1 1/2

+

2

+

+

+

+

2 1/2

+

3

+

3 1/2

+

4

+

5

6

8

10

12

14

16

25

+

+

+

32

+

+

+

+

40

+

+

+

+

50

+

+

+

+

65

+

+

+

+

80

+

+

+

+

+

100

+

+

+

+

+

125

+

+

+

+

+

150

+

200

+

250

+

300

350

400


6. FA3TM MECHANICAL FIXED FLANGE AND ROTATIONAL ALIGNMENT TOOL

6.1 KIT COMPONENTS

1 x FA3TM Tool 1 x 50 ft/lbs (67.8 Nm) Torque Wrench with 22 mm Socket1 x Instruction Manual1 x Carry-Case with Protective Foam Inserts

Product Code: FA3TMSTD

6.2 HOW THE FA3TM WORKS

1. The FA3TM is secured to the lower of the two flanges by fully inserting the lift hook into the bolt-hole which is parallel with the bolt-hole on the opposite flange. This is where the misalignment is at its greatest point.

2. The drop leg is released onto the pipe while the tool is held up level in the bolt-hole.

3. The wing retaining clip is pulled out to allow the wing to be extended to the required distance.

4. The screw bolt is turned clockwise until the friction pad comes into contact with the circumference of the opposite flange.

5. The torque wrench is set to 50 ft/lbs (max), attached to the screw bolt and turned to screw down on the flange, bringing the joint into alignment.



Do not pull after the wrench clicks. Use special care at low torque settings. If the wrench has not been used for some time: operate it several times at low torque to allow internal lubricant to recoat. When not in use set to lowest torque setting. Don’t turn handle below lowest torque setting. Your torque wrench is a precision measuring instrument and should be treated as such. Clean only by wiping, do not use any type of cleaner which may affect the special internal lubricant with which this wrench is packed at the factory.

How to use the torque wrench

Balance the wrench in your left hand and unlock the knurled handle by turning the locking knob anti-clockwise.Set the torque amount by turning the knurled handle - see example 40-46 N/m

1. Turn the handle till 0 on fine scale reach 40 N/m on base scale2. To set 46 turn handle till fine scale reach 63. Lock handle by turning the locking knob clockwise

Install the proper socket and attach to the tool. Pull handle till you feel and/or hear the wrench click. Setting of ft/lb scale is done in the same way as above.

KNURLEDHANDLE

LOCKINGKNOB

1. Do not attempt to turn the grip while it is locked2. Do not turn the grip more than one turn below the lowest scale reading or above the highest scale reading

Newton Scale (N/m)

40 N/m 46 N/m (1 on fine scale

= 1 N/m)

Foot Pound (Ft.lb)

70 ft/lb 75 ft/lb (1 on fine scale

= 0.74 ft/lb)



2. Guide the lift hook into the bolt-hole at the maximum point of misalignment.

Release the drop leg onto the pipe (using the release knob) while holding the lift hook up level with the bolt-hole.

3. Pull the wing retaining clip out and extend the wing to the required distance.

Rotate the screw bolt onto the surface of the opposite flange. Ensure that the tool is sitting level and that the friction pad on the base of the swivel is in full and even contact with the surface of the opposite flange.



LIFTHOOK

RELEASEKNOB

WING RETAINING CLIP

WINGSCREWBOLT

SWIVEL


4. Attach the torque wrench to the screw bolt and tighten in a clockwise direction until the joint comes into alignment. The torque wrench should be set at staged increases, e.g. 10 ft/lbs, 20ft/lbs until the maximum setting of 50ft/lbs (67.8 N/m) is reached.

5. Once in alignment the bolts may be inserted and tightened.

After replacing all of the bolts (apart from the bolt which will go into the bolt-hole in which the FA3TM is located), remove the tool by reversing steps 2 - 4.

Insert the last bolt and tighten.

The torque wrench will click when the full 50 ft/lbs (67.8 N/m) is achieved - exceeding 50 ft/lbs will result in damage to the tool


TORQUEWRENCH

SCREWBOLT


• On return from each job and before allocation against subsequent work the completeness of the Equalizer FA3TM kit must be established and items examined to ensure that they are serviceable


• Store the FA3TM in a cool dry place and ensure all machined surfaces are greased

• Return all items to carry case when not in use

• Ensure rollers, pins and wing remain grit free and that the rollers rotate freely

• Grease all moving parts regularly:


1. Place the tool on a flat bench.

2. Using a small flat screw driver, lever out the end of the spiral clips and then rotate anti-clockwise and remove.

3. Remove the pull pin and lift hook, unscrew the seven side plate screws, and lift off the side plate.

4. Inspect the roller pin and needle bearings within the rollers for dirt or grit. Clean and then smear a small amount of grease onto the roller pin and into the needle bearing.

Recommended grease - Rocol or Sapphire Hi-Load

5. Re-assemble by reversing steps 2-3.

SPIRALCLIP

PULLPIN

LIFTHOOK

SIDE PLATESCREW

SIDEPLATE

ROLLERPIN

NEEDLEBEARING


6.5 PARTS LIST

01

02

03

04

05

05

06

07

06

07

08

09

10 11

12

12

09

1313

14

141516

17

18

19

20

21

22

22

22

23

24

25

26

27

28

29

30

31

32

32

08

33

34

35

36

37

38

REPAIR KIT 1. (THRUST BEARING SET) PART NUMBER 403601-01 CONTAINS ITEMS 20,22 & 24.

REPAIR KIT 2. (ROLLER BEARING SET) PART NUMBER 403701-01 CONTAINS ITEMS 5,6,7 & 9.

REPAIR KIT 3. (TOOL ASSEMBLY SET) PART NUMBER 403801-01 CONTAINS ITEMS 10, 11, 14 & 36.

REPAIR KIT 4. (DROP LEG / LOCK SET) PART NUMBER 403901-01 CONTAINS ITEMS 12,13,25,26,28,29,30 & 31.

DESCRIPTION

50ft/lbs TORQUE WRENCH22 mm SOCKET SCREW BOLTWING C/W BOSSINNER ROLLERNEEDLE BEARINGOUTER ROLLERBODY PLATES & FRAMESPIRAL CLIPWING RETAINING CLIPM3 SCREWM5 x 20MM SCREW RELEASE KNOB SCREWS FOR SIDE PLATESPULL RING PULL PIN ROLL PINBALL SPRING PLUNGERLIFT HOOK SPRING CLIP

PART No.

400203-01400204-01400301-01401001-01401401-02401501-02401601-02401101-01401301-02402001-01402002-02402701-02402801-02401901-14403102-01403101-01403201-01403301-01403001-01400401-01

QUANTITY

01 each 01 each01 each01 each01 set of 2 01 set of 2 01 set of 201 set01 set of 2 01 each01 set of 2 01 set of 2 01 set of 2 01 set of 14 01 each01 each01 each01 each01 each01 each

ITEM

0102030405060708091011121314151617181920

DESCRIPTION

SWIVELTHRUST BEARING SETFRICTION PAD RETAINING SCREW COUNTER-SUNK SCREWS DROP LEG PAD DROP LEGGRUB SCREWSPRINGDROP LEG LOCKADJUSTING SCREW ROLLER PIN HANDLEHANDLE SLEEVE-YELLOWRETAINING SCREW SCREW (DROP LEG)PLASTIC WING INSERTSWIREDECALS SET (not illustrated)CARRY-CASE WITH FOAM INSERT (not illustrated)

PART No.

400501-01400601-01400801-01400901-01402601-02402501-01402401-01402301-01402201-01402901-01402902-01401201-02308201-01401702-01401801-01402101-01404501-02404601-01403401-01403501-01

QUANTITY

01 each01 each01 each01 each01 set of 2 01 each01 each01 each01 each01 each01 each01 set of 201 each01 each01 each01 each01 set of 2 0.2 m01 kit01 kit

ITEM

2122232425262728293031323334353637383940



WEIGHTS

Tool only = 8.1 kg (17.82 lbs)Carry-Case with Protective Foam Inserts = 6 kg (13.23 lbs)

GROSS KIT WEIGHT = 14 kg (30.90 lbs)

OVERALL DIMENSIONS


133 mm(5.23")

60 mm(2.36")

30 mm(1.18")

36 mm(1.41")

380 mm(14.90")

288 mm(11.36")

70 mm(2.75")

134 mm(5.28")


Problem: The friction pad is sliding in the circumference of the opposite flange as the tool is aligning the joint

Grit or dirt on wing, rollers or bearings

Ensure the rollers are rotating freely and that there is no restriction to the rollers on the wing surfaces such as dirt or grit

Wing is at full extension Check that the wing is not at full extension when aligning the joint.

Ensure that there is enough extension left to allow the tool to expand as the joint is aligned.

Problem: The tool is attached and appears to be functioning properly, but the joint will not align

There may be something restricting the joint at a point close to the flanges

Check the area around the joint to establish if there is an obstruction to the joint

The joint may require more than 3.3 T (33 kN) force to align

If the joint requires more force than that of the 3.3 T (33 kN) tool, then another method of aligning the joint should be adopted

Problem: The drop leg will not move

If the drop leg lock is in contactwith the frame of the tool when the teeth are engaged, the drop leg and drop leg lock will become jammed.

With the teeth of the drop leg and drop leg lock engaged, the drop leg lock should be adjusted with the adjusting screw by turning it anti-clockwise until there is a small gap between the lock and the frame

6.7 TROUBLESHOOTING

DROP LEG LOCK

DROPLEG

ADJUSTING SCREW



MINIMUM AND MAXIMUM FLANGE SIZES

Dimension A: must be between 30 and 133 mm (1.18” and 5.23”)

Dimension B: bolt-hole diameter must be 24 mm (0.95”) or greater

BY FLANGE TYPE, CLASS AND DIAMETER

If the flange to be aligned is not listed please use the Minimum and Maximum Flange Sizes guide above

DIMENSION

ADIMENSION

B


7. FA6TE HYDRAULIC FLANGE SPREADING WEDGE

7.1 KIT COMPONENTS

1 x FA6TE Tool 1 x 10,000 psi (700 bar) 6 T Hydraulic Cylinder1 x 10,000 psi (700 bar) Hydraulic Hose, 2 m (78.75”)1 x 10,000 psi (700 bar) HP350S Sealed Hand Pump with Gauge1 x Instruction Manual1 x Carry-Case with Protective Foam Inserts

Product Code: FA6TESTD

7.2 HOW THE FA6TE WORKS

1. The FA6TE is secured to the lower of the two flanges by fully inserting the lift hook into the bolt-hole which is parallel with the bolt-hole on the opposite flange. This is where the misalignment is at its greatest point.

2. The drop leg is released onto the pipe while the tool is held up level in the bolt-hole.

3. The lock pin is pulled out to allow the wing to be extended to the required distance.

4. The hydraulic cylinder is secured into the adjusting sleeve. The hydrualic cylinder and adjusting sleeve are rotated clockwise until the cylinder base locates onto the surface of the opposite flange.

5. The hydraulic hose and pump are attached to the cylinder and the hand pump is primed, bringing the joint into alignment.




2. Guide the lift hook into the bolt-hole at the maximum point of misalignment.

Release the drop leg onto the pipe (using the release knob) while holding the lift hook up level with the bolt-hole.

3. Pull the spring plunger out and extend the wing to the required distance.

Rotate the hydraulic adjusting cylinder clockwise until the base of the cylinder locates onto the surface of the opposite flange. Ensure that the tool is sitting level and that the swivel on the base of the cylinder is in full and even contact with the surface of the opposite flange.



LIFTHOOK

RELEASEKNOB

SPRINGPLUNGER

WINGHYDRAULIC ADJUSTING

CYLINDER

SWIVEL


4. Connect the hydraulic pump to the hydraulic hose, and the hose to the hydraulic adjusting cylinder.

Prime the pump until the joint comes into alignment.

5. Once in alignment the bolts may be inserted and tightened.

After replacing all of the bolts (apart from the bolt which will go into the bolt-hole in which the FA6TE is located), remove the tool by reversing steps 2 - 4.

Insert the last bolt and tighten.



• On return from each job and before allocation against subsequent work the completeness of the Equalizer FA6TE kit must be established and items examined to ensure that they are serviceable


• Store the FA6TE in a cool dry place and ensure all machined surfaces are greased

• Return all items to carry case when not in use

• Ensure rollers, pins and wing remain grit free and that the rollers rotate freely

• Grease all moving parts regularly:


1. Place the tool on a flat bench.

2. Remove the circlips on the support shafts and push the support shafts out. Remove the support rollers.

3. Using a small flat screw driver, lever out the end of the spiral clips and then rotate anti-clockwise and remove.

4. Remove the friction washers, rollers and finger stops.

5. Inspect the roller shafts and needle bearings within the rollers for dirt or grit. Clean and then smear a small amount of grease onto the shafts and into the needle bearings.

Recommended grease - Rocol or Sapphire Hi-Load

6. Re-assemble by reversing steps 2-4.

CIRCLIP

SUPPORTSHAFT

SUPPORTROLLER

SPIRALCLIP


7.5 PARTS LISTS

FA6TE TOOL

QUANTITY01 each

01 each01 each 01 set of 201 set of 201 set of 401 each01 each01 set of 201 set of 401 each01 each01 set of 401 set of 401 set of 401 set of 401 set of 201 set of 201 set of 201 set of 201 each 01 each01 each01 each01 each

01 each01 each01 each01 each01 each

ITEM PART No. DESCRIPTION 01 903101-01 6T HYDRAULIC ADJUSTING CYLINDER 02 900302-01 WING 03 900502-01 M10 SPRING PLUNGER 04 900701-02 FINGER STOP-FRONT 05 900801-02 SUPPORT SHAFT 06 900901-04 SUPPORT ROLLER 07 901001-01 DROP LEG 08 402501-01 DROP LEG PAD 09 402601-02 COUNTER-SUNK SCREW 10 901301-04 CIRCLIP 11 402201-01 COIL SPRING 12 402301-01 GRUB SCREW 13 901601-04 SPIRAL CLIP 14 901701-04 FRICTION WASHER 15 901801-04 ROLLER 16 901901-04 NEEDLE BEARING 17 402701-02 SCREW M5 x 20 18 902101-02 SHAFT 19 402801-02 RELEASE KNOB 20 902301-02 FINGER STOP REAR 21 902401-01 BOLT M6 x 10 22 402901-01 DROP LEG LOCK 23 902601-01 ADJUSTING SCREW 24 902701-01 MAIN BODY/HOOK (not illustrated) 902801-01 CARRY-CASE C/W FOAM (not illustrated) 902901-01 DECALS (Set of 5) (not illustrated) 28 302701-01 HYD HOSE 10,000 psi (700 bar)29 311801-01 HYD PUMP 10,000 psi (700 bar) 30 300901-01 FEMALE HALF COUPLER31 302601-01 MALE HALF COUPLER

01 02

03

04

05

06

07

08

09

10

11

12 1314

1516

1718

1920

2122

23

24


DESCRIPTION

PUMP HOUSINGSERVICE KIT A:- OIL FILTER - O-RING- RESERVOIR BLADDER- REFILLING PLUGRESERVOIRSERVICE KIT B:- TAIL BASE- SCREW- NUTSERVICE KIT C:- O-RING- BACK-UP RING- PUMP PISTON- SNAP RING- O-RING- BACK-UP RING- PUMP PISTONSERVICE KIT D:- PISTON PIN- YOKE PIN- RETAINING RING- YOKE- HANDLESERVICE KIT E:- YOKE BASE- PIN- SCREW- OIL SEALSERVICE KIT F:- WASHER- COUPLERS- CHECK BALL- SCREW- RELEASE VALVE- PIN- SCREW- SCREWSERVICE KIT G:- CHECK BALL- SPRING- CHECK BALL- SPRING- WASHER- SCREW

PART No.

710101-01715100-01

710601-01715200-01

715300-01

715400-01

715500-01

715600-01

715700-01

QUANTITY

01

01010101 01

010404

0101 01 01 01 0101

0101010101

01010201

01 01040101 01 0301

020202 02 02 02

ITEM

01

0203040506

070809

10111213141516

1718192021

22232425

2627282930313233

343536373839

DESCRIPTION

SERVICE KIT H:- CHECK BALL- SPRING END CAP- SPRING- SPRING- O-RING- SCREW- CAPO-RINGSCREWSERVICE KIT I:- BASE PLATE- SCREW

PART No.

715800-01

714701-01714802-01715900-01

QUANTITY

4020201010202020101

0102

ITEM

4404142434445464748

4950

HP350S HAND PUMP


526 mm(20.75")

295 mm(11.62")

307 mm(12.25")

106 mm(4.25")

32 mm(1.25")

240 mm(9.5")

102 mm(4.0")

250 mm(8.0")

210 mm(8.27")

35 mm(1.38")

90 mm(3.50")


WEIGHTS

Tool with Hydraulic Cylinder = 15.5 kg (34.1 lbs)Carry-Case with Protective Foam Inserts = 7.5 kg (16.5 lbs)

GROSS KIT WEIGHT = 28 kg (61.1 lbs)

OVERALL DIMENSIONS



CLOSE RELEASE VALVE

OPENRELEASEVALVE

NUTS

MAINHANDLE

OILRESERVOIR

ACTUATORCOUPLER

Problem: The tool is advancing but does not reach full pressure

Air could be present in the hydraulic system

Use the airlock removal procedure as follows:

1. Connect the hand pump to the tool with the hydraulic hose

2. Close the release valve on the pump, and prime the pump until the hydraulic cylinder is fully extended and a small pressure is achieved

3. With the hand pump held above the tool and the tool in an upright position, open the release valve causing any air that is within the system to be forced up through the pump and vented into the oil reservoir

4. Repeat steps 1 - 3 three or four times to ensure that all air is removed from the system and the tool will reach full working pressure

5. Disconnect the hand pump from the hydraulic hose, grip the baseplate of the hand pump body in a vice with the pump body vertical and the main handle at the top

6. Remove the four nuts holding the main handle and lift off

7. Grip the refilling plug with pliers and extract it by pulling and twisting simultaneously.Ensure the reservoir body is held down when removing the refilling plug as pulling up on the reservoir body will release the bladder within, and oil will spill out.

8. Fill the reservoir to the top with a good quality hydraulic oil of the grade 32 cSt

9. Reinsert the refilling plug, wipe away any oil, and reassemble by reversing the disassembly process

7.7 TROUBLESHOOTING


Problem: The friction pad is sliding in the circumference of the opposite flange as the tool is aligning the joint

Grit or dirt on wing, rollers or bearings

Ensure the rollers are rotating freely and that there is no restriction to the rollers on the wing surfaces such as dirt or grit

Wing is at full extension Check that the wing is not at full extension when aligning the joint.

Ensure that there is enough extension left to allow the tool to expand as the joint is aligned.

Problem: The tool is attached and appears to be functioning properly, but the joint will not align

There may be something restricting the joint at a point close to the flanges

Check the area around the joint to establish if there is an obstruction to the joint

The joint may require more than 6 T (60 kN) force to align

If the joint requires more force than that of the 6 T (60 kN) tool, then another method of aligning the joint should be adopted



MINIMUM AND MAXIMUM FLANGE SIZES

Dimension A: must be between 93 and 228 mm (3.75” and 9”)

Dimension B: bolt-hole diameter must be 31.5 mm (1.25”) or greater

BY FLANGE TYPE, CLASS AND DIAMETER

If the flange to be aligned is not listed please use the Minimum and Maximum Flange Sizes guide above

DIMENSION

ADIMENSION

B

Documents

HT125KM, FA3TM, FA6TE - Fairfield Industrial Sales Manuals/Equalizer/Flang… · Equalizer International Ltd cannot be responsible for damage or injury resulting from unsafe product