Equalizer TFA4TM Assembly instructions

OPERATOR INSTRUCTION MANUAL
EQUALIZER INTERNATIONAL LTD
www.equalizerinternational.com
TOWER
FLANGE
ALIGNMENT
TOOL
TFA4TM

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CONTENTS
1. INTRODUCTION
2. TOOL SAFETY
2.1 GENERAL SAFETY
2.2 PERSONNEL COMPETENCY
2.3 DISCLAIMER
2.4 DEFINITION OF TERMS
2.5 HAZARDS
3. TFA4TM MECHANICAL FLANGE ALIGNMENT TOOL
3.1 TOOL CAPABILITIES
3.2 RANGE OF APPLICATION
3.3 TOOL FUNCTION
3.4 KIT CONTENTS
3.5 TOOL DIMENSIONS
3.6 TOOL MAINTENANCE
4. TROUBLESHOOTING
4.1 TFA4TM TROUBLESHOOTING
5. REGULATORY INFORMATION
5.1 REGISTERED HEAD OFFICE
6. PARTS LISTS & SERVICE KITS
20/07/2017

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1.
INTRODUCTION
The Equalizer™ TFA4TM Tower Flange Alignment
Tool is an aid for use in normal maintenance and
installation procedures, and enables the realignment
of large anges, for example those that make up the
tower sections of a wind turbine.
It is essential that the user familiarises themselves
with the contents of this manual prior to using the
tool.
This manual contains information for the following
tools:
• TFA4TM Tower Flange Alignment Tool
2.
SAFETY INFORMATION
2.1
GENERAL SAFETY
These instructions cover the safe operation and
maintenance of THE EQUALIZER TFA4TM TOWER
FLANGE ALIGNMENT tool. The use of this tool should
be as part of a broader task-based risk assessment,
which should be carried out by the operation
supervisor or other competent person.
Failure to comply with the safety information
contained within this manual could result in personal
injury or equipment damage. Read all instructions,
warnings and cautions carefully, and follow all safety
precautions.
The safety of the operator, any assisting personnel
and the general public is of paramount importance.
Always work in accordance with applicable national,
local, site & company-wide safety procedures.
2.2
PERSONNEL COMPETENCY
Only personnel deemed competent in the use of
mechanical and hydraulic equipment should use this
tool.
2.3
DISCLAIMER
Equalizer cannot be held responsible for injury or
damage resulting from unsafe product use, lack of
maintenance or incorrect product and/or system
operation. If in doubt as to the safety precautions
and applications, contact Equalizer using the contact
details at the back of this manual.

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2.4
DEFINITION OF TERMS
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.
DO: an illustration showing how the tool should
be used.
DON’T: an illustration showing an incorrect way
to use a tool.
2.5
HAZARDS
WARNING: ensure all hydraulic components
are rated to a safe working pressure of 700 bar
(10 000 psi).
WARNING: Do not overload equipment. The
risk of hydraulic overloading can be minimised
by using the Equalizer Hand Pump, which has a
factory-set safety valve preventing the safe
working pressure being exceeded.
If alternative hydraulic pumps are used, ensure
that there are adequate systems to limit the
working pressure to 700 bar (10 000 psi).
CAUTION: ensure components are protected
from external sources of damage, such as
excessive heat, ame, moving machine parts,
sharp edges and corrosive chemicals.
CAUTION: Take care to avoid sharp bends and
kinks in hydraulic hoses. Bends and kinks can
cause severe back-up pressure and cause hose
failure. Protect hoses from dropped objects; a
sharp impact may cause internal damage to
hose wire strands. Protect hoses from crush
risks, such as heavy objects or vehicles; crush
damage can cause hose failure.
WARNING: Applying pressure to a damaged
hose may cause it to rupture.
WARNING: Immediately replace worn or
damaged parts. Use only genuine Equalizer
parts from approved distributors or service
centres. Equalizer parts have been engineered
and manufactured to be t-for-purpose.
DANGER: To minimise risk of personal injury
keep hands and feet away from the tool and
workpiece during operation.
WARNING: Always wear suitable clothing and
Personal Protective Equipment (PPE). Do not
handle pressurised hoses; escaping oil under
pressure can penetrate the skin, causing serious
injury. Seek medical attention immediately if oil
penetration is suspected.
WARNING: Only pressurize complete and fully
connected hydraulic systems. Do not pressurize
systems that contain unconnected couplers.
CAUTION: Do not lift hydraulic equipment by
the hoses or couplers. Use only the designated
carrying handles.
CAUTION: Lubricate tools as directed in this
manual prior to operation. Use only approved
lubricants of high quality, following the lubricant
manufacturers instructions.
CAUTION: Only use the designated anchor
point for xing the lanyard. Do not attach the
lanyard to the plastic handle.
DANGER: Care should be taken when using
the lanyard to avoid entanglement with body
parts.
The vibration total value to which this tool is
subjected does not exceed 2.5 m/s2.

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3.
TFA4TM
MECHANICAL FLANGE
ALIGNMENT TOOL
TheTFA4TMTower Flange Alignment Tool uses mechanical
torque to advance the screw bolt and align the anges.
3.1
TOOL CAPABILITIES
ALIGNING FORCE
Maximum SWL torque of 68 N·m (50 ft·lb) will generate
4 T (40 kN) aligning force.
3.2
RANGE OF APPLICATION
Minimum and Maximum Flange sizes:
Dimension A: must be between 30 mm and 133 mm
(1.18” and 5.23”)
Dimension B: bolt-hole diameter must be 24 mm
(0.94”) or greater
DIMENSION
A
DIMENSION
B
3.3
TFA4TM TOOL FUNCTION
MECHANICAL TOOL OPERATION
The TFA4TM Alignment tool uses mechanical torque
to advance the screw bolt and align the anges. The
torque is applied using the supplied Torque Wrench,
enabling accurate control of the force applied.
TORQUE WRENCH USAGE
Holding the Torque Wrench in one hand, unlock the
knurled handle by turning the locking knob anti-
clockwise.
Select the torque setting by turning the knurled
handle until the required torque value is indicated.
For example, to set the Torque Wrench to 46 N·m:
turn the knurled handle until the 0 on the ne scale
aligns with 40 N·m on base scale; now turn slightly
further until the 6 on the ne scale aligns with the
central line.
Setting an imperial torque (in ft·lb) is done in exactly
the same way.
Lock the handle by turning the locking knob clockwise.
Do not attempt to turn the grip while it is locked.
Install the supplied socket onto the Torque Wrench
and attach to the tool.
Slowly and smoothly pull the handle, gradually
applying more force until you feel or hear the Torque
Wrench click, indicating that the selected torque has
been achieved. Do not continue to apply force after
the Torque Wrench has clicked. Special care should
be taken when using low torque settings.

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TORQUE WRENCH CARE
Prior to storing the Torque Wrench, and between
use, leave the Torque Wrench with its lowest torque
setting selected.
To clean the Torque Wrench, wipe gently with a
damp cloth. Avoid using any detergent or solvent
as this may detrimentally affect the factory-tted
internal lubrication of the mechanism.
TFA4TM GENERAL GUIDANCE
The TFA4TM is secured into the lower of the two
anges by fully inserting the lift hook into the bolt
hole at the greatest point of misalignment.
The drop leg is adjusted by hand to land on the
tower.
The wing retaining screw is loosened to allow the
wing to be extended.
The screw bolt is adjusted to land the friction pad on
the opposite ange.
Then torque wrench is then attached to the screw
bolt and turned to provide the alignment force.
SCREW
BOLT
TORQUE
WRENCH
DROP
LEG
LIFT
HOOK
FRICTION
PAD
WING

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ACTUATING THE TFA4TM
Guide the lift hook into the bolt-hole at the
maximum point of misalignment.
Adjust the drop leg down onto the tower by turning
the adjustment knob in a clockwise direction. The
tool should be held up level within the bolt-hole
during adjustment.
DROP LEG KNOB
LIFT
HOOK
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.
SCREW
BOLT WING RETAINING
KNOB
SWIVEL
The torque wrench should be set at 19 N·m (14 ft·lb)
then attached to the screw bolt.
Tighten the screw bolt in a clockwise direction until
the anges come into alignment.
If the torque wrench has clicked and the anges
are still misaligned adjust the torque wrench up to
33 N·m (24 ft·lb) and continue until a maximum
torque wrench setting of 68 N·m (50 ft·lb) is
reached or the anges are aligned.

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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 TFA4TM
is located), remove the tool. Insert the last bolt and
tighten.
WARNING: The maximum safe working
load is 68 N·m (50 ft·lb). Exceeding 68 N·m
(50 ft·lb) will result in damage to the tool.
WARNING: 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.
3.4
TFA4TM KIT CONTENTS
STANDARD KIT
Product Code: TFA4TMSTD
1 x TFA4TM Tool
1 x Torque Wrench
1 x Instruction Manual
1 x Carry-Case
Carry-Case Dimensions:
600 mm x 370 mm x 200 mm
(23.6” x 14.6” x 7.9”)
Tool only Weight: 8.1 kg (17.9 lb)
Gross Kit Weight: 18 kg (39.7 lb)

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3.6
TFA4TM TOOL MAINTENANCE
INSPECTION
A thorough inspection should be carried out prior
to usage, storage or transportation to ensure the
completeness and condition of the tool.
Inspection should include:
• visual inspection of the outer parts of the tool,
checking for obvious damage, degradation or
missing parts.
• visual inspection of the swivel, screw bolt and
leg screw, checking for obvious damage and
degradation.
Cleaning and servicing should be undertaken as
required prior to the tool being used, stored or
transported.
CLEANING
To lightly clean the tool, wipe gently with a damp
cloth.
If more thorough cleaning is required (for example
following immersion in water) carry out the following
cleaning procedure:
• strip the tool down, observing the schematics in
section 6
• clean the components using detergent, following
the manufacturer’s guidelines
• rinse the components to remove traces of
detergent
• dry the component thoroughly
Inspect, service and lubricate the tool immediately
after the cleaning process.
3.5
TFA4TM TOOL DIMENSIONS
MINIMUM EXTENSION
344 mm
13.54”
45 mm
1.77”
51 mm
2.01”
274 mm
10.79”
MAXIMUM EXTENSION
38 mm
1.10”
178 mm
7.01”
454 mm
17.87”
357 mm
14.06”
106 mm
4.17”

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It is important that the thrust bearing is free from
dirt and corrosion and rotates freely.
With the use of a penetrating oil such as WD-40 or
similar, spray the oil between the thrust plate and
the swivel as shown below.
SWIVEL
THRUST
PLATE
PENETRATING OIL
Ensure the thrust plates rotate freely before using
the tool to align a ange joint.
ROTATE
SERVICING
Replace missing, worn or damaged parts. Use only
genuine Equalizer parts from approved distributors
or service centres. Equalizer parts have been
engineered and manufactured to be t for purpose.
Grease all moving parts by following the Lubrication
Procedure prior to usage, storage or transportation.
Ensure rollers, pins and wing remain grit free and
that the rollers rotate freely.
Secure the tool upright on a bench.
Using a small at screw driver, lever out the end of
the spiral clips and then rotate anti-clockwise and
remove.
Slide the roller shafts out in order to remove the
rollers and bearings for examination.
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
the steps above.
Recommended grease: Hi-load bearing grease, e.g.
Rocol Saphire hi-load.
SPIRAL
CLIPS
NEEDLE
BEARING
ROLLER
NEEDLE
BEARING
ROLLER
ROLLER
SHAFTS

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STORAGE AND TRANSPORTATION
Equalizer tools should be stored in a cool, dry
place. Tools should always be cleaned, serviced and
lubricated prior to storage. Ensure that tools are
stored in their designated packing cases.
SUBSEA USAGE
Using TFA4TM Sub-Sea:
The TFA4TM is actuated mechanically and can be
used sub-sea providing the following actions are
taken:
• The tool is actuated via the torque wrench by a
diver.
• The tool is stripped down, cleaned and lubricated
immediately to minimise corrosion.

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4.
TROUBLESHOOTING
4.1
TFA4TM TROUBLESHOOTING
THE THRUST PLATE IS SLIDING ALONG
THE CIRCUMFERENCE OF THE OPPOSITE
FLANGE AS THE TOOL IS ALIGNING THE
JOINT
POSSIBLE CAUSE:
Grit or dirt on wing, rollers or bearings.
RECOMMENDED ACTION:
Ensure the rollers are rotating freely and that
there is no restrictions to the rollers on the wing
surfaces such as grit or dirt.
POSSIBLE CAUSE:
Wing is at full extension.
RECOMMENDED ACTION:
Ensure the wing has sufcient travel left in order
to allow the joint to align.
THE TOOL IS ATTACHED AND APPEARS
TO BE FUNCTIONING PROPERLY, BUT
THE JOINT WILL NOT ALIGN
POSSIBLE CAUSE:
There may be something restricting the joint
from aligning.
RECOMMENDED ACTION:
Check the area around the joint to establish if
there is an obstruction to the joint.
POSSIBLE CAUSE:
The joint may require more than 4 T (40 kN)
force to align.
RECOMMENDED ACTION:
If the joint requires more force than that of
the 4 T (40 kN) tool, then another method of
alignment should be adopted.
THE THRUST PLATE IS TWISTING ON THE
CIRCUMFERENCE OF THE FLANGE WHEN
THE SCREW BOLT IS TIGHTENED
POSSIBLE CAUSE:
Theremaybegritordirtwithintheswivel/thrust
plate.
RECOMMENDED ACTION:
Check that the thrust plate rotates freely. If
the thrust plate is not rotating then spray some
penetrating liquid into the gap between the
swivel and thrust plate in order to loosen it.

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6.
PARTS LISTS
& SERVICE KITS
5.
REGULATORY
INFORMATION
5.1
REGISTERED HEAD OFFICE
EQUALIZER INTERNATIONAL LTD.
Equalizer House
Claymore Drive
Aberdeen
Scotland
AB23 8GD

ITEM NO. PART NO DESCRIPTION QTY
1 220100-01 MAIN BODY 1
2 1720005-01 MAIN SCREW 1
3 400301-01 SCREW BOLT 1
4 220300-01 SWIVEL 2
5 220400-01 FRICTION PAD 2
6 212000-01 SPRING RING 8MM 2
7 400401-01 SPRING CLIP 2
8 404701-01 THRUST RACE 2
9 404801-01 THRUST WASHER 4
10 1720006-01 FOOT CAP FLANGE 2
11 220500-01 ROLLER SHAFT 2
12 401501-01 NEEDLE BEARING 2
13 401601-01 OUTER ROLLER 2
14 901601-01 SPIROL CLIP 2
15 220700-01 LEG SCREW EXTENSION 1
16 070273-01 DROP LEG KNOB STICKER 1
17 300401-01 M5 SCKT SET SCREW 2
18 401001-01 SLIDING ARM ASS 1
19 403201-01 ROLLER PIN 1
20 1720002-01 BODY PLATE STICKER RIGHT 1
21 1720001-01 BODY PLATE STICKER LEFT 1
22 1720003-01 EQUALIZER LOGO FOR BOSS 1
23 070004-01 LOGO FOR WING 1
24 1720008-01 LOCK NUT 1
25 1720009-01 MAIN SCREW BALL JOINT 1
TFA4TM PARTS LIST
1720000-01
REV 01

3
23
18
7
4
6
9
8
9
5
10
20
19
1
22
17
2
7
4
6
9
8
9
5
10
14
21
15 16
11 12 13 14
11 12 13
25
17
24
01 REV
1720000-01
TFA4TM PARTS LIST

EQUALIZER INTERNATIONAL LTD.
Head Office
Equalizer House
Claymore Drive
Aberdeen
Scotland
UK
AB23 8GD
t: [phone]
f: [phone]
Houston Office
1330 Yale Street
Houston TX 77008
USA
t: [phone]
www.equalizerinternational.com