1900 HAND

CART
Model 1900-W-10K
HYDROSTATIC TEST HAND CART
OPERATING MANUAL

P/N 85951 December 2015 Revision 1

 ©2015 Climax Portable Machining and Welding Systems or its subsidiaries.
All rights reserved.
Except as expressly provided herein, no part of this manual may be reproduced, copied, transmitted, dissem-
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For comments or questions about this manual or other Climax documentation, please e-mail
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For quick and accurate service, please provide your factory representative with the following:
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Climax World Headquarters
Climax Portable Machining and Welding Systems
2712 South Second Street Newberg, Oregon 97132 USA
Telephone (worldwide): (503) 538-2815
Toll-free (North America):1-800-333-8311
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Telephone: +49 (0) 2421-9177-0
E-mail: [email protected]

P/N 85951, Rev. 1 Page A

 CLIMAX GLOBAL LOCATIONS

Page B 1900 HC Operating Manual

 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 one year 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 defec-
tive 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 cus-
tomer 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 prepaid,
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 guar-
antee 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.

P/N 85951, Rev. 1 Page C

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Page D 1900 HC Operating Manual

 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 RISK ASSESSMENT AND HAZARD MITIGATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 RISK ASSESSMENT CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.7 LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.7.1 Label identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.7.2 Label location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 FEATURES AND COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 ITEMS REQUIRED BUT NOT SUPPLIED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 RECEIPT AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 INSTALLING UTILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2.1 Connect air to the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2.2 Connect the drain to the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2.3 Connect water from the source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1 PRE-OPERATION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 FILLING WATER TO THE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3 HYDROSTATIC SEAT AND SHELL TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6 STORAGE AND SHIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1 STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1.1 Short-term storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1.2 Long-term storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.2 SHIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.3 DECOMMISSIONING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
APPENDIX A ASSEMBLY DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
APPENDIX B SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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Page ii 1900 HC Operating Manual

 LIST OF FIGURES
FIGURE PAGE
1-1 1900 HC front label location (P/N 85144) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-1 1900 HC controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-2 1900 HC connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4-1 Tethered hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
A-1 1900 HC assembly (P/N 85144) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
A-2 1900 HC assembly parts list 1–28 (P/N 85144) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
A-3 1900 HC assembly parts list 29–54 (P/N 85144) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
B-1 1900 HC schematic (P/N 85345) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

P/N 85951, Rev. 1 Page iii

Page iv 1900 HC Operating Manual
 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 1900 HC labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5-1 Maintenance intervals and tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

P/N 85951, Rev. 1 Page v

Page vi 1900 HC Operating Manual
 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 - - - 2
1.5 RISK ASSESSMENT AND HAZARD MITIGATION - - 4
1.6 RISK ASSESSMENT CHECKLIST - - - - - - - - - 5
1.7 LABELS - - - - - - - - - - - - - - - - - - - 6
1.7.1 Label identification - - - - - - - - - - - 6
1.7.2 Label location - - - - - - - - - - - - - - 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 1900 HC.
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 1900 HC 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.

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.

P/N 85951, Rev. 1 Page 1

 General safety precautions

WARNING
indicates a hazardous situation which, if not avoided, COULD
result in death or severe injury.

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 Calder Testing Systems (Climax) leads the way in promoting the safe use
of portable machine tools. 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. Eye and ear
protection are required when operating or working around the machine.
Work area – Keep the work area around the machine clear of clutter. Keep all
cords and hoses away from the work area when operating the machine.

1.4 MACHINE-SPECIFIC SAFETY PRECAUTIONS

Clamping – Keep hands clear while clamping. Do not release the clamp

Page 2 1900 HC Operating Manual

 Machine-specific safety precautions

while the system is pressurized.

Hazardous environments – Do not operate the machine in environments
where potentially explosive materials, toxic chemicals, or radiation may be
present.
Eye hazard – This machine utilizes high-pressure fluids during operation.
Always wear eye protection when operating the machine.
Pressurization – Do not over-pressurize the valve test system beyond the
limits described in this manual and on machine labels. Do not pressurize
the system while the side panels are removed from the test console.
Sound level – This machine produces bursts of air that could damage hear-
ing. Hearing protection is required when operating this machine or working
around it.
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.

P/N 85951, Rev. 1 Page 3

 Risk assessment and hazard mitigation

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 hydrostatic test hand carts.
The operator must perform an overall review and on-site risk assessment of the
intended application. Due to the unique nature of hydrostatic testing, identifying
one or more hazard that must be addressed is typical.
When performing an on-site risk assessment, it is important to consider the test
console and the test vessel as a whole.

WARNING
The 1900 HC is intended for use with pressurized water with a
maximum working pressure of 10,000 psi.

It is the operator’s responsibility to use the system within its

intended service pressure.

Operating the system with pressures that exceed 10,000 psi may
cause damage to the test equipment, the device under test, and
may result in personnel injury.

Page 4 1900 HC Operating Manual

 Risk assessment checklist

1.6 RISK ASSESSMENT CHECKLIST

Pressure testing is a high-risk activity. When applying stored energy to an assem-
bly, especially for the first time, there is potential for an unintended or premature
pressure release while people are in the danger zone.
The following checklist is not intended to be an all inclusive list of things to watch
out for when setting up and operating this hydrostatic test hand cart. However,
these checklists are typical of the types of risks the assembler and operator should
consider. Use these checklists as part of your risk assessment:

TABLE 1-1. RISK ASSESSMENT CHECKLIST BEFORE SET-UP

Before set-up
 I read the machine setup instructions (Section 3).
 I took note of all the warning labels on the machine (Section 1.7).
I considered the following risks associated with pressure testing:
• Test assembly rupture
 • Component or connector failure
• Test hose failure including detachment, with consequential hose whip
• Sudden release of the test medium
I considered the need for the following personnel safety measures:
 • Segregating or enclosing the test vessel
• Tethering or restraining the test console and test hoses

 Ithe
considered how this machine operates and identified the safest placement for
test vessel, the test console, and the operator.
I prepared a written safe system of work that identified how the assembly under
test can do the following:
 • Safely energized
• Safely monitored
• Have the test medium evacuated
 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 followed the required maintenance checklist (Section 5).
 I checked that the machine is safely installed (according to Section 3).
 I checked that all appropriate personnel safety measures have been employed.

 I checked that all affected personnel understand the risks of pressure testing and
are clear of the danger zone.
 I evaluated and mitigated any other potential risks specific to my work area.

P/N 85951, Rev. 1 Page 5

 Labels

1.7 LABELS
1.7.1 Label identification
The following warning labels should be on your machine. If any are defaced or
missing, contact Climax immediately for replacements.

TABLE 1-3. 1900 HC LABELS

PN 85962
Warning label: do not block sump

1.7.2 Label location

The following figures display the location of the labels on each of the components
of the 1900 HC. For further identification of location placement, refer to the
exploded views in Appendix A.

FIGURE 1-1. 1900 HC FRONT LABEL LOCATION (P/N 85144)

Label P/N: 85962

Page 6 1900 HC Operating Manual

 2 OVERVIEW
IN THIS CHAPTER:
2.1 FEATURES AND COMPONENTS - - - - - - - - - 7
2.2 CONTROLS - - - - - - - - - - - - - - - - - - 7
2.3 ITEMS REQUIRED BUT NOT SUPPLIED - - - - - - 8

2.1 FEATURES AND COMPONENTS

The Model 1900 Hand Cart is a valve test system that performs the following types
of seat leakage tests:
• Hydrostatic seat test
• Hydrostatic shell test
The following maximum pressure limitations apply:
• Test pressure: 10,000 psi (hydrostatic)

2.2 CONTROLS
The 1900 HC controls are all located on the machine, as shown in Figure 2-1 and
Figure 2-2.

HYDROSTATIC
TEST PRESSURE

REGULATED
PRESSURE

BLOCK VALVE
TEST PRESSURE
CONTROL

AIR CONTROL VALVE DUMP VALVE

WATER SUPPLY VALVE

FIGURE 2-1. 1900 HC CONTROLS

P/N 85951, Rev. 1 Page 7

 Items required but not supplied

AUXILIARY
PRESSURE
OUTLET

DRAIN WATER
PRESSURE SUPPLY
OUTLET INLET

SHOP AIR
INLET

FIGURE 2-2. 1900 HC CONNECTIONS

2.3 ITEMS REQUIRED BUT NOT SUPPLIED

The following items are required but not supplied in your Climax product kit:
• Shop air (90–125 psi)
• Supply water (160 psi maximum)
• Air tool oil (general purpose)
• Open-end wrenches
• High-pressure hose with hose restraints or alternate means to prevent
hose whip
• High-pressure hose with burst guard to prevent a high-velocity release
of contained fluid
• Structure suitable for tethering and restraining high-pressure hoses sub-
ject to hose whip
• Anti-tip device to prevent the 1900 HC from tipping over unexpectedly

Page 8 1900 HC Operating Manual

 3 SETUP
IN THIS CHAPTER:
3.1 RECEIPT AND INSPECTION - - - - - - - - - - - 9
3.2 INSTALLING UTILITIES - - - - - - - - - - - - - 9
3.2.1 Connect air to the control panel - - - - - 9
3.2.2 Connect the drain to the control panel - -10
3.2.3 Connect water from the source - - - - -10

3.1 RECEIPT 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.
When you receive your Climax product, perform the following receipt checks.
1. Inspect the shipping containers for damage.
2. Check the contents of the shipping containers against the included invoice
to make sure that all components have been shipped.
3. Inspect all components for damage.
Contact Climax immediately to report damaged or missing components.

NOTICE
Keep the shipping container and all packing materials for future
storage and shipping of the machine.

3.2 INSTALLING UTILITIES

Connect all of the following before operating the 1900 HC.

3.2.1 Connect air to the control panel

Pressurized air is the major power source for the control panel.
Connect 90–125 psi shop air to the SHOP AIR INLET (a 1/2” female National Pipe
Thread [NPT]), which is located at the air filter on the back of the test console.
Refer to Figure 2-2.

P/N 85951, Rev. 1 Page 9

 Installing utilities

NOTICE
A constant shop air supply of 75 scfm at 90 psi is recommended
for the Control Panel’s optimal performance.

3.2.2 Connect the drain to the control panel

Connect a low-pressure hose to the port labeled DRAIN (a 3/8” female NPT).
This DRAIN port is the outlet that allows test air and water to leave the test valve
and test console.

WARNING
Do not block the DRAIN port. High-pressure fluid vented to the
drain must be able to flow freely. Blocking the drain could result
in rupture of the drain line or fittings and may result in equipment
damage or personnel injury.

3.2.3 Connect water from the source

Water transmits the pressure for the valve test.
The WATER INLET, a 1/2” female NPT on the bulkhead, is located on the side of the
panel.
Connect your water line to the bulkhead.

WARNING
Do not apply high-pressure fluid to the AUXILIARY PORT. Applying
high-pressure fluid to the AUXILIARY PORT may result in
equipment damage or personnel injury.

Page 10 1900 HC Operating Manual

 4 OPERATION
IN THIS CHAPTER:
4.1 PRE-OPERATION CHECKS - - - - - - - - - - -11
4.2 FILLING WATER TO THE SYSTEM - - - - - - - -12
4.3 HYDROSTATIC SEAT AND SHELL TEST- - - - - -12

4.1 PRE-OPERATION CHECKS

Do the following checks before operating the machine:
1. Make sure that the work area is clear of non-essential personnel and equip-
ment.
2. Check that the TEST PRESSURE GAUGES show 0 psi (except for the storage
gauge, which is the maximum psi that the operator can achieve as test pres-
sure).
3. Check that all valves, including the BLOCK VALVES, are in the closed posi-
tion and the regulator is turned counter-clockwise until it stops.
4. Select test gauges appropriate for the test pressure.

WARNING
Performing a test with a gauge not rated to the test pressure will
destroy the gauge and may result in personnel injury.

5. Restrain the test console with an anti-tip device (not supplied).

WARNING
The 1900 HC is top-heavy and presents a tip-over hazard.
Failure to use an anti-tip device could result in equipment
damage or personnel injury.

P/N 85951, Rev. 1 Page 11

 Filling water to the system

6. Connect high-pressure
hoses (not supplied) with
hose restraints to the pres-
sure outlet and to the test
vessel.

WARNING
Failure to properly
restrain high-pressure
hoses and test
console could result
in equipment damage
or personnel injury.

FIGURE 4-1. TETHERED HOSE

4.2 FILLING WATER TO THE SYSTEM

Do the following to fill the system with water:
1. Check that the TEST VALVE is open.
2. Check that the DUMP VALVE is closed.
3. Open the WATER SUPPLY VALVE.
4. Open the BLOCK VALVE.
5. Fill the TEST VALVE until water overflows from the valve.
6. Seal off the TEST VALVE with a blind flange.

4.3 HYDROSTATIC SEAT AND SHELL TEST

NOTICE
At the start of every test, check that all valves are closed.
Pressure Control should be turned counter-clockwise to a stop
position to zero out any pressure.

Do the following to conduct a hydrostatic seat or shell test:

1. Open the AIR CONTROL VALVE.
2. Open the BLOCK VALVE.
3. Turn TEST PRESSURE CONTROL clockwise to increase the test pressure,
until the reading on the HYDRO TEST PRESSURE gauge reaches the target
test pressure.

Page 12 1900 HC Operating Manual

 Hydrostatic seat and shell test

4. Close the BLOCK VALVE.

5. Close the AIR CONTROL VALVE.
6. Monitor the HYDRO TEST PRESSURE gauge for any drop in pressure,
according to the end user’s test procedure.
7. Zero out the TEST PRESSURE CONTROL by turning it counter-clockwise all
the way.
8. Close the WATER SUPPLY VALVE.
9. Slowly open the DUMP VALVE to gradually release the pressure from your
test valve.
A shell test is similar to a seat test, except that the safety relief valve (that is, the
device under test) needs to be open during the test.

P/N 85951, Rev. 1 Page 13

 Hydrostatic seat and shell test

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Page 14 1900 HC Operating Manual

 5 MAINTENANCE

Table 5-1 lists maintenance intervals and their associated tasks.

TABLE 5-1. MAINTENANCE INTERVALS AND TASKS

Interval Task
Inspect the testing unit, including all hose connections, inlet supply lines, and outlet
Before each use
lines.
Check the lubricator to ensure one drip to every 30 strokes of the pump. Adjust as
During use
needed. Use the air tool oil for the lubricator.
After each use Wipe the component parts clean and dry to prevent corrosion.
Once a month Inspect mufflers for damage and plugging. Replace if any are clogged.
Clean the Y strainer.
As needed
Change the air filter (Parker #PS701P).

NOTICE
If the pump is replaced, the operator must check that the system
relief pressure is less than 10,000 psi.

P/N 85951, Rev. 1 Page 15

Page 16 1900 HC Operating Manual
 6 STORAGE AND SHIPPING
IN THIS CHAPTER:
6.1 STORAGE - - - - - - - - - - - - - - - - - -17
6.1.1 Short-term storage - - - - - - - - - - -17
6.1.2 Long-term storage- - - - - - - - - - - -17
6.2 SHIPPING - - - - - - - - - - - - - - - - - -17
6.3 DECOMMISSIONING - - - - - - - - - - - - - -18

6.1 STORAGE
Proper storage of the 1900 HC will extend its usefulness and prevent undue dam-
age.
Before storing, do the following:
1. Clean and dry the machine.
2. Remove all fluids from the system.
Store the 1900 HC in its original shipping container. Keep all packing materials for
repackaging the machine.

6.1.1 Short-term storage

Do the following for short-term storage (three months or less):
1. Remove hoses.
2. Cap the ports.
3. Spray all unpainted surfaces with LPS-2 to prevent corrosion.
4. Store the 1900 HC in its original shipping box.

6.1.2 Long-term storage

Do the following for long-term storage (longer than three months):
1. Follow the short-term storage instructions, but use LPS-3 instead of LPS-2.
2. Add a desiccant pouch to the shipping container. Replace according to
manufacturer instructions.
3. Store the shipping container in an environment out of direct sunlight with
temperature < 70ºF (21ºC) and humidity < 50%.

6.2 SHIPPING
The 1900 HC can be shipped in its original shipping container.

P/N 85951, Rev. 1 Page 17

 Decommissioning

6.3 DECOMMISSIONING
To decommission the 1900 HC prior to disposal, remove all fluids from the sys-
tem. Refer to Appendix A for component assembly information.

Page 18 1900 HC Operating Manual

APPENDIX A ASSEMBLY DRAWINGS
Drawing list
Figure A-1. 1900 HC assembly (P/N 85144) - - - - - - - - - - - - - - - 20
Figure A-2. 1900 HC assembly parts list 1–28 (P/N 85144) - - - - - - - - 21
Figure A-3. 1900 HC assembly parts list 29–54 (P/N 85144) - - - - - - - 22

P/N 85951, Rev. 1 Page 19

 23
52
25 39

40
20
3 21
35
39
28 44

50 47
17
2 16 49

13 48
24
12 11
43 27
8
4 7
41
6

22
19
18
10
53 14
45

FIGURE A-1. 1900 HC ASSEMBLY (P/N 85144)

Page 20 1900 HC Operating Manual

 PARTS LIST
ITEM QTY PART No. DESCRIPTION SCHEMATIC ID
1 1 59342 FTG ELBOW 1/4 NPTMS X 1/4 TUBE F PRESTOLOCK
NICKEL PLATED
2 1 77389 BALL VALVE 1/2 NPT FEMALE 160 PSI
3 1 77394 REGULATOR AIR 1/2 NPT 125 PSI PRV1
4 1 77399 HIGH FLOW MUFFLER 3/4 NPTM COMPACT
5 1 77421 FTG BULKHEAD 1/2 NPTF BRASS
6 1 77422 FTG TEE 1/2 NPTM X 1/2 NPTF MALE RUN TEE BRASS
7 4 77427 FTG BARB 1/2 NPTM X 1/2 HOSE 90 DEG ELBOW
8 5 77433 FTG 1/2 POHB X 1/2 F JIC SWVL
9 1 77457 FTG ELBOW 1/2 NPTM X 1/2 NPTF STREET 90 DEG
10 2 77523 WASHER 3/8 LOCK SS
11 2 77544 WASHER 1/4 FLTW SS
12 2 77602 SCREW 1/4-20 X 3/8 BHCS SS
13 1 77649 FTG BARB 1/2 NPTM X 1/2 HOSE BRASS
14 1 77784 LUBRICATOR AIR 1/2 NPTF PORTS L1
15 2 77786 FTG NIPPLE 1/2 NPTM X 1/2 NPTM BRASS HEX
16 2 77792 VALVE BALL 2 WAY 1/4 NPTF 10000 PSI V3, V4
17 1 77876 FTG BUSHING 1/2 NPTM X 3/8 NPTF BRASS
18 1 77922 FILTER AIR 1/2 NPTF PORT W/AUTOMATIC DRAIN FLT1
19 2 78672 WASHER 3/8 FLTW SS
20 1 81787 MOUNT NUT REGULATOR PANEL
21 1 81789 GAUGE PRESSURE 4 INCH DIA 1000 PSI GLYCERIN G3
FILLED 1/4 MNPT BOTTOM MOUNT CALIBRATION
CERT
22 1 81792 PUMP AIR DRIVEN 10,000 PSI WATER SERVICE P1
23 1 81794 GAUGE PRESSURE 4 IN DIA 10000 PSI 1/4" NPT G2
BOTTOM MOUNT
24 1 81796 Y-STRAINER 150 PSI 1/2 NPTF FLT2
25 1 81815 GAUGE PRESSURE 2.5 INCH DIA 160 PSI GLYCERIN G1
FILLED 1/4 MNPT C-CLAMP MOUNT CALIBRATION
CERT
26 1 81816 FTG CONNECTOR 1/4 NPTF X 1/4 TUBE PRESTOLOK
27 1 82481 MOUNT BRACKET AIR FILTER

FIGURE A-2. 1900 HC ASSEMBLY PARTS LIST 1–27 (P/N 85144)

P/N 85951, Rev. 1 Page 21

 PARTS LIST
ITEM QTY PART No. DESCRIPTION SCHEMATIC ID
28 2 82685 WASHER #10 FLTW SS
29 96 82847 HOSE LOW PRESSURE PUSH LOK 1/2 ID
30 2 83092 FTG CONNECTOR 3/8NPTM X 3/8 TUBE SUPER
DUPLEX
31 2 83094 FTG TUBE TEE UNION 3/8 TUBE SUPER DUPLEX
32 1 83101 FTG TEE 1/4 TUBE SUPER DUPLEX
33 4 83105 FTG TUBE CONNECTOR 1/4 NPTM X 3/8 TUBE SUPER
DUPLEX
34 24 83226 TUBING 1/4 OD X .049 WALL SUPER DUPLEX SAF 2507
35 1 83364 VALVE BALL 2-WAY 1/2 NPTF 1000 PSI BRASS V1
36 2 83713 FTG CONNECTOR 1/4 TUBE X 1/4 NPTM SUPER
DUPLEX
37 1 83716 FTG REDUCER 1/4 TUBE X 3/8 TUBE SUPER DUPLEX
38 1 83983 FTG ADAPTER HEX 1/2 NPTM X 1/2 NPTF BRASS
39 2 84795 FTG QUICK DISCONNECT MALE NIPPLE W/O CHECK
VALVE 15000 PSI 1/4" FNPT
40 1 84796 FTG QUICK DISCONNECT FEMALE COUPLER W/
CHECK VALVE 15000 PSI 1/4 MNPT
41 5 84954 FTG ELBOW 1/2 NPTM X JIC-8 MALE 90 DEG BRASS
42 96 85055 TUBING 3/8 OD X .049 WALL SUPER DUPLEX SAF 2507
43 1 85056 VALVE PRESSURE RELIEF AIR 90 PSI 1/2 NPTM R1
44 2 85232 FTG BULKHEAD 1/4 NPTF 15000 PSI
45 2 85271 SCREW 3/8-24 X 3/4 SHCS SS
46 12 85288 TUBING 1/4 OD X .170 ID POLYETHELYNE
47 1 85330 FTG PLUG 1/4 NPTM HEX HEAD 15 KSI
48 2 85407 FTG BULKHEAD 3/8 NPTF X 3/8 NPTF 15000 PSI SS
49 1 85411 FTG QUICK COUPLER 1/4B MALE X 3/8 NPTM AIR
INDUSTRIAL-SHAPE
50 2 85457 SCREW 10-24 X 3/8 SHCS SS
51 1 85549 LABEL SET 1900-W-10K
52 1 85557 ASSY HAND CART 1900-W-10K
53 1 85945 FTG ELBOW 1/2 NPTM X 3/8 TUBE 90 DEG SUPER
DUPLEX
54 1 85962 LABEL - DO NOT BLOCK SUMP PORT OR DRAIN LINE

FIGURE A-3. 1900 HC ASSEMBLY PARTS LIST 28–54 (P/N 85144)

Page 22 1900 HC Operating Manual

APPENDIX B SCHEMATIC

FIGURE B-1. 1900 HC SCHEMATIC (P/N 85343)

P/N 85951, Rev. 1 Page 23

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Page 24 1900 HC Operating Manual