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Summary of Contents for Climax ALDER TAT-SRV
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TAT-SRV TURN AROUND TESTER FOR SAFETY RELIEF VALVES WITH OPTIONAL HYDROSTATIC CIRCUIT OPERATING MANUAL ORIGINAL INSTRUCTIONS P/N 98061 February 2021 Revision 2...
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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-...
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CLIMAX GLOBAL LOCATIONS Page B 7912-A1 Operating Manual...
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CE DOCUMENTATION P/N 98061, Rev. 2 Page C...
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CE DOCUMENTATION Page D 7912-A1 Operating Manual...
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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.
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ENERAL 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...
secure hair, clothing, jewelry, and pocket items to prevent them from becoming entangled in moving parts. ACHINE 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.
ISK 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.
ISK 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.
ABELS The following warning and identification labels should be on your machine. If any are defaced or missing, contact CLIMAX immediately for replacements. 1-3. TAT-SRV ABLE LABELS P/N 59033 P/N 29154 Label: center of ID plate balance P/N 79328 P/N 80905...
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1-3. TAT-SRV ABLE LABELS P/N 89498 P/N 89499 Warning label: Warning label: do do not release not lift with valve the clamp the clamped valve is pres- surized P/N 89500 P/N 89548 Warning label: Warning label: do tip-over hazard not plug P/N 90533 P/N 90585 Label: clamp...
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ONTROLS The controls are all located on the control console and the clamp fixture console. PCV-02 PI-03 PI-02 PI-01 WATER PCV-04 SUPPLY CLAMP TEST VESSEL CLAMP PRESSURE PRESSURE PRESSURE PRESSURE PRESSURE GAUGE GAUGE GAUGE CONTROL CONTROL V-03 VESSEL V-02 DIVERTER CLAMP VALVE RELEASE...
SUPPLY VALVE AIR LUBRICANT AIR INLET FILL 100-150 PSI (7-10 BAR) AIR INLET WATER 6,000 PSI SUPPLY (413 BAR) VALVE MAXIMUM WATER INLET 70 PSI (5 BAR) MAX 2-2. L IGURE OWER FRONT CONSOLE CONTROLS 2-2. L ABLE OWER CONSOLE CONTROLS IDENTIFICATION Console Number Component...
This machine should only be used with ambient gas or liquid. No corrosive liquids or gas should be used in the system. TEMS REQUIRED BUT NOT SUPPLIED The following items are required but not supplied in your CLIMAX product kit: • Shop air (100–150 psi [6.9–10.3 bar]) •...
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This section describes the setup and assembly procedures for the TAT-SRV. ECEIPT AND INSPECTION Your CLIMAX product was inspected and tested prior to shipment, and packaged for normal shipment conditions. CLIMAX does not guarantee the condition of your machine upon delivery.
IFTING AND RIGGING Lift the TAT-SRV by using the forklift pockets, as seen in Figure 3-1. FORKLIFT POCKET HOLE TO SECURE THE TESTER TO THE VEHICLE (4 TOTAL) 3-1. L IGURE IFTING AND SECURING POINTS 3-1. L ABLE IFTING AND SECURING POINT IDENTIFICATION Number Component Forklift pocket.
3.4 F ILLING THE RESERVOIRS AND LUBRICATOR Do the following before operating: 1. Fill the hydraulic reservoir with hydraulic oil (AW-32 or AW-46) to half of the sight gauge. 2. Fill the lubricators with air tool oil (generic purpose, such as AW-32) and adjust the knob to set it to one drop per 25 strokes of the pump.
3.6 C LAMPING PROCEDURE Do the following (refer to Figure 2-3 on page 11 as needed): 1. Check the integrity of the o-rings on the seal plates. Replace any damaged o-rings. NOTICE Any imperfections to the o-ring surface may cause a loss of pressure during testing.
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NOTICE Precision in this operation is important to prevent overshooting the designated pressure, which could damage the valve under test. WARNING Check Table 3-2 for recommended clamping pressures. Excess clamp pressures may damage the workpiece and machine and may result in serious personnel injury.
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If using ring type joint (RTJ) plates, refer to Figure A-31 on page 63 and Table A- 3 on page 63. WARNING To minimize the risk of damage to the machine, workpiece, and personnel injury, use technical judgment and discretion when increasing the clamping pressure above the recommendations listed in Table 3-2.
NOTICE Follow any pressure ratings indicated on the load chart on the console, as shown in Table 3-2 on page 19. Exceeding the rated pressures could result in equipment damage. 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.
4.2.3 Adjusting the valve on the seal plate If the valve (device under test) needs to be adjusted, do the following while refer- ring to Figure 2-1 on page 10: 1. Reduce the water supply pressure control to zero. 2. Open seal plate drain valve slowly to release all remaining pressure within the system and to drain water from the test piece as needed from the valve under test.
3. Open the seal plate block valve and vessel outlet block valve. 4. Turn the gas vessel diverter valve upward). 5. Turn the gas supply pressure regulator clockwise and monitoring the test pressure gauge, until it reaches the desired test pressure. Increase pressure gradually.
9. Turn the vessel diverter valve to upward. 10. Turn the gas supply pressure regulator clockwise while monitoring the test pressure gauge, until it reaches the desired test pressure. Increase pressure gradually. ELEASING THE CLAMP WARNING Do not release the clamp pressure while the valves under test is pressurized.
4. Rotate the clamp pressure control to zero. 5. Check that clamp pressure gauge shows 0 psi/bar. 6. Open the clamp release valve to release the test piece from the test table. 7. Slide the clamp bars away from the test piece and remove from the table. REPARING THE MACHINE FOR TRANSPORT When transporting the machine to a different location, do the following: 1.
MAINTENANCE AINTENANCE CHECKLIST Table 5-1 lists maintenance intervals and their associated tasks. 5-1. M ABLE AINTENANCE INTERVALS AND TASKS Interval Task Inspect the testing unit, including all hose connections, inlet supply lines, and outlet lines. Before each use Check the o-rings on the seal plates for cracks or nicks. Replace if necessary. Check the lubricator to ensure one drip to every 25 strokes of the pump.
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WARNING To minimize the risk of damage to the machine, workpiece, and personnel injury, use technical judgment and discretion when increasing the clamping pressure above the recommendations listed in Table 3-2 on page 19. Page 28 7912-A1 Operating Manual...
HIPPING Check that the machine’s legs are adjusted to the lowest height (see Section 4.6 on page 26). ECOMMISSIONING To decommission the TAT-SRV before disposal, remove the air tool oil and hydraulic fluid before dismantling machine components. Refer to Appendix A for component assembly information.
ITEM P/N: DESCRIPTION 29154 PLATE SERIAL YEAR MODEL CE 2.0 X 3.0 46531 (NOT SHOWN) CRATE 79 X 54 X 48 ECORRCRATE TAT-8-25 59033 LABEL WARNING - CENTER OF BALANCE 1.5" DIA 64045 (NOT SHOWN) SLEEVE WELD COVER- 2.0 DIA W/VELCRO CLOSURE 77489 FTG CONNECTOR 3/8NPTM X 3/8 TUBE 78414...
ADD 6 INCHES OF 73786 NOTES: 1. REFER TO 97964 SCHEMATIC FOR DESIGN PRESSURE OF SYSTEM. 6000 PSI MAXIMUM DETAIL A 2. DESIGN TEMPERATURE AND SCALE 1 / 4 OPERATING TEMPERATURE RANGE OF THIS MACHINE IS 0°F(-18°C) - 130°F(55°C). A-5. C A (P/N 97861) IGURE ONSOLE ASSEMBLY DETAIL...
ITEM P/N: DESCRIPTION 88733 FTG ADAPTER 10000 PSI 3/4 NPTF X 1/4 NPTF 88735 FTG 1/4 NPTM X 1/4 NPTM SS ELBOW 89377 PUMP AIR DRIVEN 5800 PSI OIL SERVICE 89460 VALVE PRESSURE RELIEF SET @ 6200 PSI CE CERTIFIED 89497 LABEL WARNING DO NOT EXCEED MAX RATING OF DUT 89498...
PARTS LIST ITEM P/N: DESCRIPTION 79935 FTG NIPPLE 1 NPTM X 1 NPTM SS 91977 FTG ADAPTER PIPE 1 NPTM X 1/2 NPTF 92023 FTG TEE 1 NPTF SS 95334 FTG ELBOW 1 NPTF X 1 NPTF 90 DEG SS 97829 FTG ADAPTER 4 JICM X 1/2 NPTM SS 97833...
PARTS LIST ITEM P/N: DESCRIPTION 29154 PLATE SERIAL YEAR MODEL CE 2.0 X 3.0 46531 (NOT SHOWN) CRATE 79 X 54 X 48 ECORRCRATE TAT-8-25 59033 LABEL WARNING - CENTER OF BALANCE 1.5" DIA 64045 (NOT SHOWN) SLEEVE WELD COVER- 2.0 DIA W/VELCRO CLOSURE 77489 FTG CONNECTOR 3/8NPTM X 3/8 TUBE 78414...
NOTES: 1. REFER TO 97964 SCHEMATIC FOR DESIGN PRESSURE OF SYSTEM. 6000 PSI MAXIMUM DETAIL A 2. DESIGN TEMPERATURE AND SCALE 1 / 4 OPERATING TEMPERATURE RANGE OF THIS MACHINE IS 0°F(-18°C) - 130°F(55°C). A-20. C A (P/N 98223) IGURE ONSOLE ASSEMBLY DETAIL P/N 98061, Rev.
PARTS LIST ITEM P/N: DESCRIPTION 88735 FTG 1/4 NPTM X 1/4 NPTM SS ELBOW 89377 PUMP AIR DRIVEN 5800 PSI OIL SERVICE 89497 LABEL WARNING DO NOT EXCEED MAX RATING OF DUT 89498 LABEL WARNING DO NOT RELEASE CLAMP WHILE VALVE IS PRESSURIZED 89499 LABEL CAUTION DO NOT LIFT WITH VALVE CLAMPED 89500...
PARTS LIST ITEM P/N: DESCRIPTION 79935 FTG NIPPLE 1 NPTM X 1 NPTM SS 2.77 LG 83139 FTG NIPPLE 1/2 NPTM X 1/4 NPTM SS 91977 FTG ADAPTER PIPE 1 NPTM X 1/2 NPTF 92023 FTG TEE 1 NPTF SS 95334 FTG ELBOW 1 NPTF X 1 NPTF 90 DEG SS 97386...
PARTS LIST ITEM P/N: DESCRIPTION 80905 LABEL WARNING - HAND CRUSH / FORCE FROM ABOVE GRAPHIC 1.13 TALL TRIANGLE YELLOW 82666 SCREW 3/8-16 X 3 SHCS SS 84986 SCREW 5/16-18 X 5/8 SHCS SS 85923 SCREW 1/2-13 X 1 SHCS 316 STAINLESS 89421 BLOCK CONTACT CLAMP ARM 89483...
A-1. O- P/N 90025 ABLE RINGS KIT Part Description Quantity number 77589 O-RING 3-5/8 ID X 3-7/8 OD X 1/8 W NITRILE 90 DUROMETER (2-239) 77590 O-RING 4-5/8 ID X 5 OD X 3/16 W NITRILE 90 DUROMETER (2-350) 78456 O-RING 5-5/8 ID X 6 OD X 3/16 W NITRILE 90 DUROMETER (2-358) 78457 O-RING 6-3/4 ID X 7-1/8 OD X 3/16 W NITRILE 90 DUROMETER (2-364)
A-31. RTJ IGURE CLAMP PRESSURE CHART A-3. RTJ (P/N 99936) ABLE ADAPTERS KIT Part Description Quantity number 100004 SEAL PLATE TAT RTJ R29 AND R37 100071 SEAL PLATE TAT RTJ R31 AND R36 100741 CRATE 12.5 ID X 12.5 ID X 5 ID ECORRCRATE W/ SPACER P/N 98061, Rev.
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