HT125KM, FA3TM, FA6TE FLANGE ALIGNMENT TOOLS Operator Instruction Manual info@equalizerinternational.com www.equalizerinternational.com INNOVATION IN ITS MOST FUNCTIONAL FORM
INDEX 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 5 HT125KM 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 6 FA3TM 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 7 FA6TE 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 FAT IM REV 02 28.02.08 PAGE 1
1. INTRODUCTION 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. 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. 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, 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 PAGE 3
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. Overloading 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 components are protected from external sources of damage, such as excessive heat, flame, moving 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 premature hose failure. 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). DANGER: Do not handle pressurised hoses. Escaping oil under pressure can penetrate 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 equipment by the hoses or couplers. Use the carrying handle or other means of safe transport. CAUTION: Do not operate the equipment without lubricating all moving parts as in section 5.4, 6.4 & 7.4. Use only high pressure molybdenum disulphide grease. PAGE 4
3. TECHNICAL DATA HT125KM FA3TM FA6TE Tool Description Hand Alignment Tool Mechanical Fixed Flange and Rotational Alignment Tool Hydraulic Fixed Flange and Rotational Alignment Tool Aligning Force 125 kg (275 lbs) Mechanical Advantage 5 to 1 3.3 T (33kN) from 50 ft/lbs (67.8 Nm) of torque 6 T (60 kn) from 10,000 psi (700 bar) of hydraulic pressure PAGE 5
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 B POINT A PAGE 6
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. ALIGNMENT TOOL PARALLEL BOLT-HOLES 2. Insert the bolt into the aligned bolthole and release the alignment tool. The load will transfer onto the bolt. 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. ALIGNMENT TOOL PAGE 7
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. PAGE 8
5.3 INSTALLATION AND OPERATION LIFT MODE: POINT OF MAX. MISALIGNMENT 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. POINT OF MAX. MISALIGNMENT 2. From the three bushes, select the one which best fits the bolt-hole of the flange requiring alignment. BUSH 3. Attach the selected bush onto the lift pin. LIFT PIN 4. Insert the bush/lift pin into the bolthole on the lower flange. Adjust the lifting assembly or the counter-balance and tighten the butterfly nuts. COUNTER- BALANCE BUTTERFLY NUT LIFTING ASSEMBLY PAGE 9
5. Lift up on the handle and the counter-balance will push down on the higher flange bringing the joint into alignment. HANDLE PUSH MODE: By removing the handle from the lifting assembly and counter-balance, the handle can be re-inserted from the opposite side. Align the joint by pushing down on the handle. In this example the joint was being aligned from the top. However if access were limited at the top the alignment could be rectified from the bottom of the joint Care should be taken not to drop any of the component parts when removing them from the flange joint. This action will prevent injuries to either the operator s lower limbs, or to passers-by. PAGE 10
5.4 EXAMINATION, MAINTENANCE AND STORAGE On return from each job and before allocation against subsequent work the completeness of the Equalizer HT125KM 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 HT125KM in a cool dry place and ensure all machined surfaces are greased Grease all moving parts regularly Ensure the roller remains grit free PAGE 11
5.5 PARTS LIST 02 * 06 07 05 * 03 ITEM PART No. DESCRIPTION QUANTITY 22- HANDLE SLEEVE-BLUE 02 2002- MAIN BAR 03* 2009-02 BUTTERFLY NUT set of 2 04 200202- LIFTING ASSEMBLY 05 200302- COUNTER-BALANCE 06* 2102- ROLL PIN 3/4 13 * 07 200502- ROLLER 08 2006- BUSH A 04 09 200402- BOLT-HOLE LEVER 10* 20-02 O RING set of 2 12 11 2008- BUSH C 10 12 2007- BUSH B 11 13* 24- ROLL PIN 1/2 08 10 * 09 * *Repair Kit Part No: 23- with Items 03, 06, 10 & 13 5.6 WEIGHTS AND DIMENSIONS MINIMUM EXTENSION MAXIMUM EXTENSION 465 mm (18.25") 230 mm (9.00") 33.0 mm (1.30") 88 mm (3.46") TOOL WEIGHT = 2.0 kg (4.4 lbs) PAGE 12
5.7 RANGE OF APPLICATION TABLE A: RANGE OF APPLICATION on ANSI, BS & API FLANGES pressure (psi) 150 300 400 600 900 1500 2500 1/2 3/4 1 1 1/4 1 1/2 2 2 1/2 3 3 1/2 4 5 6 8 10 12 14 16 Pin Only = Ø 17.0 mm (.669 ) Bush A = Ø 21.3 mm (.836 ) Bush B = Ø 24.4 mm (.957 ) Bush C = Ø 27.4 mm (1.07 ) TABLE B: RANGE OF APPLICATION on DIN FLANGES DN PN 25 32 40 50 65 80 100 125 150 200 250 300 350 400 6 10 16 25 40 64 100 160 Pin Only = Ø 17.0 mm (.669 ) Bush A = Ø 21.3 mm (.836 ) Bush B = Ø 24.4 mm (.957 ) Bush C = Ø 27.4 mm (1.07 ) PAGE 13
6. FA3TM MECHANICAL FIXED FLANGE AND ROTATIONAL ALIGNMENT TOOL 6.1 KIT COMPONENTS 1 x FA3TM Tool 1 x 50 ft/lbs (67.8 Nm) Torque Wrench with 22 mm Socket 1 x Instruction Manual 1 x Carry-Case with Protective Foam Inserts Product Code: FA3TMSTD 6.2 HOW THE FA3TM WORKS 1. The FA3TM is secured to the lower of the two flanges by fully inserting the lift hook 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 drop leg is released onto the pipe while the tool is held up level in the bolt-hole. 3. The wing retaining clip is pulled out to allow the wing to be extended to the required distance. 4. The screw bolt is turned clockwise until the friction pad comes into contact with the circumference of the opposite flange. 5. The torque wrench is set to 50 ft/lbs (max), attached to the screw bolt and turned to screw down on the flange, bringing the joint into alignment. PAGE 14
6.3 INSTALLATION AND OPERATION 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 KNURLED HANDLE Newton Scale (N/m) LOCKING KNOB 1. Turn the handle till 0 on fine scale reach 40 N/m on base scale 2. To set 46 turn handle till fine 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. 40 N/m 46 N/m (1 on fine scale = 1 N/m) Foot Pound (Ft.lb) 70 ft/lb 75 ft/lb (1 on fine scale = 0.74 ft/lb) 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. 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 PAGE 15
1. Carry out the Flange Misalignment Determination Procedure (see section 4) to determine the points of maximum misalignment. POINT OF MAX. MISALIGNMENT In this example the points of maximum misalignment are at the top and bottom of the joint. POINT OF MAX. MISALIGNMENT 2. Guide the lift hook into the bolt-hole at the maximum point of misalignment. RELEASE KNOB Release the drop leg onto the pipe (using the release knob) while holding the lift hook up level with the bolt-hole. LIFT HOOK 3. Pull the wing retaining clip out and extend the wing to the required distance. Rotate the screw bolt onto the surface of the opposite flange. 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 flange. SWIVEL SCREW BOLT WING WING RETAINING CLIP PAGE 16
4. Attach the torque wrench to the screw bolt and tighten in a clockwise direction until the joint comes into alignment. The torque wrench should be set at staged increases, e.g. 10 ft/lbs, 20ft/lbs until the maximum setting of 50ft/lbs (67.8 N/m) is reached. TORQUE WRENCH The torque wrench will click when the full 50 ft/lbs (67.8 N/m) is achieved - exceeding 50 ft/lbs will result in damage to the tool SCREW BOLT 5. 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 FA3TM is located), remove the tool by reversing steps 2-4. Insert the last bolt and tighten. Care should be taken not to drop any of the component parts when removing them from the flange joint. This action will prevent injuries to either the operator s lower limbs, or to passers-by. PAGE 17
6.4 EXAMINATION, MAINTENANCE AND STORAGE On return from each job and before allocation against subsequent work the completeness of the Equalizer FA3TM 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 FA3TM 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: 1. Place the tool on a flat bench. SPIRAL CLIP 2. Using a small flat screw driver, lever out the end of the spiral clips and then rotate anti-clockwise and remove. 3. Remove the pull pin and lift hook, unscrew the seven side plate screws, and lift off the side plate. NEEDLE BEARING PULL PIN LIFT HOOK 4. Inspect the roller pin and needle bearings within the rollers for dirt or grit. Clean and then smear a small amount of grease onto the roller pin and into the needle bearing. Recommended grease - Rocol or Sapphire Hi-Load ROLLER PIN 5. Re-assemble by reversing steps 2-3. SIDE PLATE SIDE PLATE SCREW PAGE 18
6.5 PARTS LIST 34 02 32 14 33 35 12 08 36 03 04 05 06 07 08 32 09 10 11 13 17 13 31 30 20 37 18 05 06 29 21 07 09 12 28 22 16 15 14 27 22 22 19 26 23 24 38 25 ITEM 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 PART No. 400203-400204- 4003-40- 44-02 45-02 46-02 41-43-02 4020-402002-02 4027-02 4028-02 49-14 403102-4031- 4032-4033- 4030-4004- DESCRIPTION 50ft/lbs TORQUE WRENCH 22 mm SOCKET SCREW BOLT WING C/W BOSS INNER ROLLER NEEDLE BEARING OUTER ROLLER BODY PLATES & FRAME SPIRAL CLIP WING RETAINING CLIP M3 SCREW M5 x 20MM SCREW RELEASE KNOB SCREWS FOR SIDE PLATES PULL RING PULL PIN ROLL PIN BALL SPRING PLUNGER LIFT HOOK SPRING CLIP QUANTITY set of 2 set of 2 set of 2 set set of 2 set of 2 set of 2 set of 2 set of 14 ITEM 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 PART No. 4005-4006- 4008-4009- 4026-02 4025-4024- 4023-4022- 4029-402902- 42-02 3082-4702- 48-4021- 4045-02 4046-4034- 4035- DESCRIPTION SWIVEL THRUST BEARING SET FRICTION PAD RETAINING SCREW COUNTER-SUNK SCREWS DROP LEG PAD DROP LEG GRUB SCREW SPRING DROP LEG LOCK ADJUSTING SCREW ROLLER PIN HANDLE HANDLE SLEEVE-YELLOW RETAINING SCREW SCREW (DROP LEG) PLASTIC WING INSERTS WIRE DECALS SET (not illustrated) CARRY-CASE WITH FOAM INSERT (not illustrated) QUANTITY set of 2 set of 2 set of 2 0.2 m kit kit REPAIR KIT 1. (THRUST BEARING SET) PART NUMBER 4036- CONTAINS ITEMS 20,22 & 24. REPAIR KIT 2. (ROLLER BEARING SET) PART NUMBER 4037- CONTAINS ITEMS 5,6,7 & 9. REPAIR KIT 3. (TOOL ASSEMBLY SET) PART NUMBER 4038- CONTAINS ITEMS 10, 11, 14 & 36. REPAIR KIT 4. (DROP LEG / LOCK SET) PART NUMBER 4039- CONTAINS ITEMS 12,13,25,26,28,29,30 & 31. PAGE 19
6.6 WEIGHTS AND DIMENSIONS WEIGHTS Tool only Carry-Case with Protective Foam Inserts GROSS KIT WEIGHT = 8.1 kg (17.82 lbs) = 6 kg (13.23 lbs) = 14 kg (30.90 lbs) OVERALL DIMENSIONS 380 mm (14.90") 70 mm (2.75") 288 mm (11.36") MINIMUM EXTENSION MAXIMUM EXTENSION 36 mm (1.41") 60 mm (2.36") 30 mm (1.18") 133 mm (5.23") 134 mm (5.28") PAGE 20
6.7 TROUBLESHOOTING Problem: The friction pad is sliding in the circumference of the opposite flange 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 restriction to the rollers on the wing surfaces such as dirt or grit Wing is at full extension Check that the wing is not at full extension when aligning the joint. Ensure that there is enough extension left to allow the tool to expand as the joint is aligned. Problem: The tool is attached and appears to be functioning properly, but the joint will not align There may be something restricting the joint at a point close to the flanges Check the area around the joint to establish if there is an obstruction to the joint The joint may require more than 3.3 T (33 kn) force to align If the joint requires more force than that of the 3.3 T (33 kn) tool, then another method of aligning the joint should be adopted Problem: The drop leg will not move If the drop leg lock is in contact with the frame of the tool when the teeth are engaged, the drop leg and drop leg lock will become jammed. With the teeth of the drop leg and drop leg lock engaged, the drop leg lock should be adjusted with the adjusting screw by turning it anti-clockwise until there is a small gap between the lock and the frame DROP LEG LOCK DROP LEG ADJUSTING SCREW PAGE 21
6.8 RANGE OF APPLICATION 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 B DIMENSION A BY FLANGE TYPE, CLASS AND DIAMETER If the flange to be aligned is not listed please use the Minimum and Maximum Flange Sizes guide above PAGE 22
7. FA6TE HYDRAULIC FLANGE SPREADING WEDGE 7.1 KIT COMPONENTS 1 x FA6TE Tool 1 x 10,000 psi (700 bar) 6 T Hydraulic Cylinder 1 x 10,000 psi (700 bar) Hydraulic Hose, 2 m (78.75 ) 1 x 10,000 psi (700 bar) HP350S Sealed Hand Pump with Gauge 1 x Instruction Manual 1 x Carry-Case with Protective Foam Inserts Product Code: FA6TESTD 7.2 HOW THE FA6TE WORKS 1. The FA6TE is secured to the lower of the two flanges by fully inserting the lift hook 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 drop leg is released onto the pipe while the tool is held up level in the bolt-hole. 3. The lock pin is pulled out to allow the wing to be extended to the required distance. 4. The hydraulic cylinder is secured into the adjusting sleeve. The hydrualic cylinder and adjusting sleeve are rotated clockwise until the cylinder base locates onto the surface of the opposite flange. 5. The hydraulic hose and pump are attached to the cylinder and the hand pump is primed, bringing the joint into alignment. PAGE 23
7.3 INSTALLATION AND OPERATION POINT OF MAX. MISALIGNMENT 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. POINT OF MAX. MISALIGNMENT 2. Guide the lift hook into the bolt-hole at the maximum point of misalignment. Release the drop leg onto the pipe (using the release knob) while holding the lift hook up level with the bolt-hole. LIFT HOOK RELEASE KNOB 3. Pull the spring plunger out and extend the wing to the required distance. Rotate the hydraulic adjusting cylinder clockwise until the base of the cylinder locates onto the surface of the opposite flange. HYDRAULIC ADJUSTING CYLINDER WING SPRING PLUNGER Ensure that the tool is sitting level and that the swivel on the base of the cylinder is in full and even contact with the surface of the opposite flange. SWIVEL PAGE 24
4. Connect the hydraulic pump to the hydraulic hose, and the hose to the hydraulic adjusting cylinder. Prime the pump until the joint comes into alignment. 5. 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 FA6TE is located), remove the tool by reversing steps 2-4. Insert the last bolt and tighten. Care should be taken not to drop any of the component parts when removing them from the flange joint. This action will prevent injuries to either the operator s lower limbs, or to passers-by. PAGE 25
7.4 EXAMINATION, MAINTENANCE AND STORAGE On return from each job and before allocation against subsequent work the completeness of the Equalizer FA6TE 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 FA6TE 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: 1. Place the tool on a flat bench. SUPPORT ROLLER 2. Remove the circlips on the support shafts and push the support shafts out. Remove the support rollers. 3. Using a small flat screw driver, lever out the end of the spiral clips and then rotate anti-clockwise and remove. SUPPORT SHAFT CIRCLIP 4. Remove the friction washers, rollers and finger stops. 5. Inspect the roller shafts and needle bearings within the rollers for dirt or grit. Clean and then smear a small amount of grease onto the shafts and into the needle bearings. Recommended grease - Rocol or Sapphire Hi-Load SPIRAL CLIP 6. Re-assemble by reversing steps 2-4. PAGE 26
7.5 PARTS LISTS FA6TE TOOL 03 02 24 11 04 05 06 07 08 23 22 20 19 18 17 16 15 14 12 13 09 10 21 ITEM PART No. DESCRIPTION 9031-6T HYDRAULIC ADJUSTING CYLINDER 02 900302- WING 03 900502- M10 SPRING PLUNGER 04 9007-02 FINGER STOP-FRONT 05 9008-02 SUPPORT SHAFT 06 9009-04 SUPPORT ROLLER 07 90- DROP LEG 08 4025- DROP LEG PAD 09 4026-02 COUNTER-SUNK SCREW 10 93-04 CIRCLIP 11 4022- COIL SPRING 12 4023- GRUB SCREW 13 96-04 SPIRAL CLIP 14 97-04 FRICTION WASHER 15 98-04 ROLLER 16 99-04 NEEDLE BEARING 17 4027-02 SCREW M5 x 20 18 9021-02 SHAFT 19 4028-02 RELEASE KNOB 20 9023-02 FINGER STOP REAR 21 9024- BOLT M6 x 10 22 4029- DROP LEG LOCK 23 9026- ADJUSTING SCREW 24 9027- MAIN BODY/HOOK (not illustrated) 9028- CARRY-CASE C/W FOAM (not illustrated) 9029- DECALS (Set of 5) (not illustrated) 28 3027- HYD HOSE 10,000 psi (700 bar) 29 3118- HYD PUMP 10,000 psi (700 bar) 30 3009- FEMALE HALF COUPLER 31 3026- MALE HALF COUPLER QUANTITY set of 2 set of 2 set of 4 set of 2 set of 4 set of 4 set of 4 set of 4 set of 4 set of 2 set of 2 set of 2 set of 2 PAGE 27
HP350S HAND PUMP ITEM 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 PART No. 71-715100- 7106-715200- 715300-715400- 715500-715600- 715700- DESCRIPTION PUMP HOUSING SERVICE KIT A: - OIL FILTER - O-RING - RESERVOIR BLADDER - REFILLING PLUG RESERVOIR SERVICE KIT B: - TAIL BASE - SCREW - NUT SERVICE KIT C: - O-RING - BACK-UP RING - PUMP PISTON - SNAP RING - O-RING - BACK-UP RING - PUMP PISTON SERVICE KIT D: - PISTON PIN - YOKE PIN - RETAINING RING - YOKE - HANDLE SERVICE KIT E: - YOKE BASE - PIN - SCREW - OIL SEAL SERVICE KIT F: - WASHER - COUPLERS - CHECK BALL - SCREW - RELEASE VALVE - PIN - SCREW - SCREW SERVICE KIT G: - CHECK BALL - SPRING - CHECK BALL - SPRING - WASHER - SCREW QUANTITY 04 04 02 04 03 02 02 02 02 02 02 ITEM 4 40 41 42 43 44 45 46 47 48 49 50 PART No. 715800-7147- 714802-715900- DESCRIPTION SERVICE KIT H: - CHECK BALL - SPRING END CAP - SPRING - SPRING - O-RING - SCREW - CAP O-RING SCREW SERVICE KIT I: - BASE PLATE - SCREW QUANTITY 4 02 02 02 02 02 02 PAGE 28
7.6 WEIGHTS AND DIMENSIONS WEIGHTS Tool with Hydraulic Cylinder Carry-Case with Protective Foam Inserts GROSS KIT WEIGHT = 15.5 kg (34.1 lbs) = 7.5 kg (16.5 lbs) = 28 kg (61.1 lbs) OVERALL DIMENSIONS 526 mm (20.75") 90 mm (3.50") 307 mm (12.25") 295 mm (11.62") MINIMUM EXTENSION MAXIMUM EXTENSION 32 mm (1.25") 106 mm (4.25") 35 mm (1.38") 250 mm (8.0") 102 mm (4.0") 240 mm (9.5") 210 mm (8.27") PAGE 29
7.7 TROUBLESHOOTING Problem: The tool is advancing but does not reach full pressure Air could be present in the hydraulic system Use the airlock removal procedure as follows: 1. Connect the hand pump to the tool with the hydraulic hose OIL RESERVOIR 2. Close the release valve on the pump, and prime the pump until the hydraulic cylinder is fully extended and a small pressure is achieved OPEN RELEASE VALVE 3. With the hand pump held above the tool and the tool in an upright position, open the release valve causing any air that is within the system to be forced up through the pump and vented into the oil reservoir 4. Repeat steps 1-3 three or four times to ensure that all air is removed from the system and the tool will reach full working pressure ACTUATOR COUPLER CLOSE RELEASE VALVE 5. Disconnect the hand pump from the hydraulic hose, grip the baseplate of the hand pump body in a vice with the pump body vertical and the main handle at the top 6. Remove the four nuts holding the main handle and lift off 7. Grip the refilling plug with pliers and extract it by pulling and twisting simultaneously. Ensure the reservoir body is held down when removing the refilling plug as pulling up on the reservoir body will release the bladder within, and oil will spill out. MAIN HANDLE 8. Fill the reservoir to the top with a good quality hydraulic oil of the grade 32 cst NUTS 9. Reinsert the refilling plug, wipe away any oil, and reassemble by reversing the disassembly process PAGE 30
Problem: The friction pad is sliding in the circumference of the opposite flange 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 restriction to the rollers on the wing surfaces such as dirt or grit Wing is at full extension Check that the wing is not at full extension when aligning the joint. Ensure that there is enough extension left to allow the tool to expand as the joint is aligned. Problem: The tool is attached and appears to be functioning properly, but the joint will not align There may be something restricting the joint at a point close to the flanges Check the area around the joint to establish if there is an obstruction to the joint The joint may require more than 6 T (60 kn) force to align If the joint requires more force than that of the 6 T (60 kn) tool, then another method of aligning the joint should be adopted PAGE 31
7.8 RANGE OF APPLICATION MINIMUM AND MAXIMUM FLANGE SIZES Dimension A: must be between 93 and 228 mm (3.75 and 9 ) Dimension B: bolt-hole diameter must be 31.5 mm (1.25 ) or greater DIMENSION B DIMENSION A BY FLANGE TYPE, CLASS AND DIAMETER If the flange to be aligned is not listed please use the Minimum and Maximum Flange Sizes guide above PAGE 32