Equalizer International MG7TM Assembly instructions

MG7TM
MINI-GAP
FLANGE SPREADER
Operator Instruction Manual
[email protected]
www.equalizerinternational.com
INNOVATION IN ITS MOST FUNCTIONAL FORM

FLANGE SPREADING WEDGES
OPERATOR INSTRUCTION MANUAL PAGE 1
SECTION CONTENTS PAGE NO.
1 INTRODUCTION 1
2 SAFETY INFORMATION 2-3
3 TECHNICAL DATA 4
4 HOW THE FLANGE SPREADING WEDGES WORK 4
5 EXAMINATION, MAINTENANCE AND STORAGE 5
6 MG7TM MINI-GAP FLANGE SPREADER 5-12
6.1 KIT COMPONENTS 5
6.2 INSTALLATION AND OPERATION 6-8
6.3 MAINTENANCE AND LUBRICATION 9-11
6.3 PARTS LIST 12
6.4 WEIGHTS AND DIMENSIONS 13
7 RANGE OF APPLICATION CHARTS 14-19
INDEX
IM-MG-REV07-A4
21.11.12
1. INTRODUCTION
The Equalizer MG7TM MINI-GAP FLANGE SPREADER is designed to aid the safe separation of
flange faces. This system has a unique ability to break flange joints with a 2mm gap between the
flange faces. The tool is designed to separate flanges while applying an immense amount of force
to the correct point of separation.
To extend the service life of the tool and to ensure the tool is used safely, operators must read this
instruction manual carefully before using the equipment. Following these instructions will ensure
maintenance and/or installation procedures are carried out in a reliable and safe manner.
The Equalizer MG7TM Mini-Gap Flange Spreader:
• Offers a safe and reliable working method
• Provides 6.8 tonnes of spreading force
• Separates flange faces with a gap of 2mm or greater
• Is lightweight and easy to use

FLANGE SPREADING WEDGES
OPERATOR INSTRUCTION MANUAL PAGE 2
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.
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 MG7TM MINI-
GAP MECHANICAL TOOLS during normal maintenance/installation operations. All other safety
aspects must be controlled by the operation supervisor.

FLANGE SPREADING WEDGES
OPERATOR INSTRUCTION MANUAL PAGE 3
ACAUTION is used to indicate correct operating or maintenance procedures and practices to
prevent damage to, or destruction of equipment or other property.
AWARNING indicates a potential danger that requires correct procedures or practices to avoid
personal injury.
ADANGER 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 mechanical equipment. The operator
must have read and understood all instructions,
safety issues, cautions and warnings before
starting to operate the Equalizer equipment.
WARNING: Do not overload equipment.
Overloading causes equipment failure and
possible personal injury.
CAUTION:Makesurethatallsystemcomponents
are protected from external sources of damage,
such as excessive heat, flame, moving machine
parts, sharp edges and corrosive chemicals.
WARNING: Immediately replace worn or
damaged parts with genuine Equalizer parts.
Equalizer parts are designed to fit 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).
WARNING: Never place fingers in a joint
held by an activated tool
CAUTION: Never hammer nor force the
tool into a bolt hole; if it does not fit easily
you are using the wrong size of tool.
CAUTION: Do not operate the equipment
without lubricating all moving parts. Use
only high pressure molybdenum disulphide
grease.

FLANGE SPREADING WEDGES
OPERATOR INSTRUCTION MANUAL PAGE 4
3. TECHNICAL DATA
Spreading Force
MG7TMSTD
6.8 T (68 kN) per tool
It is recommended that tools are used in pairs giving
2 x 6.8 = 13.6 T (136 kN)
The tool achieves a spreading distance of 27mm from a 2mm gap. At a 7mm gap the tool steps
down the spreading force applied from 6.8 tonnes to 3.9 tonnes.
4. HOW THE FLANGE SPREADING WEDGES WORK
1) Select tool configuration
2) Tool assembly
3) Flange spreading
The operator MUST read this
manual prior to using the tools.

FLANGE SPREADING WEDGES
OPERATOR INSTRUCTION MANUAL PAGE 5
Before and after using any Equalizer tool, ensure the full kit is available and check for any
damage or wear.
Any missing or damaged items are to be replaced as soon as possible, prior to the
tool being used again.
Store in a cool dry place and ensure all machined surfaces are greased
Grease all moving parts prior to use
5. EXAMINATION, MAINTENANCE AND STORAGE
6. MG7TM MINI-GAP FLANGE SPREADER
6.1 KIT COMPONENTS
1 x MG7TM Tool
1 x 0 16mm (0.63”) Spreading Bar
1 x 0 20mm (0.79”) Spreading Bar
1 x Instruction Manual
Product Code: MG7TMSTD

FLANGE SPREADING WEDGES
OPERATOR INSTRUCTION MANUAL PAGE 6
6.2 INSTALLATION AND OPERATION
Before attaching the tool, ensure at
least two flange bolts remain in place,
180 degrees apart, with nuts loosened
sufficiently enough for flange work to be
carried out. These bolts will reduce lateral
flange movement during flange spreading
and will help support the unit.
Do not extend the handle or use the smaller spreading bar as an extension bar.
Be aware of the dangers of breaking sealed flange joints. Ensure that relevant risk
assessments have been carried out for the task and your company procedures must
be followed at all times.
2. Choose the suitable configuration for the size and class of flange joint you wish to separate.
See the application charts found on page 14 - 19 of this manual.
The spreading bars are designed to only fit the correct flange specification. No two spreading bars
can fit the same stud hole.
Tool Configuration 1 Tool Configuration 2
Large
0 20mm (0.79”)
Spreading bar
Small
0 16mm (0.63”)
Spreading bar

FLANGE SPREADING WEDGES
OPERATOR INSTRUCTION MANUAL PAGE 7
3. Place the tool over the flange joint and align with
the desired stud hole.
4. Engage the spreading bar through the leg of the
tool and the flange stud hole.
5. Take care to ensure the spreading bar is correctly
fitted through the second leg of the tool. Check
the wedge is positioned in the gap between the
flange faces.
The flange bolting should be disassembled
as per your company's procedures and risk
assessment.
Do not hammer or use excessive force to fit
the spreading bar. The bar should be fitted by
hand.

FLANGE SPREADING WEDGES
OPERATOR INSTRUCTION MANUAL PAGE 8
6. It is strongly recommended that two
MG7TM Tools are used on the flange
joint positioned 180 degrees apart.
7. Turn each opposing tool a half turn at a time until the
desired gap is achieved. Care must
be taken to ensure the force is applied evenly.
The maximum spreading distance for the MG7TM is
27mm.
Flange
separation
Flange spreading
and seal removal
27 MAX

FLANGE SPREADING WEDGES
OPERATOR INSTRUCTION MANUAL PAGE 9
6.3 MAINTENANCE AND LUBRICATION
Before and after each job, the Equalizer Mini-Gap mechanical tool kit must be checked to
establish that they are complete and all items must be examined to ensure that they are
serviceable.
At regular intervals, and specifically after being exposed
to salt water, Mini-Gap mechanical tools should be
dismantled and lubricated as follows:
1. Lay the tool on a bench or flat
surface with the right hand side
face down.
2. Pull the spreading bar out of the
tool.
4. Remove the right hand cast leg
from the tool.
3. To Remove the left hand cast leg from the tool.
Pull the spring loaded plunger to release the leg.

FLANGE SPREADING WEDGES
OPERATOR INSTRUCTION MANUAL PAGE 10
5. Drive the handle so that the splitter
wedge moves down. Then remove
the Splitter wedge and Thrust
bearing from the tool.
6. Fully unscrew the drive screw.
Remove the main body and the
outer sleeve from the tool.

FLANGE SPREADING WEDGES
OPERATOR INSTRUCTION MANUAL PAGE 11
7. Apply grease to the drive screw.
Clean all components and inspect
for wear anddamage. Replace all
worn and damaged components
with genuine Equalizer spares.
8. Reassemble by reversing the disassembly
procedure (steps 2 to 7).
Note: it is recommended
that the tool is wiped
down with a clean rag
and WD40 or similar
cleaning fluid to remove
any dirt or grit and then
liberally greased with a
high load bearing grease
(Rocol sapphire high
load 2 or similar)

FLANGE SPREADING WEDGES
OPERATOR INSTRUCTION MANUAL PAGE 12
6.3 PARTS LIST
ITEM
NO. PART NO DESCRIPTION QTY.
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
301301-01
313401-01
313501-01
403102-01
632001-01
740101-01
740201-01
740301-01
740401-01
740501-01
740601-01
740701-01
740901-01
741101-01
741802-01
742001-01
742101-01
743101-01
READ INST. STICKER
QC SEALED STICKER
MG7TM WRAP STICKER
M6X12 GRUB SCREW
THRUST WASHER
THRUST RACE
SPLIT RING 1 1/4”
M8 SPRING PLUNGER
CAST LEG LEFT HAND
CAST LEG RIGHT HAND
MAIN BODY
SPLITTER WEDGE
LARGE SPREADING BAR
SMALL SPREADING BAR
DRIVE SCREW
OUTER SLEEVE
8 MM PLUNGER
HANDLE ASSEMBLY
BEARING WASHER
7 MM PLUNGER
COILED SPRING PIN
01 each
01 each
01 each
01 each
01 set of 2
01 each
01 each
01 set of 2
01 each
01 each
01 each
01 each
01 each
01 each
01 each
01 each
01 set of 2
01 each
01 each
01 set of 2
01 each

FLANGE SPREADING WEDGES
OPERATOR INSTRUCTION MANUAL PAGE 13
6.4 WEIGHTS AND DIMENSIONS
MG7TM MINI-GAP FLANGE SPREADER = 5 kg (11.05 lbs)
GROSS KIT WEIGHT = 5.5 kg (12.13 lbs)
Packaging Dimensions: 60 x 270 x 300 mm (7.48” x 7.09” x 12.60”)
Large φ20mm (0.79”) spreading bar
TOOL CONFIGURATION 1 TOOL CONFIGURATION 2
OPEN CLOSED
Small φ16mm (0.63”) spreading bar
TOOL CONFIGURATION 1 TOOL CONFIGURATION 2
OPEN CLOSED

FLANGE SPREADING WEDGES
OPERATOR INSTRUCTION MANUAL PAGE 14
ASME B16.5 Weldneck, Threaded, Slip-on and Blind flanges see page 15
B16.5 Socket welded see page 15
B16.5 Long welding neck flange see page 16
B16.5 Lapped flange see page 16
B16.47 Weldneck and Blind flanges see page 17
ANSI Reducing see page 17
Orifice - Weldneck flange see page 18
Orifice - Slip-on and Threaded flanges see page 18
BS 10 see page 19
7. RANGE OF APPLICATION CHARTS
Use the charts on the following pages to determine which spreading bar is suitable for a
particular flange.
The charts are categorised as per flange type.
Tool Configuration 1 Tool Configuration 2
Large
Spreading bar Small Spreading bar

FLANGE SPREADING WEDGES
OPERATOR INSTRUCTION MANUAL PAGE 15
ASME B16.5 Weldneck, threaded, slip-on and blind flanges
ASME B16.5 Socket welded flange

FLANGE SPREADING WEDGES
OPERATOR INSTRUCTION MANUAL PAGE 16
ASME B16.5 Lapped flange
ASME B16.5 Long welding neck flange
Class
NPS 150 300 600 900
1/2" Small Bar Small Bar Small Bar Large Bar
3/4" Small Bar Small Bar Small Bar Large Bar
1" Small Bar Small Bar Small Bar Large Bar
1 1/4" Small Bar Small Bar Small Bar Large Bar
1 1/2" Small Bar Small Bar Small Bar Large Bar
2" Small Bar Small Bar Small Bar Large Bar
2 1/2" Small Bar Large Bar Large Bar Large Bar
3" Small Bar Large Bar Large Bar Large Bar
3 1/2" Small Bar Large Bar Large Bar Large Bar
4" Small Bar Large Bar Large Bar Large Bar
5" Large Bar Large Bar Large Bar Large Bar
6" Large Bar Large Bar Large Bar Large Bar
8" Large Bar Large Bar Large Bar Large Bar
10" Large Bar Large Bar Large Bar
12" Large Bar Large Bar Large Bar
14" Large Bar Large Bar
16" Large Bar Large Bar
18" Large Bar Large Bar
20" Large Bar Large Bar
22"
24" Large Bar Large Bar
26" Large Bar
28" Large Bar
30" Large Bar

FLANGE SPREADING WEDGES
OPERATOR INSTRUCTION MANUAL PAGE 17
ANSI Reducing
ASME B16.47 Weldneck and blind flanges

FLANGE SPREADING WEDGES
OPERATOR INSTRUCTION MANUAL PAGE 18
ANSI Orifice - Weldneck flange
ANSI Orifice - Slip-on and Threaded flanges

FLANGE SPREADING WEDGES
OPERATOR INSTRUCTION MANUAL PAGE 19
BS 10