Equalizer FA4TM Assembly instructions
FA4TM & FA9TE
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
5FA4TM MECHANICAL FIXED FLANGE AND ROTATIONAL
ALIGNMENT TOOL
5.1 KIT COMPONENTS 8
5.2 HOW THE FA4TM 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 WORKS 19
6.3 INSTALLATION AND OPERATION 20-22
6.4 EXAMINATION, MAINTENANCE AND STORAGE 23-24
6.5 PARTS LISTS 25-27
6.6 WEIGHTS AND DIMENSIONS 28
6.7 TROUBLESHOOTING 29-30
6.8 APPLICATION DIMENSIONS 31
7. RANGE OF APPLICATION
7.1 BS10, API6BX AND API6B FLANGE TABLES 32
7.2 ASME B16.5, B16.47 AND DIN WELD NECK FLANGE TABLES 33
7.3 SPO FLANGE TABLE 34
FA4TM_FA9TE REV 06 06/06/14
INDEX
FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 2
The Equalizer FA4TM and FA9TE TOOLS are aids for use in normal maintenance and installa-
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respective working capacities. For example, all of the tools can be used to assist in the
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promote safe use, and maximize the service life of the tools. It is recommended that the
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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
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(TXDOL]HU,QWHUQDWLRQDO/WGFDQQRWEHUHVSRQVLEOHIRUGDPDJHRULQMXU\UHVXOWLQJIURPXQVDIH
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 15cSt.
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
SHUVRQDOLQMXU\
A DANGERLVRQO\XVHGZKHQ\RXUDFWLRQRUODFNRIDFWLRQPD\FDXVHVHULRXV LQMXU\ RU HYHQ
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: 7R DYRLG SHUVRQDO LQMXU\ DQG
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
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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
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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.
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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
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properly and withstand rated loads. For
repair or maintenance service contact your
Equalizer distributor or service centre.
DANGER: 7R DYRLG SHUVRQDO LQMXU\ NHHS
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-
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RLOLVLQMHFWHGXQGHUWKHVNLQVHHNPHGLFDO
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
7KHWRROEHLQJXVHGPXVWQRWEHDWWDFKHGWRDÀDQJHGMRLQWSULRUWRWKHPLVDOLJQPHQW
procedure being carried out.
4.1 LATERAL MISALIGNMENT
1. /RRVHQDQGUHPRYHHYHU\VHFRQGEROWDURXQGWKHÀDQJHFRQWLQXHZLWKWKLVXQWLO
misalignment occurs.
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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
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are in alignment but the operator is unable
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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
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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
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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. 7KH)$70LVVHFXUHGWRWKHORZHURIWKHWZRÀDQJHVE\IXOO\LQVHUWLQJWKH
lift hook into the bolt-hole at the point of greatest misalignment.
2. 7KHGURSOHJLVDGMXVWHGGRZQWRWKHSLSHZKLOHWKHWRROLVKHOGOHYHOLQWKHEROWKROH
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
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5. The torque wrench is set to 50 ft/lbs (max), attached to the screw bolt and turned to
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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
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reach 40 N/m on base scale
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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
RQ¿QHVFDOH
= 1 N/m)
Foot Pound (Ft.lb)
70 ft/lb 75 ft/lb
RQ¿QHVFDOH
= 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
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2. Guide the lift hook into the bolt-hole
at the maximum point of
misalignment.
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SLSHE\WXUQLQJWKHDGMXVWLQJNQRE
in a clockwise direction. The tool
should be held up level within the
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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
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Rotate the screw bolt onto the
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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
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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
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alignment; or the torque wrench
“clicks”
If the torque wrench has clicked
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DGMXVWWKHWRUTXHZUHQFKXSWR
24.2 ft/lbs (33 Nm) and continue
until a maximum torque wrench
setting of 50t/lbs (67.8N/m) is
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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
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either the operator’s lower limbs, or to passers-by.
FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 13
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completeness of the Equalizer FA4TM kit must be established and
items examined to ensure that they are serviceable
$Q\PLVVLQJRUGDPDJHGLWHPVDUHWREHUHSODFHGDVVRRQDVSRVVLEOHDQGSULRUWRWKH
tool being used again
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are greased
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(QVXUHUROOHUVSLQVDQGZLQJUHPDLQJULWIUHHDQGWKDWWKHUROOHUVURWDWHIUHHO\
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5.4 EXAMINATION, MAINTENANCE AND STORAGE
1. Secure the tool upright on a
bench.
2. 8VLQJDVPDOOÀDWVFUHZGULYHUOHYHU
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
DÀDQJHMRQW
PENETRATING OIL
SWIVEL
THRUST
PLATE
ROTATE
FLANGE ALIGNMENT TOOLS
OPERATOR INSTRUCTION MANUAL PAGE 15
25
27
20
28
13
10
292
16
3
18
15
21
22
4
19
517 18
24
23
7
1
24
8
6
30
26
175
22
9
19
19
12
11
14
30
5.5 PARTS LIST
ITEM NO.
PART NO
DESCRIPTION
QTY.
1 220500-01
ROLLER SHAFT
2
2 230802-01
BUCKLE
1
3 230803-01
ROUND BASE PAD
1
4 400301-01
SCREW BOLT
1
5 400401-01
SPRING CLIP
1
6 220300-01
SWIVEL
1
7 220400-01
FRICTION PAD
1
8 401501-01
NEEDLE BEARING
2
9 401601-01
OUTER ROLLER
2
10 404701-01
THRUST RACE
1
11 404801-01
THRUST WASHER
2
12 901601-01
SPIROL CLIP
4
13 220100-01
MAIN BODY
1
14 401001-01
SLIDING ARM ASS
1
15 220700-01
LEG SCREW EXTENSION
1
16 220600-01
LEG SCREW
1
17 402601-01
CTRS SCREW M6X10
3
18 212000-01
SPRING RING 8MM
1
19 070270-01
BODY PLATE STICKER LEFT
1
20 070271-01
BODY PLATE STICKER RIGHT
1
21 070004-01
LOGO FOR WING
1
22 070272-01
EQUALIZER LOGO FOR BOSS
1
23 070273-01
DROP LEG KNOB STICKER
1
24 220602-01
SPIROL CLIP
1
25 300401-01
M5 SCKT SET SCREW
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
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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 (QVXUHWKHZLQJKDVVXI¿FLHQWWUDYHOOHIWLQRUGHUWRDOORZWKHMRLQWWR
align
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There may be something
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aligning
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WRWKHMRLQW
7KHMRLQWPD\UHTXLUHPRUH
than 4.0T (40 kN) force to
align
,IWKHMRLQWUHTXLUHVPRUHIRUFHWKDQWKDWRIWKH7N1WRRO
then another method of aligning should be adopted
3UREOHP7KHWKUXVWSODWHLVWZLVWLQJRQWKHFLUFXPIHUDQFHRIWKHÀDQJHZKHQWKHVFUHZEROWLVWLJKWHQHG
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
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