Troubleshoot Like a Pro: Common Flange Spreader Issues Solved

Portable Flange Spreaders: Solutions for On-Site Maintenance

Flange spreaders are invaluable for the controlled separation of pipe joints during maintenance. However, heavy usage inevitably leads to wear and damage. When flange spreaders malfunction, identifying the root cause is essential for completing repairs.

For maintenance teams, having go-to guides to reference typical flange spreader problems can optimize diagnostics and restoration because operators can resolve issues independently and minimize downtime confidently.

Below, our expert team discusses how to troubleshoot common flange spreader issues, giving multiple actionable solutions.

No Spreading Force or Action 

Failed Hydraulic Pump

Flange spreaders rely on a healthy pump to generate the force needed for spreading. If the spreader isn’t responding, a faulty pump could be the culprit. Common pump failures include:

  • Blown seals are leaking, preventing any pressure build-up.
  • Internal valves can become jammed, restricting fluid flow.
  • Worn bearings can create friction and reduce pressure.

To diagnose a possible dead pump, remove the hoses from the pump and activate the spreader. If there’s no pressure build-up, the pump is likely faulty.

There are several options to repair the pump:

  • In some cases, rebuild kits can restore functionality.
  • Depending on the severity of the damage, replacing specific components within the pump might be an option.
  • A complete replacement might be necessary if the pump is heavily damaged or parts are unavailable.

Note: While a faulty pump can significantly reduce or eliminate spreading force, it may not necessarily mean “no power” altogether. Other hydraulic functions might still be operational depending on the system design.

Loose Hose Connections 

Loose hydraulic connections can cause fluid leaks, robbing your spreader of the proper pressure to function correctly. If you’re experiencing weak spreading force, check all couplings for tightness:

  • Inspect couplings, looking for any loose or leaking connections.
  • Use appropriate wrenches to tighten any loose fittings.

Replace any worn or cracked hoses losing hydraulic pressure. Ensure they’re the correct size and pressure for the spreader and that connections are correctly threaded before tightening.

Note: While worn or cracked hoses can contribute to pressure loss, they’re not always the sole culprit. Internal leaks within the pump or other components could also be the issue.

Blocked Ram Slideways

Built-up grit and debris can restrict the movement of wedge flange spreaders, impacting spreading force. To restore smooth operation:

  • Flush slideways – Thoroughly clean the slideways with a solvent suitable for the specific material (e.g., mineral spirits for steel).
  • Lubricate – Apply penetrating oil to the slideways to reduce friction.

Uneven or Insufficient Spreading

Bent Spreader Arms/Frames

Uneven spreading can often stem from bent or distorted spreader arms or frames. These distortions can occur due to various reasons, including:

  • Dropping tools or equipment onto the spreader
  • Overloading the spreader beyond its capacity
  • Impact during use or improper storage

Carefully inspect the arms and frame for any visible bends or misalignments. Use a machinist’s straight edge to identify even minor deviations that might affect performance.

For minor bends, attempt gentle correction using clamped blocks and controlled force with appropriate tools (avoid hammering). However, it’s crucial to prioritize safety and avoid over-stressing the components.

Replacing the affected components is crucial if the distortion is significant or compromises the spreader’s integrity. Consult the manufacturer’s instructions or seek professional assistance for safe and proper replacement.

Misaligned Actuation Points

Uneven force application can also indicate misaligned actuation points. Here’s how to address this:

  • Carefully adjust threaded rods or wedges to apply pressure evenly across the entire flange diameter.
  • Use appropriate shims (e.g., metal or plastic) to level any angled foot plates until they’re parallel with the flanges.
  • Advance the threaded rods gradually and evenly in unison to prevent binding and further misalignment. 

Note: Avoid over-tightening the rods, as this can damage the spreader.

Loose Components or Connections

Worn Adjustment Threads 

Repeated use, improper lubrication, or excessive force can wear down threaded components like length adjustment rods, slider blocks, or threaded collars. Inspect the spreader for:

  • Rounded or damaged threads
  • Excessive play or looseness when adjustments are made

Replacements are necessary if threads are sloppy or degraded and hold adjustments poorly. Use high-quality replacements and consider thread lock compound. Choose a type suitable for the material and application. Follow the product instructions for safe and effective use.

Loose Pivot Points

Loose pivot pins, retention clips, or locking collars can hinder smooth operation in compound lever spreaders. Check for loose or missing pins, clips, collars, and worn or damaged hinge components causing excessive play.

Fix loose pivots by:

  • Tightening any loose components with appropriate tools. Remember, over-tightening can cause further damage.
  • Replacing worn or damaged parts to ensure proper engagement and smooth articulation.
  • Inspecting articulated designs for worn teeth and adjusting engagement if necessary. Consult manufacturer instructions or seek professional assistance for complex mechanisms.
  • Use a suitable light oil to lubricate joints and materials. Avoid over-lubricating, as excess oil can attract dirt and debris.

ALLTORC: Flange Spreader Troubleshooting Pros

Getting flange spreaders back up and running quickly minimizes maintenance downtime. By learning to diagnose issues accurately and rectify common failures, technicians can restore full functionality themselves without delays.

At ALLTORC Bolting Solutions, we offer troubleshooting support for our full range of specialty flange spreading equipment. Our experts have seen it all and can quickly identify any spreader problems your team encounters. Contact us today if your flange tool requires service.