EQUALIZER International Limited

Range of Flange Alignment Tools

Operator Instruction Manual
 INDEX
THE EQUALIZER RANGE OF FIXED
FLANGE & ROTATIONAL ALIGNMENT TOOLS
Instruction Manual

SECTION CONTENTS PAGE NO(S)

01. GENERAL INFORMATION 01
1.01 INTRODUCTION 01
1.02 SAFETY INFORMATION 01
1.03 MIS-ALIGNMENT DETERMINATION 02
PROCEDURE
1.04 ROTATIONAL (TWIST) MIS-ALIGNMENT 02
1.05 STORAGE 02
02. THE EQUALIZER HAND ALIGNMENT TOOL 03
2.01 HOW IT WORKS 04
2.02 COMPONENT PARTS 04
2.03 EXAMINATION & MAINTENANCE 04
2.04 INSTALLATION & OPERATION 05-06
2.05 PARTS LIST (EXPLODED DRAWING) 06
2.06 MINIMUM / MAXIMUM EXTENSIONS 07
2.07 WEIGHTS & DIMENSIONS 07
2.08 RANGE OF APPLICATION (TYPE, CLASS & DIAMETER) 07
2.09 DISMANTLING THE EQUALIZER HAND ALIGNMENT TOOL 07
2.10 SPECIFICATION 07
03. THE EQUALIZER 3T(M) MECHANICAL FIXED FLANGE & 08
ROTATIONAL ALIGNMENT TOOL
3.01 HOW IT WORKS 09
3.02 COMPONENT PARTS 09
3.03 EXAMINATION & MAINTENANCE 09
3.04 INSTALLATION & OPERATION 10
3.05 PARTS LIST (EXPLODED DRAWING) 11
3.06 LUBRICATING THE TOOL 12
3.07 TROUBLE SHOOTING 12
3.08 MINIMUM / MAXIMUM EXTENSIONS 13
3.09 RANGE OF APPLICATION (QUICK GUIDE) 13
3.10 RANGE OF APPLICATION (TYPE, CLASS & DIAMETER) 14
3.11 WEIGHTS & DIMENSIONS 14
3.12 DISMANTLING THE EQUALIZER 3T(M) 15
3.13 SPECIFICATION 15
3.14 SETTING THE DROP LEG LOCK 15
04. THE EQUALIZER 5T(E) HYDRAULIC FIXED FLANGE & 16
ROTATIONAL ALIGNMENT TOOL
4.01 HOW IT WORKS 17
4.02 COMPONENT PARTS 17
4.03 EXAMINATION & MAINTENANCE 17
4.04 INSTALLATION & OPERATION 18
4.05 PARTS LIST (EXPLODED DRAWING) 19
4.06 LUBRICATING THE TOOL 20
4.07 TROUBLE SHOOTING 20
4.08 AIR LOCK REMOVAL 21
4.09 MINIMUM / MAXIMUM EXTENSIONS 21
4.10 RANGE OF APPLICATION (QUICK GUIDE) 22
4.11 RANGE OF APPLICATION (TYPE, CLASS & DIAMETER) 22
4.12 WEIGHTS & DIMENSIONS 23
4.13 DISMANTLING THE EQUALIZER 5T(E) 23
4.14 SPECIFICATION 23
4.15 DIS-ASSEMBLY / ASSEMBLY 24

AIM001 Rev 0
10/01/05
1. GENERAL INFORMATION PAGE 1

1.01 INTRODUCTION
The EQUALIZER Hand Alignment Tool, The EQUALIZER 3T(M) Mechanical Fixed Flange &
Rotational Alignment Tool, & The EQUALIZER 5T(E) Hydraulic Fixed Flange & Rotational
Alignment Tool are aids for use in normal maintenance and installation procedures and enable
the realignment of mis-aligned 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 the safe use and maximum service life of each tool.
It is recommended that the operator read the relevant sections of this Instruction manual for the
particular alignment tool to be used.

1.02 SAFETY INFORMATION

In all installations the site safety requirements must be adhered to. Of paramount importance is the
safety of the operator and any assisting personnel.
These instructions are only to cover the safe operation of The EQUALIZER Hand Alignment Tool,
The EQUALIZER 3T(M) Mechanical Fixed Flange & Rotational Alignment Tool, & The
EQUALIZER 5T(E) Hydraulic Fixed Flange & Rotational Alignment Tool respectively during a
normal maintenance / installation operation. All other safety aspects must be controlled by the
operation supervisor.
Please note the following:
1. the tools must not be attached to a pressure vessel nozzle, and;
2. The tools must not be attached to a flange joint prior to misalignment.

1.03. MISALIGNMENT DETERMINATION PROCEDURE

The tool being used must not be attached to a flanged joint prior to the misalignment
determination procedure being carried out.

Every second bolt should be slackened and removed around the flange. Continue with this
procedure. Misalignment may not occur until only a few bolts remain. At this point the direction
of any misalignment should become obvious.

The tool being used, once attached, can be levered against the higher of the flanges in order to
bring the joint back into alignment.
Misalignment in various directions. A flanged joint, once broken down, may spring out of
alignment at any point, or in any direction around it`s circumference. See example on Figs 1 & 2
respectively.
A
A

The alignment tool being used should be

attached at the maximum point of
misalignment shown on the two flange joints:
FIG 1 i.e. Points A or B on Fig 1. Or Fig 2. FIG 2
Each of the examples shows where where the
tool being used should be attached.

B
 PAGE 2
1.04. ROTATIONAL (TWIST) MISALIGNMENT

This is a common problem on both onshore and offshore pipeline installations

(see Fig.1.) Quite often the flanges are in alignment but the operator is
unable to fit the bolt into any two corresponding bolt-holes on the joint`s
circumference.
FIG 1
The alignment tool being used, within it`s safe working capacity, has the
ability to ‘manipulate’ the flange joint in various directions.

The setting-up procedure will be the same shown in sections

5.04, 6.04, & 7.04 respectively with one possible exception.
The alignment tool being used can be attached to the most
FIG 2 accessible point on the joint`s circumference because the
misalignment occurs at all bolt -holes to the same degree.

The recommended operating procedures are:

1. Select the most convenient or accessible point on the
joint`s circumference and attach the tool being used there.
(Follow steps 1 thru 3 in sections 5.04, 6.04, & 7.04
A respectively);
2. In this situation when both flanges are aligned but rotational misalignment is present, the alignment
tool is used to push the flanges out of alignment until one pair of bolt-holes becomes parallel
(see point A on FIG 2), & ;
3. Insert the bolt into the bolt-hole at point A and then release the alignment tool. The load will transfer
onto the inserted bolt.

The alignment tool can then be attached

at another point on the joint`s
circumference (see FIG.3) pushing
FIG 3 against the inserted bolt. Advance
the Hydraulic Cylinder until another,
or all the bolt-holes are parallel. FIG 4
Once the remaining bolts are inserted
the alignment tool can be removed
(see FIG.4).

Please note that in some situations the operator may have to ‘chase’ the misalignment around the
joint`s circumference and attach the alignment tool at several different positions to rectify the
misalignment. On each occasion the procedures outlined in steps 1 thru 3 in sections 5.04, 6.04, & 7.04
respectively should be followed.

1.05. STORAGE
Each of the tools should be stored in a cool dry place. Machined surfaces should be smeared with grease.
2. THE EQUALIZER HAND ALIGNMENT TOOL PAGE 3
 PAGE 4
2.01. HOW IT WORKS

The EQUALIZER Hand Alignment Tool should be

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.
Adjust the counter-balance to the desired
distance and tighten the butterfly nut on top.
The flange can now be levered up into alignment
and the bolts inserted.

2.02. COMPONENT PARTS

1 x Hand Alignment Tool

3 x Adaptor Bushes
1 x Instruction Manual
1 x Poly Bag
GROSS WEIGHT = 2 kg (4.4 lbs)

2.03. EXAMINATION & MAINTENANCE

On return from each job, and before allocation against subsequent work, the completeness of
The EQUALIZER Hand Alignment Tool 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 being used
again.

Grease all moving parts regularly.

Ensure roller remains grit free.

 PAGE 5
2.04. INSTALLATION AND OPERATION

A. Lift Mode

Step 1. - The Problem

Determine the maximum points of misalignment. On the
opposite example these points are on the top or bottom of
the joint, as illustrated by the arrows.

Step 2. - Bush Selection

From the three bushes, select the one which best fits the
bolt-hole of the flange requiring alignment. Once the correct
bush has been selected it should be attached onto the lift
pin of The EQUALIZER Hand Alignment Tool.

On this occasion the illustration shows the joint being

aligned from the top, but if access should be a problem the
alignment could be rectified from the bottom of the joint.

Lift Pin

Step 3. - Locating Bush On Lift Pin

Attach the bush to the lift pin as illustrated.

Counter-Balance

Lifting Assembly
Step 4. - Inserting Bush / Lift Pin
Insert the bush / lift pin into the bolt-hole on the lower
flange. Adjust the lifting assembly or the counter-balance,
and tighten the butterfly nuts.
 PAGE 6
Step 5. - Lift Up On Handle
Lift Mode

Lift up on handle and the counter-balance will push

down on the higher flange bringing the joint into
alignment.

B. - Push Mode
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

2.05. PARTS LIST (EXPLODED DRAWING)

ITEM PART No DESCRIPTION QTY

01 201201-01 Handle Sleeve-Blue 01 ea

02 200102-01 Main Bar 01 ea
03
04 * 200901-02
200202-01
Butterfly Nut
Lifting Assembly
01 set of 2
01 ea
05 200302-01 Counter-balance 01 ea
06
07
08
* 201102-01
200502-01
Roll Pin 3/4“
Roller
Bush A
01 ea
01 ea
01 ea
200601-01
09 200402-01 Bolt-Hole Lever 01 ea
10
11 * 201001-02
200801-01
“O” Ring
Bush C
Bush B
01 set of 2
01 ea
01 ea
12 200701-01

*
13 201401-01 Roll Pin 1/2“ 01 ea 01

* Repair Kit Part No: 201301-01 C/W Items 03,06,10 & 13 02

* 03
05

13 *
* 06 04

12
07 11
10
*
09
10
08
*
 PAGE 7
2.06. MINIMUM / MAXIMUM EXTENSIONS

Minimum Extension Maximum Extension

33.0 mm (1.30“) 88.0 mm (3.46“)

2.07. WEIGHTS AND DIMENSIONS

465 mm (18.25“)

230 mm
(9.00“)

Gross Weight = 2.00 Kg (4.4 lbs)

2.08. RANGE OF APPLICATION (TYPE, CLASS, & DIAMETER)
Table A: Range of Application on ANSI, BS & API Flanges
Pressure Flange Size (In Inches)
(psi)
½ ¾ 1 1¼ 1½ 2 2½ 3 3½ 4 5 6 8 10 12
150
300
400
600 Pin Only = 17.0 mm (.669)
900 Bush A = 21.3 mm (.836“)
1500 Bush B = 24.4 mm (.957“)
2500 Bush C = 27.4 mm (1.07“)

Table B: Range of Application on DIN Flanges

DN Flange Size (mm)
PN
10 15 25 32 40 50 65 80 100 125 150 200 250 300 350 400
6
10
16
25
40
64 Pin Only = 17.0 mm (.669)
100 Bush A = 21.3 mm (.836“)
160 Bush B = 24.4 mm (.957“)
250 Bush C = 27.4 mm (1.07“)

2.09. DISMANTLING THE EQUALIZER HAND ALIGNMENT TOOL

Care should be taken not to drop any of the component parts when removing them from the
aligned joint. This action will prevent injuries to either the operator`s lower limbs, or to passers-by.

2.10. SPECIFICATION
The EQUALIZER Hand Alignment Tool gives a mechanical advantage of 6:125 kg (55 lbs) on
handle = 3.3 kn (330 lbs) at the joint.
3. THE EQUALIZER 3T(M) MECHANICAL FIXED FLANGE PAGE 8
& ROTATIONAL ALIGNMENT TOOL
 PAGE 9

3.01. HOW IT WORKS

The EQUALIZER 3T(M) should be 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. The drop
leg should be released onto the pipe while the tool
is held up level in the bolt-hole.

Pull out on wing release clip to allow the wing to

be extended to the desired distance.

Turn the screw bolt clockwise until the swivel /

friction pad comes into contact with the circumference of the opposite flange.

The swivel at the base of the screw bolt should always rest fully and evenly on the circumference
of the opposite flange.

Using the torque wrench supplied in the kit, set the torque wrench to 50 ft lbs (MAX), attach to
the screw bolt and start to screw down on the flange. The torque wrench will click when the full
50 ft lbs is achieved (Exceeding the 50 ft lbs will result in damage to the tool).

3.02. COMPONENT PARTS

1 x 3T(M) Alignment Tool

1 x 50 ft lbs Torque Wrench C/W 22 mm
Socket
1 x Instruction Manual
1 x Carry-Case with Foam Insert
Carry-Case Dimensions:
50 x 37 x 11 cm (19.75“ x 14.5” x 4.25”)
Carry-Case Gross Weight: 13.5 kg (29.7 lbs)

3.03. EXAMINATION & MAINTENANCE

On return from each job and, before allocation against subsequent
work, the completeness of The EQUALIZER 3T(M) 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 being used again.

Grease all moving parts regularly.

Ensure rollers and pins remain grit free.

Return all items to the carry-case when not in use.

 PAGE 10
3.04. INSTALLATION AND OPERATION

Step 1. - The Problem

Determine the maximum points of misalignment. On the

opposite example these points are on the top or bottom of
the joint, as illustrated by the arrows.

Step 2. - Attaching The Tool

The lift hook of the tool should be guided into the bolt-hole
at the maximum point of misalignment as illustrated.

The drop leg should be released onto the pipe while the Hold Tool up level
In the bolt hole Drop Leg
lift hook is held up level in the bolt-hole. Release Knob

Step 3. - Aligning The joint Extend Wing

Pull out the lock clip to allow the wing to be extended

out to the desired distance. Rotate the screw bolt onto
the surface of the opposite flange. At this stage ensure
that the tool is sitting level and that the end of the friction
pad is in full contact with the surface of the opposite Lock Clip

flange.

The torque wrench may now be set to the 50 ft lbs and

attached to the screw bolt. Tighten in a clockwise direction
until the joint comes into alignment.

Step 4. -The Aligned Joint

Once in alignment the bolts may be inserted and

tightened. Remove the tool and insert the last bolt and
tighten.
 PAGE 11
3.05. PARTS LIST (EXPLODED DRAWING)

01

34 02

33
32 14
35
03
08
05 06 07
36
12 04 08
09
32
10 11

17 13
13

31
37
05
30 18 06
20

29 07
12
21 09
16
28 22
15 14

22
27
22 19

23
26
38
24

25

ITEM PART NO DESCRIPTION QTY ITEM PART NO DESCRIPTION QTY

01 400203-01 50ft lbs Torque Wrench 01 ea 20 400401-01 Swivel 01 ea

02 400204-01 22 mm Socket 01 ea 21 400501-01 Thrust Bearing set 01 ea
03 400301-01 Screw Bolt 01 ea 22 400601-01 Friction Pad 01 ea
04 401001-01 Wing C/W Boss 01 ea 23 400801-01 Retaining Screw 01 ea
05 401401-02 Inner Roller 01 set of 2 24 400901-01 Counter-sunk Screws 01 ea
06 401501-02 Needle Bearing 01 set of 2 25 402601-02 Drop Leg Pad 01 set of 2
07 401601-02 Outer Roller 01 set of 2 26 402501-01 Drop Leg 01 ea
08 401101-01 Body Plates & Frame 01 set 27 402401-01 Grub Screw 01 ea
09 401301-02 Spiral Clip 01 set of 2 28 402301-01 Spring 01 ea
10 402001-01 Wing Retaining Clip 01 ea 29 402201-01 Drop Leg Lock 01 ea
11 402002-02 M3 Screw 01 set of 2 30 402901-01 Adjusting Screw 01 ea
12 402701-02 M5 x 20mm Screw 01 set of 2 31 402902-01 Roller Pin 01 ea
13 402801-02 Release Knob 01 set of 2 32 401201-02 Handle 01 set of 2
14 401901-14 Screws for Side Plates 01 set of 14 33 308201-01 Handle Sleeve-yellow 01 ea
15 403102-01 Pull Ring 01 ea 34 401702-01 Retaining Screw 01 ea
16 403101-01 Pull Pin 01 ea 35 401801-01 Screw (Drop Leg) 01 ea
17 403201-01 Roll Pin 01 ea 36 402101-01 Plastic Wing Inserts 01 ea
18 403301-01 Ball Spring Plunger 01 ea 37 404501-02 Wire 01 set of 2
19 403001-01 Lift Hook 01 ea 38 404601-01 Decals set 0.2 mtr
20 400401-01 Spring Clip 01 ea 39 403401-01 Carry-Case c/w Foam 01 kit
40 403501-01 Insert ( Not Illustrated) 01 kit

REPAIR KIT 1: (THRUST BEARING SET) PART NUMBER 403601-01 CONTAINS ITEMS 20,22 & 24.
REPAIR KIT 2: (ROLLER BEARING SET) PART NUMBER 403701-01 CONTAINS ITEMS 5,6,7 & 9.
REPAIR KIT 3: (TOOL ASSEMBLY SET) PART NUMBER 403801-01 CONTAINS ITEMS 10, 11, 14 & 36.
REPAIR KIT 4: (DROP LEG / LOCK SET) PART NUMBER 403901-01 CONTAINS ITEMS 12,13,25,26,28,29,30 & 31.
 PAGE 12

3.06. LUBRICATING THE TOOL

Always ensure that the wing of the tool is grit free and that the rollers rotate freely and are well
lubricated. This will enhance the tool’s performance and lifetime.

LUBRICATING THE ROLLER NEEDLE BEARINGS

RECOMMENDED GREASE (ROCOL, SAPPHIRE HI-LOAD)

Fig 1. Fig 2. Rollers & Bearings

Spiral Clip

Spiral Clip
Pull Pin

Release Knob
Screws
Hook

Step 1. Place tool flat on bench

Step 2. Using a small flat screw driver, lever out the end of the spiral clips and then rotate anti-clock
wise and remove. Repeat this procedure on both spiral clips. (See Fig 1.)
Step 3.Remove pull pin and hook, unscrew the 7 button head screws and lift off the side plate
(See Fig 2.)
Step 4. Inspect the roller shaft and needle roller bearings within the roller for grit or dirt. Clean and
then smear a small amount of grease onto the shaft and into the needle bearing
Step 5. Re-assemble in reverse order of 4 thru 1

3.07. TROUBLE SHOOTING

PROBLEM 1: THE FRICTION PAD IS SLIDING ON THE CIRCUMFERENCE OF THE OPPOSITE

FLANGE AS THE TOOL IS ALIGNING THE JOINT.

CAUSE: Grit or dirt on wing, rollers or bearings. Wing is at full extension

SOLUTION: Ensure the rollers are rotating freely and that there is no restriction to the rollers on
the wing surfaces such as dirt or grit. 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 2: THE TOOL IS ATTACHED AND APPEARS TO BE FUNCTIONING PROPERLY, BUT

THE JOINT WILL NOT ALIGN.

CAUSE: There may be something restricting the joint at a point close to the flanges. The joint
may require more than 3 ton (30.41Kn) force to align

SOLUTION: Check the area around the joint to establish if there is an obstruction to the joint. If the
joint requires more force than that of the 3 ton (30.41Kn) tool, then another method to
align the joint should be adopted
 PAGE 13

3.08. MINIMUM / MAXIMUM EXTENSIONS

Minimum Extension Maximum Extension

60 mm
(2.36“)
36 mm
(1.41“)

133 mm
30 mm (5.23“)
(1.18“)

3.09. RANGE OF APPLICATION (QUICK GUIDE)

MINIMUM / MAXIMUM FLANGE SIZES (VISUAL)

The friction pad of the screw bolt A

must rest fully on the circumference Min distance = 30 mm (1.18“)
of the flange to be pushed. Max distance = 133 mm (5.23“)

24 mm
B Min bolt-hole size = (0.95“) Hook into this bolt-hole

Two basic dimensions will determine if The EQUALIZER 3T(M) can be used to align the joint. If the
flange joint to be aligned is between 30 mm and 133 mm apart as illustrated by (A) , has a bolt-hole
size of 24 mm or greater (B), then T he EQUALIZER 3T(M) can be attached and alignment achieved.
 PAGE 14

3.10. RANGE OF APPLICATION

By flange type, class and diameter

ANSI B16.5 ANSI B16.5 ANSI B16.5

WELD NECK FLANGES LAP JOINT FLANGES SLIP-ON FLANGES
150# 10“ THRU 24” 150# NILL 150# 10“ THRU 24”
300# 8“ THRU 24” 300# 12“ THRU 24” 300# 8“ THRU 24”
400# 3“ THRU 24” 400# 10“ THRU 24” 400# 3“ THRU 24”
600# 31/2“ THRU 24” 600# 8“ THRU 24” 600# 31/2“ THRU 24”
900# 1“ THRU 20” 900# 5“ THRU 24” 900# 1“ THRU 20”
1500# 1“ THRU 10” 1500# 4“ THRU 16” 1500# 1“ THRU 21/2”
2500# 1“ THRU 6” 2500# 2“ THRU 10”

ANSI B16.5 ANSI B16.5 API STANDARD 605

THREADED FLANGES SOCKET WELD FLANGES WELD NECK FLANGES
150# 8“ THRU 24” 1500# 1“ THRU 21/2” 150# 34“ THRU 60”
300# 8“ THRU 24” 300# 26“ THRU 36”
400# 31/2“ THRU 24”
600# 31/2“ THRU 24” BS 3293 BS 3293
900# 1“ THRU 20” SLIP-ON FLANGES RTJ WELD NECK FLANGES RTJ
1500# 1“ THRU 10” 300# 26“ THRU 36” 300# 26“ THRU 28”
2500# 1“ THRU 6” 400# 26“ ONLY 400# 26“ ONLY

API TYPE 6B API TYPE 6BX BS 3293

INTEGRAL FLANGES WELD NECK FLANGES WELD NECK FLANGES
10,000# 2,9/16“ THRU 21,1/4” 10,000# 2,9/16“ THRU 5,1/8” 150# 26“ THRU 48”
15,000# 1,13/16“ THRU 13,5/8” 15,000# 1,13/16“ THRU 4,1/16” 300# 26“ THRU 36”
20,000# 1,13/16“ THRU 9” 20,000# 1,13/16“ THRU 3,1/16“ 400# 26“ THRU 32”
600# 26“ ONLY

API TYPE 6BX BS 3293

INTEGRAL FLANGES SLIP-ON FLANGES
2000# 3,1/2“ THRU 21,1/4” 150# 26“ THRU 48”
3000# 2,1/16“ THRU 16,3/4” 300# 26“ THRU 36”
5000# 2“ THRU 9” 400# 26“ THRU 32”
600# 26“ ONLY

If the Flange to be aligned is not listed above, please use 15. RANGE OF APPLICATION
(QUICK GUIDE) on page 14 of this book.

3.11.WEIGHTS & DIMENSIONS

Side View End View

380 mm 70 mm
(14.9“) (2.75“)

288 mm
(11.36“)

Tool Only = 8.1 kg (17.82lbs)

Torque Wrench C/W Socket = 0.9 kg (1.98lbs)
Carry-Case C/W Foam Insert = 4.5 kg (9.90lbs)

GROSS KIT WEIGHT = 13.5 kg (29.70lbs)

 PAGE 15

3.12. DISMANTLING THE EQUALIZER 3T(M)

Once alignment is achieved, all work on the joint finished, and bolt-up completed (apart from the
bolt-hole in which The EQUALIZER 3T(M) is located), the tool can be removed from the joint by
reversing steps 1 thru 3 in section 6.04.

Care should be taken not to drop any of the component parts when removing them from the aligned
joint. This action will prevent injuries to either the operator`s lower limbs, or to passers-by.

3.13. SPECIFICATION

The EQUALIZER 3T(M) is capable of generating 3 tons (30.00Kn) force from 50 ft lbs of torque.

3.14. SETTING THE DROP LEG LOCK

FIG 1.

1. If the leg lock is in contact with the frame of the tool

when the teeth are engaged, this will cause the drop leg
& lock to become jammed as illustrated in FIG 1.
FRAME

LEG LOCK

FIG 2.

2. With the teeth of the drop leg and the lock engaged, the ADJUSTING
lock should be adjusted with the adjusting screw turned anti- SCREW

clockwise until there is a small gap between the lock & the
frame as shown in FIG 2.
4. THE EQUALIZER 5T(E) HYDRAULIC FIXED FLANGE PAGE 16
& ROTATIONAL ALIGNMENT TOOL
 PAGE 17

4.01. HOW IT WORKS

The EQUALIZER 5T(E) should be 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. The
drop leg should be released onto the pipe while the tool is
held up level in the bolt-hole. Pull out on wing release clip
to allow the wing to be extended to the desired distance.

The hydraulic cylinder is secured into the adjusting

sleeve. Rotate the cylinder and adjusting sleeve
clockwise until the swivel at the base of the cylinder
comes into contact with the circumference of the
opposite flange.

The swivel at the base of the hydraulic cylinder should always rest fully and evenly on the
circumference of the opposite flange. Attach the hydraulic pump / hose to the cylinder and prime
the hand pump.

4.02. COMPONENT PARTS

1 x 5T(E) Tool
1 x 10,000 psi 5T Hydraulic Cylinder
1 x 10,000 psi Hydraulic Hose,
1 x 10,000 psi Hydraulic Hand Pump
1 x Instruction Manual
1 x Carry-Case C/W Foam Insert:
Dimensions: 60 x 54 x 18 cm (23.5“ x 21.25“ x 7“)
KIT GROSS WEIGHT = 27.5 kg (60 lbs)

4.03. EXAMINATION & MAINTENANCE

On return from each job, and before allocation against subsequent work, the completeness of the
5T(E) 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 being used again.

Grease all moving parts regularly.

Ensure rollers and pins remain grit free.

Return all items to the carry-case when not in use.

 PAGE 18

4.04. INSTALLATION AND OPERATION

Step 1.-The Problem

Determine the maximum points of misalignment. On the
opposite example the maximum points are on the top or
bottom of the joint, as illustrated by the arrows.

Step 2.-Attaching The Tool

The lift hook of the tool should be guided into the bolt-hole
at the maximum point of misalignment as shown in Step 2.

The drop leg should be released onto the pipe while the lift
hook is held up level in the bolt-hole. Hold Tool up level Drop leg
In the bolt hole release knob

Step 3.-Aligning The Joint

Pull out the lock pin to allow the wing to be extended Extend wing
out to the desired distance. Rotate the cylinder / adjusting
sleeve clockwise until it locates onto the surface of the
opposite flange. At this stage ensure that the tool is sitting Cylinder
Adjusting
level and that the end of the cylinder is in full contact with Sleeve Lock Pin
the surface of the higher flange.

The hydraulic hose / pump may now be connected and the

pump primed until the joint comes into alignment.
 PAGE 19

4.05. PARTS LIST (EXPLODED DRAWING)

31

32
33

30

34

26

25
27 24
01

23
22
21
20
14 19
18
03
17
02 15 16

07

08
09
13
05

06
10
04

12

11

ITEM PART NO DESCRIPTION QTY ITEM PART NO DESCRIPTION QTY

01 900101-01 HYDRAULIC CYLINDER 5T 01 ea 19 901901-04 NEEDLE BEARING 01 set of 4
02 900201-01 ADJUSTING SLEEVE 01 ea 20 402701-02 SCREW M5 X 20 01 set of 2
03 900301-01 WING 01 ea 21 902101-02 SHAFT 01 set of 2
04 403301-01 BALL SPRING PLUNGER 01 ea 22 402801-02 RELEASE KNOB 01 set of 2
05 900501-01 PULL PIN 01 ea 23 902301-02 FINGER STOP REAR 01 set of 2
06 403102-01 PULL RING 01 ea 24 903501-01 BOLT M6 X 12 01 ea
07 900701-02 FINGER STOP-FRONT 01 set of 2 25 402902-01 DROP LEG LOCK 01 ea
08 900801-02 SUPPORT SHAFT 01 set of 2 26 902601-01 ADJUSTING SCREW 01 ea
09 900901-04 SUPPORT ROLLER 01 set of 4 27 902701-01 MAIN BODY/HOOK 01 ea
10 901001-01 DROP LEG 01 ea (NOT ILLUSTRATED)
11 402501-01 DROP LEG PAD 01 ea 28 902801-01 CARRY-CASE C/W FOAM 01 ea
12 402601-02 COUNTER-SUNK SCREW 01 set of 2 29 902901-01 DECALS (SET Of 5) 01 ea
13 901301-02 CIRCLIP 01 set of 4 30 302701-01 HYD HOSE 10,000 psi 01 ea
14 402201-01 COIL SPRING 01 ea 31 311801-01 HYD PUMP 10,000 psi 01 ea
15 402301-01 GRUB SCREW 01 ea 32 311901-01 MALE/FEMALE ADAPTOR 01 ea
16 901601-04 SPIROL CLIP 01 set of 4 33 300901-01 FEMALE HALF COUPLER 01 ea
17 901701-04 FRICTION WASHER 01 set of 4 34 302601-01 MALE HALF COUPLER 01 ea
18 901801-04 ROLLER 01 set of 4
 PAGE 20

4.06. LUBRICATING THE TOOL

Always ensure that the wing of the tool is grit free and that the rollers rotate freely and are well
lubricated. This will enhance the tool’s performance and lifetime.

LUBRICATING THE ROLLER NEEDLE BEARINGS

RECOMMENDED GREASE (ROCOL, SAPPHIRE HI-LOAD)

Fig 1. Fig 2.
Spiral Clips

Spiral Clips

Step 1. Place tool flat on bench

Step 2. Remove circlips on support shafts and push out support shafts. The support rollers can now be
removed (see FIG 1.)
Step 3.Using a small flat screw driver, lever out the end of the spiral clip and then rotate anti-clockwise
and remove. Repeat this procedure on all 4 spiral clips.
Step 4. Remove the outer washer, roller and finger stop.
Step 5. Inspect the roller shaft and needle roller bearing within the roller for grit or dirt, clean, and then
smear a small amount of grease onto the shaft and into the needle bearing.
Step 6.Re-assemble in reverse order of 4 thru 1.

4.07.. TROUBLE SHOOTING

PROBLEM 1: THE FRICTION PAD IS SLIDING ON THE CIRCUMFERENCE OF THE OPPOSITE

FLANGE AS THE TOOL IS ALIGNING THE JOINT.

CAUSE: Grit or dirt on wing, rollers or bearings. Wing is at full extension

SOLUTION: Ensure the rollers are rotating freely and that there is no restriction to the rollers on
the wing surfaces such as dirt or grit. 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 2: THE TOOL IS ATTACHED AND APPEARS TO BE FUNCTIONING PROPERLY, BUT

THE JOINT WILL NOT ALIGN.

CAUSE: There may be air in the hydraulic system restricting the force on the flanges.
There may be something restricting the joint at a point close to the flanges. The joint
may require more than 5 ton (50.0Kn) pressure to align.

SOLUTION: See air lock removal section 7.08. Check the area around the joint to establish if there
is an obstruction to the joint. If the joint requires more force than that of the 5 ton
(50.0Kn) of the tool, then another method to align the joint should be adopted
 PAGE 21

4.08. AIR LOCK REMOVAL

Step 1. Remove the air vent cap on top of the hydraulic pump and check hydraulic oil level to ensure
there is enough oil to advance the cylinder.

Step 2. Replace air vent cap, but do not tighten the cap. The cap must remain loose to allow air to
enter and leave the pump during use. The cap should only be tightened fully when the tool
is to be returned to the carry-case after use.
3.Prime Handle
Step 3. With the air vent cap loose, connect the pump to the tool with 1.Loosen Air Vent Cap
the hydraulic hose supplied within the carry-case.

Step 4. Stand the tool on a level surface, hold the hydraulic pump above
the tool, close the release valve on the pump, and prime the
pump to advance the hydraulic cylinder until the cylinder is
fully advanced and a small pressure is achieved.
2.Close Return Valve
Step 5. With the hydraulic pump held above the tool, open the
release valve allowing the cylinder to retract fully back.
While the cylinder is retracting, any air that is within
the system will be forced up to the pump and vented
out through the air vent cap.

Step 6. Repeat the above procedure three

or four times to ensure
that all air is removed
and the tool will reach
full working pressure.

4.09. MINIMUM / MAXIMUM EXTENSIONS

Minimum extension Maximum extension

102mm
(4“)

32mm
(11/4“)

250mm
(8“)
240mm
(91/2“)
106mm
(41/4“)
 PAGE 22

4.10.. RANGE OF APPLICATION (QUICK GUIDE)

MINIMUM / MAXIMUM FLANGE SIZES (VISUAL)

The friction pad of the hydraulic

cylinder must rest fully on the A
circumference of the flange to be Min distance = 93mm (3.75“)
pushed. Max distance = 228mm (9“)

B Min bolt-hole size = 31.5mm

(1.25“) Hook into this bolt-hole

Two basic dimensions will determine if The EQUALIZER 5T(E) can be used to align the joint. If the
flange joint to be aligned is between 93mm (3.75“) and 228mm (9”) apart as illustrated by (A) , has
a bolt-hole size of 31.5mm (1.25“) or greater (B), then The EQUALIZER 5T(E) can be attached and
alignment achieved.

4.11. RANGE OF APPLICATION

(By flange type, class and diameter)

ANSI B 16.5 ANSI B 16.5 API TYPE 6B

WELD NECK FLANGES SLIP_ON FLANGES INTEGRAL FLANGES
600# 18“ Thru 24” 600# 18“ Thru 24” 2,000# 263/4“ Thru 30”
900# 14“ Thru 24” 900# 14“ Thru 24” 3,000# 263/4“ Thru 30”
1500# 6“ Thru 24” 5,000# 135/8“ Thru 211/4”
2500# 5“ Thru 12” 10,000# 71/16“ Thru 163/4”
15,000# 71/16“ Thru 135/8”
ANSI B 16.5 ANSI B 16.5 20,000# 41/16“ Thru 9”
LAP JOINT FLANGES THREADED FLANGES
600# 24“ 600# 20“ Thru 24” API TYPE 6BX
900# 18“ Thru 24” 900# 18“ Thru 24 INTEGRAL FLANGES
1500# 10“ Thru 24” 1500# 8“ Thru 12” 3,000# 203/4“
2500# 6“ Thru 12” 2500# 5“ Thru 12” 5,000# 9“ Thru 11”

BS 3293 BS 3293 API STANDARD 605

SLIP-ON FLANGES RTJ WELD NECK FLANGE RTJ WELD NECK FLANGES
300# 28“ Thru 36” 300# 28“ Thru 36” 300# 30“ Thru 60”
400# 26“ Thru 36” 400# 26“ Thru 36”
600# 26 Thru 36“ 600# 26“ Thru 36” API TYPE 6BX
WELD NECK FLANGES
10,000# 71/16“ Thru 163/4”
15,000# 71/4“
BS 3293 BS 3293 20,000# 41/16“ Thru 71/16”
SLIP-ON FLANGES WELD NECK FLANGES
300# 30“ Thru 36” 300# 28“ Thru 36” MSS SP-44
400# 26“ Thru 36” 400# 26“ Thru 36” WELD NECK RTJ
600# 26 Thru 36“ 600# 26“ Thru 36” 300# 28“ Thru 36”
400# 26“ Thru 36”
600# 26“ Thru 36”
900# 26“ Thru 36”
 PAGE 23

4.12. WEIGHTS AND DIMENSIONS

Side View End View

90mm
526mm
(3.50“)
(20.75“)

307mm 295mm
(12.25“) (11.62“)

Tool c/w Hydraulic Cylinder = 15.5 kg (34.1 lbs)

Hand Pump = 2.5 kg (5.5 lbs)
Hydraulic Hose = 1.0 kg (2.2 lbs)
Carry-Case c/w Foam Insert = 8.5 kg (18.7 lbs)

GROSS KIT WEIGHT = 27.5 kg (60.0lbs)

4.13. DISMANTLING THE EQUALIZER 5T(E)

Once alignment is achieved, all work on the joint finished, and bolt-up completed (apart from the bolt-
hole in which The EQUALIZER 5T(E) is located), the tool can be removed from the joint by reversing
steps 1 thru 3 in section 7.04.

Care should be taken not to drop any of the component parts when removing them from the aligned
joint. This action will prevent injuries to either the operator`s lower limbs or to passers-by.

4.14. SPECIFICATION
The EQUALIZER 5T(E) is capable of generating 5 tons (50.00Kn) force from 10,000psi of hydraulic
pressure.
 PAGE 24

4.15. Dis-assembly / Assembly

STEP 1 STEP 2 STEP 3

STEP 4 STEP 5 STEP 6

STEP 7 STEP 8