Equalizer International HT125KM Montageanleitung
HT125KM, FA3TM,
FA6TE
FLANGE ALIGNMENT
TOOLS
Operator Instruction Manual
www.equalizerinternational.com
INNOVATION IN ITS MOST FUNCTIONAL FORM
FLANGE ALIGNMENT TOOLS
OPERATOR 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 6
4.2 ROTATIONAL (TWIST) MISALIGNMENT 7
5HT125KM 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
6FA3TM MECHANICAL FIXED FLANGE AND ROTATIONAL ALIGNMENT TOOL 14-21
6.1 KIT COMPONENTS 14
6.2 HOW THE FA3TM WORKS 14
6.3 INSTALLATION AND OPERATION 15-17
6.4 EXAMINATION, MAINTENANCE AND STORAGE 18
6.5 PARTS LIST 19
6.6 WEIGHTS AND DIMENSIONS 20
6.7 TROUBLESHOOTING 21
6.8 RANGE OF APPLICATION 22
7FA6TE HYDRAULIC FIXED FLANGE AND ROTATIONAL ALIGNMENT TOOL 23-31
7.1 KIT COMPONENTS 23
7.2 HOW THE FA6TE WORKS 23
7.3 INSTALLATION AND OPERATION 24-25
7.4 EXAMINATION, MAINTENANCE AND STORAGE 26
7.5 PARTS LISTS 27-28
7.6 WEIGHTS AND DIMENSIONS 29
7.7 TROUBLESHOOTING 30-31
7.8 RANGE OF APPLICATION 32
INDEX
FAT IM REV 02
28.02.08
FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 2
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
FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 3
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 nozzle
2. The tools must not be attached to a flange joint prior to
misalignment
FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 4
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.
FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 5
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
FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 6
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
FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 7
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.
PARALLEL
BOLT-HOLES
BOLT
ALIGNMENT
TOOL
ALIGNMENT
TOOL
FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 8
5. HT125KM HAND ALIGNMENT TOOL
5.1 KIT COMPONENTS
1 x HT125KM Tool
3 x Adaptor Bushes
1 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.
Dieses Handbuch passt für folgende Modelle
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