Equalizer International FA4TM Assembly instructions

FA4TM & FA9TE
FLANGE ALIGNMENT
TOOLS
Operator Instruction Manual
INNOVATION IN ITS MOST FUNCTIONAL FORM

EQUALIZER法兰错位校正器FA4TM 爱泽工业ize-industries
EQUALIZER法兰错位校正器FA4TM套件组件包括：
1 x FA4TM工具
1 x 68N·m（50ft·lb）扭矩扳手
1 x 22mm插座
1 x 棘轮带
1 x 使用说明书
1 x 携带箱
特殊功能
紧凑的轻巧设计8.6kg（19lbs）
4T（40kN）对准力
配有固定带

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
5FA4TM MECHANICAL FIXED FLANGE AND ROTATIONAL
ALIGNMENT TOOL
5.1 KIT COMPONENTS 8
5.2 HOW THE FA4TM MKII WORKS 8
5.3 INSTALLATION AND OPERATION 9-12
5.4 EXAMINATION, MAINTENANCE AND STORAGE 13-14
5.5 PARTS LIST 15
5.6 WEIGHTS AND DIMENSIONS 16
5.7 TROUBLESHOOTING 17
5.8 APPLICATION DIMENSIONS 18
6. FA9TE HYDRAULIC FIXED FLANGE AND
ROTATIONAL ALIGNMENT TOOL
6.1 KIT COMPONENTS 19
6.2 HOW THE FA9TE MKII WORKS 19
6.3 INSTALLATION AND OPERATION 20-22
6.4 EXAMINATION, MAINTENANCE AND STORAGE 23-25
6.5 PARTS LISTS 26-27
6.6 WEIGHTS AND DIMENSIONS 28
6.7 TROUBLESHOOTING 29-30
6.8 APPLICATION DIMENSIONS
7. RANGE OF APPLICATION
7.1 BS10, API6BX AND API6B FLANGE TABLES 31
7.2 ASME B16.5, B16.47 AND DIN WELD NECK FLANGE TABLES 32
7.3 SPO FLANGE TABLE 33
INDEX
FA4TM_FA9TE REV 02_04/10/2011

FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 2
The Equalizer FA4TM and FA9TE TOOLS are aids for use in normal maintenance and installa-
tion procedures, and enable the realignment of misaligned anges 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 ange 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 ange
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 FA4TM AND
FA9TE FLANGE ALIGNMENT TOOLS, during normal maintenance/installation operations.
All other safety aspects must be controlled by the operation supervisor.

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, 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 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
FA4TM Mechanical
Fixed Flange and Rotational Alignment Tool
4.0 T (40kN)
from 50 ft/lbs (67.8 Nm) of torque
FA9TE Hydraulic
Fixed Flange and Rotational Alignment Tool
9.0 T (90 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 anged joint prior to the misalignment
procedure being carried out.
4.1 LATERAL MISALIGNMENT
1. Loosen and remove every second bolt around the ange , continue with this until
misalignment occurs.
A anged 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).
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 anges
are in alignment but the operator is unable
to t 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) and use it to
push the anges 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 ange 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
5.1 KIT COMPONENTS
1 x FA4TM Tool
1 x 50 ft/lbs (67.8 Nm) Torque
Wrench with 22 mm Socket
1 x Ratchet and Strap
1 x Instruction Manual
1 x Carry-Case
Product Code: FA4TMSTD
5.2 HOW THE FA4TM WORKS
1. The FA4TM is secured to the lower of the two anges by fully inserting the
lift hook into the bolt-hole at the point of greatest misalignment.
2. The drop leg is adjusted down to the pipe while the tool is held level in the bolt-hole
3. The wing retaining screw is loosened to allow the wing to be extended out.
4. The screw bolt is turned clockwise until the friction pad comes into contact with the
circumference of the opposite ange.
5. The torque wrench is set to 50 ft/lbs (max), attached to the screw bolt and turned to
screw down on the ange, bringing the joint into alignment.
5. FA4TM MECHANICAL FIXED FLANGE AND ROTATIONAL
ALIGNMENT TOOL

FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 9
5.3 INSTALLATION AND OPERATION
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 ne scale
reach 40 N/m on base scale
2. To set 46 turn handle till ne scale
reach 6
3. 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.
KNURLED
HANDLE LOCKING
KNOB
1. Do not attempt to turn the grip while it is locked
2. 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 ne scale
= 1 N/m)
Foot Pound (Ft.lb)
70 ft/lb 75 ft/lb
(1 on ne scale
= 0.74 ft/lb)

FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 10
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. Guide the lift hook into the bolt-hole
at the maximum point of
misalignment.
Adjust the drop leg down onto the
pipe by turning the adjusting knob
in a clockwise direction. The tool
should be held up level within the
bolt-hole during adjustment.
N.B. The tool must be parallel to the
pipe at all times.
3. Loosen the wing retaining knob
and extend the wing over to the
opposite ange.
Rotate the screw bolt onto the
surface of the opposite ange.
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 ange.
POINT OF MAX.
MISALIGNMENT
POINT OF MAX.
MISALIGNMENT
DROP LEG KNOB
LIFT
HOOK
SCREW
BOLT
WING RETAINING
knob
SWIVEL
PARALLEL

FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 11
4. Attach the hook of the strap
through the buckle on top
of the base plate as shown.
5. Now place the hook of the ratchet
mechanism through the opposite
side of the buckle as shown.
6. Feed the open end of the strap
through the ratchet mechanism
as shown. Tighten the strap using
the ratchet mechanism.

FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 12
7. The torque wrench should be
set at 14 ft/lbs (19Nm) then
attached to the screw bolt
8. Tighten the screw bolt in a clockwise
direction until the anges come into
alignment; or the torque wrench
“clicks”
If the torque wrench has clicked
and the anges are still mis-aligned
adjust the torque wrench up to
24.2 ft/lbs (33 Nm) and continue
until a maximum torque wrench
setting of 50t/lbs (67.8N/m) is
reached or the anges are aligned.
The maximum safe
working load is 50
ft/lbs (67.8 N/m)
exceeding 50 ft/lbs will
result in damage to the
tool
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 FA4TM
is located), remove the
tool by reversing steps 2 -8.
Insert the last bolt and tighten.
Care should be taken not to drop any of the component parts when
removing them from the ange joint. This action will prevent injuries to
either the operator’s lower limbs, or to passers-by.

FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 13
• On return from each job and before allocation against subsequent work the
completeness of the Equalizer FA4TM 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 FA4TM 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:
5.4 EXAMINATION, MAINTENANCE AND STORAGE
1. Secure the tool upright on a
bench.
2. Using a small at screw driver, lever
out the end of the spiral clips and
then rotate anti-clockwise and
remove.
3. Slide the roller shafts out in order to
remove the rollers and bearings for
examination.
4. Inspect the roller shafts, rollers and
bearings for damage. If there is no
damage present then they can be
cleaned, greased and re-assembled
by reversing steps 1-4
Recommended grease -
Hi-load bearing grease
e.g. Rocol Saphire hi-load
SPIRAL
CLIPS
NEEDLE
BEARING
ROLLER
NEEDLE
BEARING
ROLLER
ROLLER
SHAFTS

FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 14
5. It is important that the thrust
bearing is free from dirt and
corrossion and rotates freely.
6. With the use of a penatrating oil
such as WD 40 or similar. Spray
the oil between the thrust plate
and the swivel as shown opposite.
7. Ensure the thrust plate rotates
freely before using the tool to align
a ange jont.
PENETRATING OIL
SWIVEL
THRUST
PLATE
ROTATE

FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 15
5.5 PARTS LIST
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
220100-01
220200-01
220700-01
220600-01
300401-01
230802-01
230803-01
400901-01
401601-01
401501-01
400401-01
400301-01
400501-01
404701-01
404801-01
Main Body
Sliding Arm
Leg Scrw. Extension
Leg Screw
M5X6 Grub Srew
Buckle
Round Base Pad
Ctrs Screw M6X10
Outer Roller
Needle Bearing
Spring Clip
Screw Bolt
Swiver
Thrust Race
Thrust Washer
01 ea
01 ea
01 ea
01 ea
02 ea
01 ea
01 ea
04 ea
02 ea
02 ea
01 ea
01 ea
01 ea
01 ea
02 ea
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
400801-01
220500-01
901601-01
230203-01
403201-01
713001-01
400204-01
400203-01
400280-01
400270-01
070004-01
070272-01
070273-01
070270-01
070271-01
Friction Pad
Roller Shaft
Spirol Clip
M6 Release Knob
Roller Pin
Release Valve
22 mm Socket
Torque Wrench
Ratchet Strap
Ratchet
Logo For Wing
Equalizer L. For Boss
Drop Leg Knob Sticker
Body Plate Sticker L.
Body Plate Sticker R.
01 ea
02 ea
02 ea
01 ea
01 ea
01 ea
01 ea
01 ea
01 ea
01 ea
01 ea
01 ea
01 ea
01 ea
01 ea
Item Part Description Qty Item Part Description Qty
12
2
11
19
13
15
14
15
16
8
20
17 10 9
18
21
5
3
1
18
6
4
591017
7
8
8
8
22
23
24
26
30
29
27
25
28
ITEM NO. SUP PART NO WEIGHT PART NO DESCRIPTION
Default/
QTY.
1 - 3494.62 220100-01 MAIN BODY 1
2
- 1901.90 220200-01 SLIDING ARM 1
3
- 118.55 220700-01 LEG SCREW EXTENSION 1
4
- 1444.16 220600-01 LEG SCREW 1
5
- 0.089 300401-01 M5X6MM SCKT SET SCREW 2
6
- 63.46 230802-01 BUCKLE 1
7
- 65.06 230803-01 ROUND BASE PAD 1
8
ISO 10642 3.21 400901-01 CTRS SCRW M6X10 4
9
- 105.57 401601-01 OUTER ROLLER 2
10
B-2010 (TIMKEN) 33.87 401501-01 NEEDLE BEARING 2
11
SBM0200 0.90 400401-01 SPRING CLIP 1
12
- 673.93 400301-01 SCREW BOLT 1
13
- 112.79 400501-01 SWIVEL 1
14
AXK1226 4.25 404701-01 THRUST RACE 1
15
AS1226 3.07 404801-01 THRUST WASHER 2
16
- 45.43 400801-01 FRICTION PAD 1
17
- 112.35 220500-01 ROLLER SHAFT 2
18
ES-30 2.23 901601-01 SPIROL CLIP 2
19
3714.W065 30.29 230203-01 M6 RELEASE KNOB 1
20
- 1.46 403201-01 ROLLER PIN 1
21
E1604 70.76 713001-01 RELEASE VALVE 1
22
- 103.77 400204-01 22 mm SOCKET 1
23
- 400203-01 TORQUE WRENCH 1
24
- 400280-01 RATCHET STRAP 1
25
- 400270-01 RATCHET 1
26
- 070004-01 LOGO FOR WING 1
27
- N/A 070272-01 EQUALIZER LOGO FOR BOSS 1
28
- N/A 070273-01 DROP LEG KNOB STICKER 1
29
- N/A 070270-01 BODY PLATE STICKER LEFT 1
30
- N/A 070271-01 BODY PLATE STICKER RIGHT 1

FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 16
5.6 WEIGHTS AND DIMENSIONS
WEIGHTS
Tool only = 8.6 kg (18.96 lbs)
Torque wrench/socket = 0.9 kg (1.98 lbs)
Plastic Carry-Case = 2.52 kg (5.55 lbs)
GROSS KIT WEIGHT = 11.7 kg (25.8 lbs)
DIMENSIONS
MINIMUM EXTENSION
MAXIMUM EXTENSION
367 mm (14.45”)
45 mm (1.77”)
100 mm (3.94”)
292 mm
(11.49”)
480 mm (18.89”)
357 mm
(14.06”)
158 mm (6.22”)
54 mm
(2.12”)

FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 17
5.7 TROUBLESHOOTING
Problem: The thrust plate is sliding along the circumferance of the opposite ange 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 restrictions
to the rollers on the wing surfaces such as grit or dirt
Wing is at full extension Ensure the wing has sufcient travel left in order to allow the joint to
align
Problem: The tool is attached and appears to be functioning properly, but the joint will not align
There may be something
restricting the joint from
aligning
Check the area around the joint to establish if there is an obstruction
to the joint
The joint may require more
than 4.0T (40 kN) force to
align
If the joint requires more force than that of the 4.0 T (40kN) tool,
then another method of aligning should be adopted
Problem: The thrust plate is twisting on the circumferance of the ange when the screw bolt is tightened
There may be Grit or Dirt
within the swivel / thrust plate
Check that the thrust plate rotates freely. If the thrust plate is not
rotating then spray some penetrating liquid into the gap betweeen
the swivel and thrust plate in order to loosen it

FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 18
5.8 APPLICATION DIMENSIONS
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
DIMENSION
A
DIMENSION
B