Equalizer NS12TI, NS15TI, NS20TI Operator's Instruction Manual
OPERATOR INSTRUCTION MANUAL
NS12TI
NS15TI
NS20TI
EQUALIZER INTERNATIONAL LTD
www.equalizerinternational.com
INTEGRAL
HYDRAULIC
NUT SPLITTERS
OPERATOR INSTRUCTION MANUAL
IM_NS12_15_20TI_Rev03_A4
NS12TI, NS15TI, NS20TI
INTEGRAL HYDRAULIC NUT SPLITTERS
2
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. TOOL OPERATION
3.1 GENERAL GUIDANCE
3.2 TOOL SELECTION
3.3 HYDRAULIC TOOL OPERATION
3.4 HANDLE
3.5 SAFETY LANYARD
3.6 POSITIONING THE TOOL
4. TOOL MAINTENANCE
4.1 INSPECTION
4.2 CLEANING
4.3 CUTTING TIP REPLACEMENT
4.4 MAINTENANCE
4.5 STORAGE & TRANSPORTATION
4.6 OPERATING CONDITIONS
4.7 SUB-SEA USAGE
5. TECHNICAL SPECIFICATIONS
5.1 NS12TI KIT CONTENTS
5.2 NS12TI TOOL DIMENSIONS
5.3 NS15TI KIT CONTENTS
5.4 NS15TI TOOL DIMENSIONS
5.5 NS20TI KIT CONTENTS
5.6 NS20TI TOOL DIMENSONS
6. TROUBLESHOOTING
6.1 NS12TI/NS15TI/NS20TI TROUBLESHOOTING
7. REGULATORY INFORMATION
7.1 REGISTERED HEAD OFFICE
8. PARTS LISTS & SERVICE KITS
22/08/2017
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2.
TOOL SAFETY
2.1
GENERAL SAFETY
These instructions cover the safe operation and
maintenance of THE EQUALIZER NS12TI, NS15TI and
NS20TI NUT SPLITTER tools. The use of these tools
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 these tools.
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.
1.
INTRODUCTION
The Equalizer™ NS Range of tools has been developed
to assist in the removal of corroded, seized or damaged
nuts.
The NS tools have a shrouded cutting head to contain the
split nut and have been developed to increase the access
to tight ange joints. The tools have no exposed nger
pinch points and are supplied with a swivel handle and a
safety lanyard as standard.
It is essential that the users familiarise themselves with
the contents of this manual prior to using the tool.
This manual contains information for the following tools:
• NS12TI Integral Hydraulic Nut Splitter
• NS15TI Integral Hydraulic Nut Splitter
• NS20TI Integral Hydraulic Nut Splitter
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NS12TI, NS15TI, NS20TI
INTEGRAL HYDRAULIC NUT SPLITTERS
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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 safety lanyard. Do not attach
the safety lanyard to the plastic handle.
DANGER: Care should be taken when using
the safety lanyard to avoid entanglement with
body parts.
The vibration total value to which this tool is
subjected does not exceed 2.5 m/s
2
.
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.
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INTEGRAL HYDRAULIC NUT SPLITTER
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If the specication of the nut is unknown then a vernier
calliper or measure tape should be used to determine
the Across-Flats (A/F) size of the nut to be split and the
correct tool.
A/F
3.
TOOL OPERATION
3.1
GENERAL GUIDANCE
The Equalizer™ Nut Splitter Tools have been designed to
t a range of nut sizes and grades and the correct tool
should be selected prior to commencing work by following
the instructions in this section.
CAUTION: A thick grease should be applied to
the Cutting Tip before every cut. This will
ease the splitting operation, prolong the life of
the Cutting Tip and limit the risk of sparking
and debris projectiles.
3.2
TOOL SELECTION
CAUTION: It is important that the correct tool
is selected for each nut and the correct Cutting
Tip is used for each tool. Each tool in the Nut
Splitter range comes with the appropriate
Cutting Tips for that tool. Please refer to the
table below to choose the correct tool for your
application.
NS TOOLS
UNC HEAVY HEX
STUD SIZE
UNC HEAVY
NUT A/F SIZE
METRIC
STUD SIZE
METRIC
NUT A/F SIZE
NS12
1/2”, 5/8”
0.88” to 1.06”
M12, M16, M20
19 mm to 30 mm
NS15
3/4”, 7/8”
1.25” to 1.44”
M16, M20, M22
24 mm to 32 mm
NS20
7/8”, 1”, 1-1/8”
1.44” to 1.81”
M24, M27, M30
36 mm to 46 mm
NS36
1-1/4”, 1-3/8”,
1-1/2”, 1-5/8”
2” to 2.56”
M33, M36, M39, M42
50 mm to 65 mm
NS50
1-5/8”, 1-3/4”,
1-7/8”
2.56” to 2.94”
M42, M45, M48
65 mm to 75 mm
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INTEGRAL HYDRAULIC NUT SPLITTERS
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USING THE NS12TI/NS15TI/NS20TI
Position the tool as per Section 3.6.
When the pump is operated the piston and the Cutting
Tip will advance. Ensure the tool is at against the ange
and the Cutting Tip perpendicular to the nut throughout
the operation. Slowly actuate the Nut Splitter to advance
the Cutting Tip against a at of the nut and increase the
pressure until the nut splits.
Releasing the pump will depressurise the cylinder and
cause it to retract under the force of its internal spring.
It is likely that the nut will require a second split to fully
remove the nut from the stud. Ideally a second split
should be carried out at 180° to the rst cut, splitting the
nut in half to enable removal.
After the nut has been split, always check the Cutting Tip
for damage and replace if required before positioning the
tool on another nut.
CAUTION: Split nuts often have sharp edges
and should be handled with great care.
3.4
HANDLE
The handle can be swivelled around the central axis of the
tool, to improve access to the nut and allow the tool to be
easily held in the vertical or horizontal orientation.
3.5
SAFETY LANYARD
The NS tools are supplied with a secure anchor point and
a safety lanyard. The safety lanyard should be used to
minimise the risks associated with the tool dropping.
Attach one end of the safety lanyard to the tool using
the supplied shackle. The other end of the safety lanyard
should be xed to a secure point close to the work-site
using an appropriate shackle.
Avoid using the safety lanyard as a means for picking up
or carrying the tool. Do not x the safety lanyard to the
handle.
3.3
HYDRAULIC TOOL OPERATION
Prior to operation, ensure the air-vent in the integr al hand
pump is not obstructed. Any obstruction in the air-vent
can cause a vacuum in the system which can limit the
cylinder’s travel.
The NS12TI, NS15TI and NS20TI Nut Splitter use an
integral hydraulic pump to drive the cylinder and advance
the Cutting Tip to split the nut. The hydraulic pressure
is applied using the integrated hand pump, enabling
accurate control of the force applied.
The integral hand pump has a control lever which allows
the user to select advance (+) or retract (-)
ACTUATING THE NS12TI/NS15TI/NS20TI
When advance (+) is selected, pumping the handle will
advance the piston with the Cutting Tip and split the nut.
RETRACTING THE NS12TI/NS15TI/NS20TI
Selecting Retract (-) will depressurise the cylinder and
cause it to retract under the force of its internal spring.
The handle doesn’t need to be pumped to retract the
cylinder.
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The anchor point and safety lanyard hav e been engineered
to safely sustain a drop over the full safety lany ard length.
It is recommended that all parts are inspected following
a drop incident, as damage may compromise the safety
of the tool.
CAUTION: Only use the designated anchor
point for xing the safety lanyard. Do not attach
the safety lanyard to the plastic handle.
DANGER: Care should be taken when using
the safety lanyard to avoid entanglement with
body parts.
3.6
POSITIONING THE TOOL
Prior to splitting the nut, an assessment should be carried
out to determine the most appropriate positioning of the
tool around the nut.
Please see next page for more information.
OPERATOR INSTRUCTION MANUAL
IM_NS12_15_20TI_Rev03_A4
NS12TI, NS15TI, NS20TI
INTEGRAL HYDRAULIC NUT SPLITTERS
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CAUTION: It is recommended that suitable
hearing protection, i.e. ear defenders or ear
plugs are worn.
CAUTION: It is recommended that a face
shield or suitable eye protection, i.e. safety
glasses or goggles are worn.
Place the tool on the nut with the at surface of the cutting
head at against one of the nut ats and the Cutting Tip
centered. Ensure the bottom face of the cutting head sits
at on the same surface that the nut is seated.
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4.3
CUTTING TIP REPLACEMENT
Ensure the correct Cutting Tip is tted to the tool and
has been checked for damage. Some minor bluntening is
acceptable, but cracked or chipped Cutting Tips should be
replaced.
The Cutting Tip is retained in the piston by the tip retention
screw. Unscrew the tip retention screw with a hex-key and
pull the Cutting Tip out to replace. Do not apply excessive
force when inserting the Cutting Tip into the tool. If the
Cutting Tip does not come out easily, slightly extend the
piston to gain better access. When replacing the Cutting
Tip, the tip retention screw and alignment screw should
also be replaced every time.
TIP RETENTION SCREW
SMALLER HEX KEY
CUTTING TIP
CAUTION: Ensure the retention grub screw is
fully inserted in the piston before actuating the
tool.
ALIGNMENT SCREW
LARGER HEX KEY
4.
TOOL MAINTENANCE
4.1
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 Cutting-Tip (this may require
tool actuation)
Cleaning and servicing should be undertaken as required
prior to the tool being used, stored or transported.
4.2
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 8
• clean the components using detergent, following the
manufacturer’s guidelines
• rinse the components to remove traces of detergent
• dry the components thoroughly
Inspect, service and lubricate the tool immediately after
the cleaning process.
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4.6
OPERATING CONDITIONS
Minimum Cutting Tip Contact Temperature: -20 °C
Maximum Cutting Tip Contact Temperature: 70 °C
4.7
SUB-SEA USAGE
Using Equalizer Integral Hydraulic
Nut-Splitters
The NS12TI/NS15TI/NS20TI are actuated by means of
single-acting spring-return hydraulic cylinder and can be
used sub-sea providing the following actions are taken:
• The pump release valve is fully opened and remains
open until the tool has descended to the working
depth. This will allow the pressure to equalise.
• The tool is actuated via the hand-pump by a diver.
• Upon completion of works the release valve is left in
the fully-open position until the tool has ascended to
the surface.
• The tool and pump are stripped-down, cleaned and
lubricated immediately to minimise corrosion.
4.4
MAINTENANCE
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.
Do not apply excessive force when inserting the Cutting
Tips into the tool. Always replace the tip retention screw
and alignment screw when replacing the Cutting Tip.
The alignment screw in the side of the cutting head sits in
the slot of the piston and keeps the Cutting Tip aligned.
This screw should not be fully tightened; back off the
alignment screw by 1/4 turn after insertion.
If topping up or replacing hydraulic oil as part of a service,
use only premium quality hydraulic oil of the grade 15 cSt.
A thick grease should be applied to the Cutting Tip before
every cut. This will ease the splitting operation, prolong
the life of the Cutting Tip and limit the risk of sparking and
debris projectiles.
4.5
STORAGE & 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.
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NS12TI, NS15TI, NS20TI
INTEGRAL HYDRAULIC NUT SPLITTER
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5.
TECHNICAL
SPECIFICATIONS
5.1
NS12TI KIT CONTENTS
Product Code: NS12TISTD
1 x NS12TI Nut Splitter
1 x Spare Cutting Tip
1 x Spare Tip Retention Screw
1 x Spare Alignment Screw
1 x Hex key for Tip Retention Screw
1 x Hex key for Alignment Screw
1 x Safety Lanyard
1 x Instruction Manual
1 x Carry Case
580 mm x 350 mm x 180 mm (22.8” x 13.8” x 7.1”)
Tool only Weight: 5.8 kg (12.8 lb)
Gross Kit Weight: 9.0 kg (20.0 lb)
5.2
NS12TI TOOL DIMENSIONS
350 mm
(13.8”)
152 mm
(6.0”)
81 mm
(3.2”)
5.3
NS15TI KIT CONTENTS
Product Code: NS15TISTD
1 x NS15TI Nut Splitter
1 x Spare Cutting Tip
1 x Spare Tip Retention Screw
1 x Spare Alignment Screw
1 x Hex key for Tip Retention Screw
1 x Hex key for Alignment Screw
1 x Safety Lanyard
1 x Instruction Manual
1 x Carry Case
580 mm x 350 mm x 180 mm (22.8” x 13.8” x 7.1”)
Tool only Weight: 6.3 kg (13.9 lb)
Gross Kit Weight: 9.4 kg (20.7 lb)
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