Christie WCA4TM Assembly instructions

WCA4TM FLANGE ALIGNMENT TOOL
OPERATOR INSTRUCTION MANUAL
Ref: WCOI.088 Date: April 2012 Issue: 1

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CONTENTS
Section Description Page
1 Introduction 1
2 Safety Information 2
3 Technical Data 3
4 Flange Misalignment Determination Procedure 3-4
4.1 Lateral Misalignment 3
4.2 Rotational (Twist) Misalignment 4
5 WCA4TM –Mechanical Fixed Flange and Rotational Alignment Tool 5-11
5.1 Kit Components 5
5.2 How the WCA4TM Works 5
5.3 Installation and Operation 6-7
5.4 Weights and Dimensions 8
5.5 Troubleshooting 9
5.6 Range of Application 10
1 - INTRODUCTION
The Christie WCA4TM is an aid for use in normal maintenance and installation procedures, and enable
the realignment of mis-aligned flanges within their respective working capacities. For example, the tool
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 WCA4TM flange alignment tool.

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2 –SAFETY INFORMATION
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.
W. Christie (Industrial) Limited cannot be responsible for damage or injury resulting from unsafe product
use, lack of maintenance or incorrect product and/or system operation. Contact W. Christie (Industrial)
Limited when in doubt as to the safety precautions and applications. To protect your warranty, use only
good quality hydraulic oil of the grade 32cSt.
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 CHRISTIE WCA4TM FLANGE
ALIGNMENT TOOL, during normal maintenance/installation operations. All other safety aspects must
be controlled by the operation supervisor.
Please note the following:-
1) The tools must not be attached to a flange joint prior to misalignment
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: The operator must have read
and understood all instructions, safety issues,
cautions and warnings before starting to operate
the Christie equipment.
WARNING: Do not overload equipment.
Overloading causes equipment failure and
possible personal injury.
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.
WARNING: Immediately replace worn or
damaged parts with genuine Christie parts.
Christie parts are designed to fit properly and
withstand rated loads. For repair or maintenance
service contact W. Christie (Industrial) Limited
DANGER: To avoid personal injury keep hands
and feet way from the tool and workpiece during
operation.
WARNING: Always wear suitable clothing and
Personal Protective Equipment (PPE).
CAUTION: Do not operate the equipment
without lubricating all moving parts as in section
5.4. Use only high pressure molybdenum
disulphide grease.

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3 –TECHNICAL DATA
TOOL
TOOL DESCRIPTION
ALIGNING FORCE
WCA4TM
Mechanical Fixed Flange and Rotational
Alignment Tool
4.0 T (40kN) from 50 lbf.ft (67.8 Nm) of
torque
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) Loosen 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 section 5.3.

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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 occurred.
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 section 5.3) and
use it to push the flanges out of alignment until one pair
of bolt-holes becomes parallel.
2) Insert the bolt into the aligned bolt- hole and release the
alignment tool. The load will transfer onto the 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.

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5 –WCA4TM MECHANICAL FIXED FLANGE AND ROTATIONAL ALIGNMENT TOOL
5.1 –KIT COMPONENTS
1 x WCA4TM Tool
1 x 50 lbf.ft (67.8 Nm) Torque Wrench with 22mm Socket
1 x Ratchet and Strap
1 x Instruction Manual
1 x Carry Case
5.2 –HOW THE WCA4TM WORKS
1) The WCA4TM is secured to the lower of the two flanges by fully inserting the lift hook into the
bolt-hole at the point of greatest misalignment.
2) The drop leg is adjusted down to the pipe while the tool is held level in the bolt-hole.
3) The wing retaining screw is loosened to allow the wing to be extended out.
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 lbf.ft (67.8 Nm) (max), attached to the screw bolt and turned to
screw down on the flange, bringing the joint into alignment.

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5.3 –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
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.
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.
INSTALLATION AND OPERATION
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.
2) Guide the lift hook into the bolt-hole at the maximum point
of misalignment.
Adjust the drop leg down onto the pipe by turning the
adjusting knob in a clockwise direction. The tool should be
held up level within the bolt-hole during adjustment.
N.B. The tool must be parallel to the pipe at all times

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3) Loosen the wing retaining knob and extend the wing over to the
opposite flange.
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.
4) Attach the hook of the strap through
the buckle on top of the base plate as
shown.
5) Now place the hook of the ratchet
mechanism through the opposite side
of the buckle as shown.
6) Feed the open end of the strap
through the ratchet mechanism as
shown. Tighten the strap using the
ratchet mechanism.
7) The torque wrench should be set at 14
ft/lbs (19Nm) then attached to the
screw bolt.
8) Tighten the screw bolt in a clockwise direction until the flanges come
into alignment; or the torque wrench “clicks” If the torque wrench has
clicked and the flanges are still mis-aligned adjust the torque wrench
up to 24.2 lbf.ft (33 Nm) and continue until a maximum torque
wrench setting of 50t/lbs (67.8N/m) is reached or the flanges are
aligned.
The maximum safe working load is 50 lbf.ft (67.8 Nm) Exceeding 50
lbf.ft will result in damage to the tool.
9) 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
WCA4TM is located), remove the tool by reversing steps 2 –8. 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.
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5
6
7

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5.4 –WEIGHTS AND DIMENSIONS
WEIGHTS
Tool only = 8.6 kg (18.96 lbs)
Torque Wrench with Socket = 0.9 kg (1.98 lbs)
Plastic Carry Case = 2.52 kg (5.55 lbs)
GROSS KIT WEIGHT = 11.7 kg (25.80 lbs)
OVERALL DIMENSIONS
MINIMUM EXTENSION
MAXIMUM EXTENSION

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5.5 –TROUBLESHOOTING
Problem: The thrust plate is sliding in the circumference of the opposite flange as the tool is aligning
the joint
- Grit or dirt on wing, rollers or
bearings
- Wing is at full extension
- Ensure the rollers are rotating freely and that there is no restriction
to the rollers on the wing surfaces such as dirt or grit
- Ensure the wing has sufficient travel left in order to allow the joint
to align.
Problem: The tool is attached and appears to be functioning properly, but the joint will not align
- There may be something
restricting the joint from
aligning.
- The joint may require more
than 4 T (40 kN) force to
align.
- 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 4 T (40 kN) tool,
then another method of aligning the joint should be adopted
Problem: The thrust plate is twisting on the circumference of the flange when the screw bolt is
tightened
- There may be grit or dirt
within the swivel / thrust plate.
- 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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5.6 –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
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