Climax ALDER TAT-SRV User manual

TAT-SRV
TURN AROUND TESTER FOR
SAFETY RELIEF VALVES
WITH OPTIONAL HYDROSTATIC CIRCUIT
OPERATING MANUAL
ORIGINAL INSTRUCTIONS
P/N 98061
February 2021
Revision 2

P/N 98061, Rev. 2 Page A
©2021 CLIMAX or its subsidiaries.
All rights reserved.
Except as expressly provided herein, no part of this manual may be reproduced, copied, transmitted, dissem-
inated, downloaded, or stored in any storage medium, without the express prior written consent of CLIMAX.
CLIMAX hereby grants permission to download a single copy of this manual and of any revision hereto onto
an electronic storage medium to be viewed and to print one copy of this manual or any revision hereto, pro-
vided that such electronic or printed copy of this manual or revision must contain the complete text of this
copyright notice and provided further that any unauthorized commercial distribution of this manual or any
revision hereto is prohibited.
At CLIMAX, we value your opinion.
For comments or questions about this manual or other CLIMAX documentation, please e-mail
[e-mail].
For comments or questions about CLIMAX products or services, please call CLIMAX or e-mail
[email protected]. For quick and accurate service, please provide your representative with the following:
• Your name
• Shipping address
• Telephone number
• Machine model
• Serial number (if applicable)
• Date of purchase
CLIMAX World Headquarters
2712 East 2nd Street
Newberg, Oregon 97132 USA
Telephone (worldwide): [phone]
Toll-free (North America): 1-800-333-8311
Fax: [phone]
H&S Tool World Headquarters
715 Weber Dr.
Wadsworth, OH 44281 USA
Telephone: [phone]
Fax: [phone]
hstool.com
CLIMAX | H&S Tool (UK Headquarters)
Unit 7 Castlehill Industrial Estate
Bredbury Industrial Park
Horsfield Way
Stockport SK6 2SU, UK
Telephone: [phone]
CLIMAX | H&S Tool (European Headquarters)
Am Langen Graben 8
52353 Düren, Germany
Telephone: [phone]
E-mail: [e-mail]
CLIMAX | H&S Tool (Asia Pacific Head-
quarters)
316 Tanglin Road #02-01
Singapore 247978
Telephone: [phone]
Fax: [phone]
CLIMAX | H&S Tool (Middle East Headquarters)
Warehouse #5, Plot: 369 272
Um Sequim Road
Al Quoz 4
PO Box 414 084
Dubai, UAE
Telephone: [phone]

Page B 7912-A1 Operating Manual
CLIMAX GLOBAL LOCATIONS

P/N 98061, Rev. 2 Page C
CE DOCUMENTATION

Page D 7912-A1 Operating Manual
CE DOCUMENTATION

P/N 98061, Rev. 2 Page E
LIMITED WARRANTY
CLIMAX Portable Machine Tools, Inc. (hereafter referred to as “CLIMAX”) warrants that all new machines
are free from defects in materials and workmanship. This warranty is available to the original purchaser for a
period of two years after delivery. If the original purchaser finds any defect in materials or workmanship
within the warranty period, the original purchaser should contact its factory representative and return the
entire machine, shipping prepaid, to the factory. CLIMAX will, at its option, either repair or replace the
defective machine at no charge and will return the machine with shipping prepaid.
CLIMAX warrants that all parts are free from defects in materials and workmanship, and that all labor has
been performed properly. This warranty is available to the customer purchasing parts or labor for a period of
90 days after delivery of the part or repaired machine or 180 days on used machines and components. If the
customer purchasing parts or labor finds any defect in materials or workmanship within the warranty period,
the purchaser should contact its factory representative and return the part or repaired machine, shipping pre-
paid, to the factory. CLIMAX will, at its option, either repair or replace the defective part and/ or correct any
defect in the labor performed, both at no charge, and return the part or repaired machine shipping prepaid.
These warranties do not apply to the following:
• Damage after the date of shipment not caused by defects in materials or workmanship
• Damage caused by improper or inadequate machine maintenance
• Damage caused by unauthorized machine modification or repair
• Damage caused by machine abuse
• Damage caused by using the machine beyond its rated capacity
All other warranties, express or implied, including without limitation the warranties of merchantability and
fitness for a particular purpose are disclaimed and excluded.
Terms of sale
Be sure to review the terms of sale which appear on the reverse side of your invoice. These terms control and
limit your rights with respect to the goods purchased from CLIMAX.
About this manual
CLIMAX provides the contents of this manual in good faith as a guideline to the operator. CLIMAX cannot
guarantee that the information contained in this manual is correct for applications other than the application
described in this manual. Product specifications are subject to change without notice.

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P/N 98061, Rev. 2 Page i
TABLE OF CONTENTS
CHAPTER/SECTION PAGE
1 INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1
1.1 HOW TO USE THIS MANUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 SAFETY ALERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 GENERAL SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 MACHINE-SPECIFIC SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 RISK ASSESSMENT AND HAZARD MITIGATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 RISK ASSESSMENT CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.7 LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 OVERVIEW - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -9
2.1 FEATURES AND COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5 ITEMS REQUIRED BUT NOT SUPPLIED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 SETUP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -15
3.1 RECEIPT AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 LIFTING AND RIGGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3 SECURING THE TEST STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3.1 Bolting the test stand to a service vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3.2 Strapping the test stand to a service vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4 FILLING THE RESERVOIRS AND LUBRICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.5 CONNECTING AIR FROM THE SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.5.1 High-pressure sources for testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.6 CLAMPING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -21
4.1 PRE-OPERATION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 CONDUCTING HYDROSTATIC TESTS (ONLY WITH TAT-SRV PLUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2.1 Purging the system with water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2.2 Hydrostatic test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2.3 Adjusting the valve on the seal plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.3 CONDUCTING AHIGH-PRESSURE AIR OR NITROGEN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.3.1 Purging the vessel and system of water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.3.2 Running the high-pressure air or nitrogen test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.3.3 Adjusting the valve on the seal plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.4 CONDUCTING AN AIR OR NITROGEN OVER WATER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.5 RELEASING THE CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.6 PREPARING THE MACHINE FOR TRANSPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Page ii 7912-A1 Operating Manual
TABLE OF CONTENTS (CONTINUED)
CHAPTER/SECTION PAGE
5 MAINTENANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27
5.1 MAINTENANCE CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6 STORAGE AND SHIPPING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29
6.1 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.1.1 Short-term storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.1.2 Long-term storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2 SHIPPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.3 DECOMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
APPENDIX A ASSEMBLY DRAWINGS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 31
APPENDIX B SCHEMATICS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65
APPENDIX C SDS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69

P/N 98061, Rev. 2 Page iii
LIST OF FIGURES
FIGURE PAGE
2-1 Upper console controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-2 Lower front console controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-3 TAT-SRV dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-1 Lifting and securing points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-1 Seal cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
A-1 TAT-SRV assembly with hydro front detail (P/N 96229). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
A-2 TAT-SRV assembly with hydro back detail (P/N 96229). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
A-3 TAT-SRV assembly with hydro back detail 2 (P/N 96229) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
A-4 TAT-SRV assembly with hydro parts list (P/N 96229) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
A-5 Console assembly detail A (P/N 97861) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
A-6 Console assembly detail B and C (P/N 97861). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
A-7 Console assembly interior (P/N 97861) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
A-8 Console assembly detail E (P/N 97861) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
A-9 Console hose assembly (P/N 97861) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
A-10 Console low-pressure hose assembly (P/N 97861) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
A-11 Console 6 KSI hose assembly and detail H (P/N 97861) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
A-12 Console interlock assembly (P/N 97861) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
A-13 Console assembly parts list 1 (P/N 97861). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
A-14 Console assembly parts list 2 (P/N 97861). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
A-15 TAT-SRV 1" (25 mm) sub-assembly (P/N 97998). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
A-16 TAT-SRV without hydro assembly front detail (P/N 98222) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
A-17 TAT-SRV without hydro assembly back detail 1 (P/N 98222). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
A-18 TAT-SRV without hydro assembly back detail 2 (P/N 98222). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
A-19 TAT-SRV assembly with hydro parts list (P/N 98222) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
A-20 Console assembly detail A (P/N 98223) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
A-21 Console assembly detail B and C (P/N 98223). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
A-22 Console assembly interior (P/N 98223) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
A-23 Console assembly detail E (P/N 98223) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
A-24 Console hose assembly (P/N 98223) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
A-25 Console 3 KSI and 6 KSI hose assembly (P/N 98223). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
A-26 Console interlock assembly (P/N 98223) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
A-27 Console assembly parts list 1 (P/N 98223). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
A-28 Console assembly parts list 2 (P/N 98223). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
A-29 TAT-SRV 1" (25 mm) with check sub-assembly (P/N 98331). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
A-30 Clamp arm assembly (P/N 97981) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
A-31 RTJ clamp pressure chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
B-1 Schematic (P/N 97964). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
B-2 Schematic (P/N 98245). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

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P/N 98061, Rev. 2 Page v
LIST OF TABLES
TABLE PAGE
1-1 Risk assessment checklist before set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-2 Risk assessment checklist after set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-3 TAT-SRV labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-1 Upper console control identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-2 Lower console controls identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-1 Lifting and securing point identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-2 Hydraulic load chart for flanged valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-1 Maintenance intervals and tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
A-1 O-rings kit P/N 90025 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
A-2 Spare parts kit (P/N 91731). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
A-3 RTJ adapters kit (P/N 99936) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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P/N 98061, Rev. 2 Page 1
1 INTRODUCTION
IN THIS CHAPTER:
1.1 HOW TO USE THIS MANUAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.2 SAFETY ALERTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.3 GENERAL SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
1.4 MACHINE-SPECIFIC SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
1.5 RISK ASSESSMENT AND HAZARD MITIGATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
1.6 RISK ASSESSMENT CHECKLIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
1.7 LABELS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
1.1 HOW TO USE THIS MANUAL
This manual describes information necessary for the setup, operation, mainte-
nance, storage, shipping, and decommissioning of the TAT-SRV.
The first page of each chapter includes a summary of the chapter contents to help
you locate specific information. The appendices contain supplemental product
information to aid in setup, operation, and maintenance tasks.
Read this entire manual to familiarize yourself with the TAT-SRV before attempt-
ing to set it up or operate it.
1.2 SAFETY ALERTS
Pay careful attention to the safety alerts printed throughout this manual. Safety
alerts will call your attention to specific hazardous situations that may be encoun-
tered when operating this machine.
Examples of safety alerts used in this manual are defined here1:
DANGER
indicates a hazardous situation which, if not avoided, WILL result in
death or severe injury.
WARNING
indicates a hazardous situation which, if not avoided, COULD result in
death or severe injury.
1. For more information on safety alerts, refer to ANSI/NEMA Z535.6-2011, Product
safety Information in Product Manuals, Instructions, and Other Collateral Materials.

Page 2 7912-A1 Operating Manual
CAUTION
indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE
indicates a hazardous situation which, if not avoided, could result in
property damage, equipment failure, or undesired work results.
1.3 GENERAL SAFETY PRECAUTIONS
CLIMAX leads the way in promoting the safe use of portable machine tools and
valve testers. Safety is a joint effort. You, the end user, must do your part by being
aware of your work environment and closely following the operating procedures
and safety precautions contained in this manual, as well as your employer’s safety
guidelines.
Observe the following safety precautions when operating or working around the
machine.
Training – Before operating this or any machine tool, you should receive
instruction from a qualified trainer. Contact CLIMAX for machine-specific
training information.
Risk assessment – Working with and around this machine poses risks to
your safety. You, the end user, are responsible for conducting a risk assess-
ment of each job site before setting up and operating this machine.
Intended use – Use this machine in accordance with the instructions and
precautions in this manual. Do not use this machine for any purpose other
than its intended use as described in this manual.
Personal protective equipment – Always wear appropriate personal pro-
tective gear when operating this or any other machine tool.
Work area – Keep the work area around the machine clear of clutter. Restrain
cords and hoses connected to the machine. Keep other cords and hoses
away from the work area.
Lifting – Many CLIMAX machine components are very heavy. Whenever
possible, lift the machine or its components using proper hoisting equip-
ment and rigging. Always use designated lifting points on the machine.
Lock-out/tag-out – Lock-out and tag-out the machine before performing
maintenance.
Moving parts – CLIMAX machines have numerous exposed moving parts
and interfaces that can cause severe impact, pinching, cutting, and other
injuries. Except for stationary operating controls, avoid contact with mov-
ing parts by hands or tools during machine operation. Remove gloves and

P/N 98061, Rev. 2 Page 3
secure hair, clothing, jewelry, and pocket items to prevent them from
becoming entangled in moving parts.
1.4 MACHINE-SPECIFIC SAFETY PRECAUTIONS
Eye hazard – Always wear eye protection when operating the machine.
Sound level – This machine produces potentially harmful sound levels.
Hearing protection is required when operating this machine or working
around it.
Hazardous environments – Do not operate the machine in environments
where potentially explosive materials, toxic chemicals, or radiation may be
present.
Pressurization – Do not over-pressurize the valve test system beyond the
limits described in this manual and on machine labels.
Test gauges – Do not use any gauge above its rating. Do not remove test
gauges while the system is pressurized.
Utility service requirements – Do not exceed the pressure ratings stated in
this manual and on the machine labels.
WARNING
This machine is equipped with an interlocking valve control knob to
prevent accidental release of clamp pressure while the valve under test
is pressurized.
Do not operate this machine if these interlocking knobs are missing,
damaged, or altered. Doing so could result in property damage or
personnel injury.

Page 4 7912-A1 Operating Manual
1.5 RISK ASSESSMENT AND HAZARD MITIGATION
To achieve the intended results and to promote safety, the operator must under-
stand and follow the design intent, set-up, and operation practices that are unique
to valve testers.
The operator must perform an overall review and on-site risk assessment of the
intended application. Due to the unique nature of high-pressure water testing, iden-
tifying one or more hazards that must be addressed is typical.
When performing the on-site risk assessment, it is important to consider the valve
tester and the workpiece as a whole.
WARNING
High-pressure valve testing may result in the sudden, unexpected
release of stored energy with the potential to cause property damage or
personnel injury. Potential hazards may include the possibility of high-
velocity fluid escaping and high-energy projectile impact. The end-user
must assess the application and install protective barrier devices, as
appropriate.

P/N 98061, Rev. 2 Page 5
1.6 RISK ASSESSMENT CHECKLIST
The following checklist is not intended to be an all inclusive list of things to watch
out for when setting up and operating this valve testing machine. However, these
checklists are typical of the types of risks the assembler and operator should con-
sider. Use these checklists as part of your risk assessment:
TABLE 1-1. RISK ASSESSMENT CHECKLIST BEFORE SET-UP
Before set-up
I took note of all the warning labels on the machine.
I removed or mitigated all identified risks (such as tripping, cutting, crushing, entan-
glement, shearing, or falling objects).
I considered the need for personnel safety guarding and installed any necessary
guards.
I considered the potential hazards that are inherent in high-pressure valve testing,
including the possibility of high velocity fluid escape or workpiece fragmentation,
and have installed appropriate protective barriers.
I read the machine assembly instructions (Section 3) and took inventory of all the
items required but not supplied (Section 2.5).
I considered how this machine operates and identified the best placement for the
controls, cabling, and the operator.
I evaluated and mitigated any other potential risks specific to my work area.
TABLE 1-2. RISK ASSESSMENT CHECKLIST AFTER SET-UP
After set-up
I checked that the machine is safely installed (according to Section 3).
I identified all possible pinch points, such as those caused by rotating parts, and
informed the affected personnel.
I followed the required maintenance checklist (Section 5).
I checked that all affected personnel have the recommended personal protective
equipment, as well as any site-required or regulatory equipment.
I checked that all affected personnel understand and are clear of the danger zone.
I evaluated and mitigated any other potential risks specific to my work area.

Page 6 7912-A1 Operating Manual
1.7 LABELS
The following warning and identification labels should be on your machine. If any
are defaced or missing, contact CLIMAX immediately for replacements.
TABLE 1-3. TAT-SRV LABELS
P/N 29154
ID plate
P/N 59033
Label: center of
balance
P/N 79328
Warning label:
read the operat-
ing manual
P/N 80905
Warning label:
hand crush hazard
P/N 81008
Warning label:
wear ear and
eye protection
P/N 82144
Warning label:
danger, use cau-
tion
P/N 90160
Warning label:
high-pressure
water release
hazard
P/N 89497
Warning label: do
not exceed the
maximum pres-
sure rating of the
valve