TM-7 Truck Mounted Valve Operator
Contents
1. CM 48 Chapter 8 Parts Lists and Drawings 51 Chapter 9 Accessories and Spare Parts 75 ACCESSORIES ed 75 Chapter 10 Ordering Information 77 Ordering Replacement Paris wie ree RE sede Bead awe els hae eae 2 77 Repair Informati n usa se LA ir s 77 Warranty Information e E E he a 78 Return Goods Address oe Je oe ade e e eaters 78 2 17 00 6 0309 Wachs Chapter 1 About This Manual Chapter 1 About This Manual PURPOSE OF THIS MANUAL This manual explains how to operate and maintain the TM 7 truck mounted valve operator It includes instructions for set up operation and maintenance It also contains parts lists diagrams and service information to help you order replacement parts and perform user serviceable repairs Before operating the TM 7 you should read through this manual and become familiar with all instructions At a min imum make sure you read and understand the following chapters e Chapter 1 About This Manual e Chapter 2 Safety e Chapter 3 Introduction to the Equipment e Chapter 5 Operating Instructions e Chapter 9 Accessories If2. 1041007 ONY SININOdWOD 0 41101007 ZW1L 0332 83MOd ATEAWASSV 118 7 00 4 AAFONASNVAL 34055444 189 255 65 00 61 41 HOLMS ALIWIXOdd 189255 65 00 1 Qa VOS LINDAID 3 5 ONILNNOW 8 9 1 1 005 X GE 8 SOHS 0 0 0 06 005 06 0956 SOHS S 0 0S0 06 005 1 81 1 SOHS S 1 090706 005 X GE 9 SOHS GO 100 06 AIGWASSV JIAVD 604 00 6 HOLMS 310001 1008 0 601 41 Q31VNIWTTII 1545 3192901 HOLMS 00 601 41 9 255 318 00 0ZE Z1 AFONASNVAL 34055444 18 255 118 7 00 81 41 HOLMS ALIWIXOdd ATAWASSV 318 00 9 Le Z1 YOLOANNOD TANVd 9 255 318 00 7 YOLDANNOD TANVd Nid dvO 00 60 6 00 106 6 1 009 d4O QNVIS SO veli 31d vO LAN 8 TWAS LO 6Z ONILNNOW 3 015601 12 NOO383 M ZWL 12856 vO 9 l Zl NO2O33 M ZWL TIv8 310 72 INNOW EO VELIE TIVE 00 6 0 62 8 LAN 00 1 60 21 DIA 06 dido 318v2 OO0 Ee 62 NOO33 M ZWL 02 21060 2 60 FANSOTONZ 0 961 21 gt ZWL 02 21060 3alnsOTON3 SOFELZI 6 6 y Y
3. Wachs 600 Knightsbridge Parkway Lincolnshire IL 60069 www ehwachs com TM 7 Truck Mounted Valve Operator User s Manual LY ve E H Wachs No 17 00 Rev 6 0309 March 2009 Copyright 2009 E H Wachs All rights reserved This manual may not be reproduced in whole or in part without the written consent of E H Wachs TM 7 Truck Mounted Valve Operator No 17 00 Rev 6 0309 E H Wachs Table of Contents Table of Contents Chapter 1 About This Manual 1 Purpose Mantal Poe 9 E RE ewe OM V e SOON 1 How te Use The Ip oN OS AR ROUEN ARS 2 Symbols and Warnings ru Soe ea eee 2 Manual Updates and Revision Tracking eS 3 Chapter 2 Safety ns EE 5 Operator ae eM a Pd E EE 5 Safety SYMBOLS dann wide ues tede ae SRS 6 Protective Equipment Requirements 7 Safety Labels amp Chapter 3 Introduction to Equipment 9 TM 7 Configurations ce an 9 Equipment Deseriplion 14222222 hee ete 10 B
4. Figure 5 11 Press in the right flow control to turn the valve clockwise Try to turn the valve at the minimum pressure setting s CAUTION If the valve will not turn release the flow control and increase torque by turning pressure knob one Do not increase the torque turn clockwise while holding the flow control open Figure 5 12 To increase the torque turn the pressure knob clockwise Each turn increases the torque by approximately 250 lb ft Do not increase the pressure more than one turn at a time 7 Try to turn the valve again by pressing in the flow control If it will not turn increase the torque by one turn of the pressure knob 36 Part No 17 MAN 00 Rev 6 0309 E H Wachs Chapter 5 Operating Instructions Performing the Valve Operation 8 Once you have started the valve turning release the flow control and reduce the torque to the minimum required to keep the valve turning You may have to stop and adjust the torque several times TM 7 with Manual Controls i CAUTION It is important to operate the valve at the minimum torque required If you reach the end of travel using high torque setting you may damage the 1 Set the TM 7 up at the valve location as described valve above in Setting Up the Valve Operator 2 your TM 7 is equipped with a gas engine start the engine as described above in Starting the Engine 3 Adjust the engine throttle to oper
5. Chapter 8 Parts Lists and Drawings The following pages include parts lists and drawings for components of the TM 7 Refer to the drawings for identi fying and ordering replacement parts E H Wachs Part No 17 MAN 00 Rev 6 0309 51 MANUAL CONTROL ASSEMBLY REF NO ITEM NO DESCRIPTION DEM 07 142 00 Cord Power 12 11 004 00 Connector 17 018 00 Retaining Ring 17 004 00 Pinion Gear 17 024 00 Manifold 17 079 00 Valve Direction Control 17 080 00 Valve Torque Control 17 081 00 Switch Counter 17 082 00 Roller Actuator 17 083 00 Bracket Switch 17 084 00 Enclosure 17 085 50 Counter 17 086 00 Grip Cable 90 018 50 Plug SAE 8 ORB 90 050 05 SHCS 1 4 20 x 1 2 90 050 07 SHCS 1 4 20 x 3 4 90 058 54 Adapter 1 4 M F 45 90 059 62 Plug 1 4 NPT 90 060 30 SHCS 5 16 18 3 90 128 93 Adapter ORB JIC 3 4 MPL 90 238 56 Adapter 1 JIC 3 4 ORB 58 141 00 Standard Duty Torque Gauge 07 087 00 Heavy Duty Torque Gauge 17 305 00 Switch Assembly oo ql lt 7 MANUAL CONTROL ASSEMBLY TM7 SLIDE AND CONTROL COMPONENTS ITEM NO NUMBER DESCRIPTION QTY 1 17 006 00 SLIDE FRAME 1 2 17 136 02 ENCLOSURE MODIFIED 7 W RECON 1 ENCLOSURE COVER MODIFIED TM7 4 79 333 00 CABLE GRIP 90 DEG 1 3 17 091 00 NUT 3 8 NPT NYLON 4 6 79
6. Y IWV 65 00 900 1 SE 1D O 5 20 AJaWNN 1 ON Wall 10 15 08 v 2 gt 0 0 2 0 gt RUGGEDIZED CONTROL EQUIPED UNITS 15HP GAS ENGINE ASSEMBLY indicates part not shown in exploded view NO PART NO DESCRIPTION QUANTITY 14 136 00 9AL Battery 17 054 00 15HP Gas Engine 17 055 00 15HP Engine Muffler 17 056 00 Muffler Guard 17 057 00 Exhaust Deflector 17 058 00 Wiring Harness 17 059 00 PTO Adapter 17 060 00 Hydraulic Pump 17 061 00 Drive Coupling 17 062 00 Pump Hose 17 063 00 Tank Hose 17 064 00 Choke Cable 17 065 00 Throttle Cable 17 066 00 14 Tie Down Strap 90 078 11 Nipple 3 8 x 6 59 060 00 Terminal Cover 59 035 00 Tach Hourmeter 59 093 00 Fuse Holder 67 204 00 7 5 AMP Fuse 90 055 15 1 4 20 Wing Nut 90 057 00 1 4 Sg x 1 Key 90 059 37 1 4 20 x 3 4 CRG Bolt 90 065 06 5 16 18 Wing Nut 90 069 37 5 16 18 x 3 4 CRG Bolt 90 071 10 3 8 16 x 1 HHCS 90 071 12 3 8 16 x 1 1 4 HHCS 90 075 52 3 8 Lockwasher 90 218 95 ORB x JIC 3 4 M90 Adapter 90 238 60 ORB x JIC 1 EL 90 501 06 1 4 Male Terminal 90 501 15 3 8 Yellow Ring Terminal 90 501 32 6 Ga 1 4 Terminal 90 501 33 6 Ga 3 8 Ring Terminal 90 501 42 16 Ga Bullet M Terminal 90 501 43 16 Ga Bullet F Terminal 90 900 60 Loop Clamp 90 901 06 14 Ga B
7. 17 MAN 00 Rev 6 0309 E H Wachs Chapter 9 Accessories and Spare Parts Chapter 9 Accessories and Spare Parts In This Chapter ACCESSORIES ACCESSORIES Table 1 TM 7 Accessories Part Number Description 17 418 00 TM 7 Refurbish 17 415 00 Cover TM 7 Vinyl 17 310 00 7 Manual Override for units manufactured prior to 1 1 04 17 401 00 Hydraulic Cooler required to add Class 2 Circuit 17 402 00 15 Gas Engine Hydraulic Power Supply for standard duty drive only 17 403 00 20 HP Gas Engine Hydraulic Power Supply Heavy duty hose reel for remote operation of accessory hydraulic tools Hose reel is auto retract 17 412 00 and includes 45 ft 1 2 High pressure 2000 PSI hose with stop collar dimensions are 25 High 15 wide and 26 1 2 long High Mount Frame Rail Extension for standard 17 404 00 duty drive only Switch Kit Toggle TM7 Power Board Control 17 109 10 Replaces micro switch on TM 7 machines manu factured prior to 8 1 08 17 027 SK Kit Seal Non Recon TM7 Enclosures 07 406 04 4 Steel Valve Key E H Wachs Part No 17 00 Rev 6 0309 75 7 Truck Mounted Valve Operator Table 1 TM 7 Accessories Part Number Description 07 406 06 6 Steel Valve Key 07 406 08 8 Steel Valve Key 07 406 10 10 Steel Valve Key 07 406 12 12 Steel Valve Key
8. 90 058 58 1 4 Hex HD Nipple 90 059 62 NPT 1 4 Plug 90 061 17 5 16 18 x 1 3 4 HHCS 90 065 01 5 16 18 Hex Nut 90 065 51 5 16 Split Ring Lockwasher 90 065 52 5 16 Flat Washer 90 071 08 3 8 16 x 7 8 HHCS 90 075 52 3 8 Lockwasher 90 075 65 3 8 16 x 1 1 2 SSS 90 218 93 ORB JIC 3 4 MAL Adapter 90 218 94 M ORB x F NPT 3 4 Adapter 90 218 97 ORB JIC SWVL 3 4 Adapter 90 218 96 Bulkhead 3 4 JIC M Adapter 90 238 52 W SWVL 1 90 ST EL 90 238 57 1 NPT 1 JIC Male EL 90 238 58 1 NPT Male Female Tee 90 900 50 BL 3 8 16 x 1 3 8 Knob 90 075 05 3 8 16 Nylock nut 90 238 61 Adpt Orb nptf 90 90 098 65 Elbow Male 1 2 HP 90 098 58 Hex Nipple 1 2 HP 09 025 00 Disconnect FML Htma 09 026 00 Disconnect ML Htma 90 098 75 Bushing Red 1 2 x 1 N ATENASSV ANVL Z IN L TM 7 Wiring Diagram Manual Controller LEGEND BRN BROWN USER COUNTER ON 6 FILTER TM 7 Wiring Diagram USED DEC 2001 TO PRESENT Q E I SOLENOID VALVE REXROTH 7 WIRING DIAGRAM REXROTH SOLENOID VALVE TM 7 Truck Mounted Valve Operator THERMOSTATIC CONTROL TO SYSTEM CONTROLS 12V BATTERY LEGEND BLK BLACK TM 7 ENGINE amp OPTIONAL COOLER WIRING DIAGRAM WHT WHITE YEL YELLOW 0107DIA4 7 Truck Mounted Valve Operator 74 Part No
9. SETTING UP THE VALVE OPERATOR Follow all safety guidelines for parking and positioning the vehicle to perform a valve operation 1 Park the vehicle so that the TM 7 extension slide can reach over the valve The power head can be extended up to 2771686 mm from the TM 7 frame 2 Ifyou using TM 7 a swivel trailer release the swivel clamps and move the TM 7 to the required orientation Re tighten the swivel clamps Figure 5 1 For a swivel mounted TM 7 loosen the swivel clamps one each side to position the TM 7 In This Chapter SETTING UP THE VALVE OPERATOR PERFORMING THE VALVE OPERATION OPERATING AUXILIARY EQUIPMENT CHARGING OR JUMP STARTING THE BATTERY E H Wachs Part No 17 MAN 00 Rev 6 0309 27 7 Truck Mounted Valve Operator 3 Release the latch lever holding the extension slide Figure 5 2 Pull the locking lever to release the exten sion Slide 4 Pull the slide out to position the power head over the valve Lock the latch lever holding slide The head does not have to 5 Insert the valve key adapter through the head be perfectly positioned over attachment swivels to allow off center operation em 4 i Figure 5 3 Insert the valve key adapter through the power head 28 Part No 17 MAN 00 Rev 6 0309 E H Wachs Chapter 5 Operating Instructions Performing the Valve Ope
10. 039 00 BALL CRADLE SWIVEL 1 1 17 136 03 MOUNT CRADLE BALL TM7 W RECON 1 BRACKET W RECON ENCLOSURE 9 9 333 0 SEAL RING 3 8 NPT CABLE GRIP 4 10 17 136 05 STAND OFF 8 32 3 4 BODY LENGTH 4 11 79 301 00 CONTROL BOARD 1 12 79 309 00 CAP 4 PANEL CONNECTOR 1 13 17 324 00 CABLE ASSEMBLY PANEL CONNECTOR 1 14 17 316 00 CABLE ASSEMBLY PROXIMITY SWITCH 1 3 17 318 00 CABLE ASSEMBLY PRESSURE TRANSDUCER 1 16 17 320 00 CABLE ASSEMBLY DIRECTIONAL VALVE 1 17 17 109 00 SWITCH TOGGLE SPST ILLUMINATED 1 18 17 109 02 BOOT TOGGLE SWITCH 1 19 17 322 00 CABLE ASSEMBLY POWER 1 20 90 001 05 SHCS 6 32 x 500 2 21 20 060 15 SHCS 3125 18 x 1 500 1 22 90 050 05 SHCS 250 20 x 500 3 23 90 020 05 SHCS 8 32 x 500 2 24 17 136 08 MOUNTING SCREW CIRCUIT BOARD 4 25 17 917 00 SENSOR ASSEMBLY PROXIMITY SWITCH 1 26 17 319 00 SENSOR ASSEMBLY PRESSURE TRANSDUCER 27 17 323 00 CABLE ASSEMBLY POWER FEED 1 28 07 170 00 SOLENOID VALVE 29 11 004 00 CORD CONNECTOR 1 30 90 238 56 1 JIC 3 4 ORB ADAPTER 2 31 07 018 00 RETAINING RING 32 17 004 00 PINION GEAR 1 33 17 022 00 STANDARD DUTY HYDRAULIC MOTOR 1 17 023 00 HEAVY DUTY HYDRAULIC MOTOR 34 17 080 00 TORQUE CONTROL VALVE 1 332 17 024 00 MANIFOLD BLOCK 1 RUGGEDIZED CONTROL EQUIPPED UNITS 10 15 08 v 2 2 gt 0 l O 02 2 0 2 lt l v gt STANDARD DUTY MOTOR SHOWN 80 91 01 SLINN
11. 27 Starting the Engines ois x gon ad AW OOM CAGED RRO ER FE UU S REY 20 Performing the Valve Operation re 29 7 with Vitals Recon 29 Intelligent Reverse and Turn Valve Exercising 29 Starting the Valve vows sade an ee qe 30 E H Wachs Part No 17 MAN 00 Rev 6 0309 1 7 Truck Mounted Valve Operator Running the Wachs Controller Program 33 Operating TM 7 with Manual Override Controls 34 7 with Manual Controls vat ed Ics et 37 Operating Auxiliary Equipment sn rl 39 Charging or Jump Starting the Battery 40 Chapter 6 Routine Maintenance 43 aa C RI 43 lg 5 CCP 44 Hydraulic System Dex bd SN NM RR C Oh Qu VES c DR EA Sen a 44 Oll and Filler ssa eae an SUCCO GUN DER a loe FOUDRE 45 Chapter 7 Service eR bo Ih p n ERREUR 47 Replacing the Counter Proximity Sensor 47 Replacing the Transducer oed ur aree ee SERI eR boa EE E 48 Control Box Seal KIC as EA
12. 7 is equipped with a gas engine start the engine as described above in Starting the Engine 3 Adjust the engine throttle to operating speed For PTO driven configurations engage the PTO 4 Make sure the pressure relief knob on the hydraulic manifold is set to maximum Turn it all the way clockwise for the maximum setting 30 Part No 17 MAN 00 Rev 6 0309 E H Wachs Chapter 5 Operating Instructions Performing the Valve Operation PRESSURE RELEF VALVE T TO WHEN USING TM CONTROLLER TO MINIMUM WHEN USING MANUAL CONTROL PERATION MANUAL FOR DEALS Figure 5 4 Turn the pressure relief knob all the way clockwise for maximum pressure when operating the TM 7 using the Vitals Recon controller 5 Pressthe switch on the TM 7 control box to the ON position The power indicator on the switch will light Figure 5 5 Push the switch the control box to the ON position the Vitals Recon controller out of its storage cra dle and press the power button to turn it on The Win dows Mobile screen will come up En NOTE Make sure the controller is connected to the control box before turning on the switch E H Wachs Part No 17 MAN 00 Rev 6 0309 31 7 Truck Mounted Valve Operator n NOTE Remove the stylus from the back of the controller and use it to tap the touch screen con trols Figure 5 6 Press the power button to turn on the Vita
13. Instructions Charging Jump Starting the Battery Figure 5 18 Disconnect the cable to the control box before charging or jump starting the battery 1 Remove the battery compartment cover on the side of the TM 7 enclosure Figure 5 19 Remove the battery cover on the side of the TM 7 enclosure 2 To charge battery disconnect TM 7 cables from the battery then connect the charger cables 3 To jump start the TM 7 engine leave the TM 7 cables connected to the battery Connect the jumper cables to the battery posts and start the engine with the switch E H Wachs Part No 17 MAN 00 Rev 6 0309 41 7 Truck Mounted Valve Operator 42 Part No 17 MAN 00 Rev 6 0309 E H Wachs Chapter 6 Routine Maintenance Chapter 6 Routine Maintenance In addition to the procedures described in this chapter per form the following checks on your TM 7 periodically Check all bolts and fasteners for tightness and integrity e Check all electrical connections and components for integrity corrosion and insulation where appropriate e Inspect the extension slide and rails for wear LUBRICATION There are 4 grease fittings on the TM 7 one on each exten sion rail and two on the power head Apply grease to all 4 fittings each time you use the machine Figure 6 1 Grease the fittings on the side rails There is one fitting on each side one side shown In This Chapt
14. M90 Adapter 90 238 60 ORB JIC 1 EL 90 085 51 7 16 Lock Washer 90 075 52 3 8 Lock Washer 90 071 12 3 8 16 1 1 4 HHCS 90 501 06 1 4 Male Terminal 90 501 15 3 8 YEL Ring Terminal 90 501 45 6 Ga 7 16 Ring Terminal 90 501 33 6 Ga 3 8 Ring Terminal 90 501 42 16 Ga Bullet M Terminal 90 501 43 16 Ga Bullet F Terminal 90 900 60 Loop Clamp 90 901 06 14 Ga Black Wire 90 901 07 6 Ga Red Wire 90 901 08 6 Ga Black Wire 90 901 09 18 Ga White Wire 90 901 10 14 Ga Yellow Wire PO NN 4 RH HAS RROD AHN OO AH AH H Aa N AH AH AH SB SB SB SB NO N SH HSH SS N 22 _ 067 7 20HP GAS ENGINE ASSEMBLY 54 AUXILLIARY COOLER ASSEMBLY indicates part not shown in exploded view REF NO PART NO DESCRIPTION QUANTITY 17 051 00 Oil Cooler 17 052 00 Thermostat Switch 17 053 00 Cooler Hose 90 238 57 1 NPT 1 JIC Male EL 90 238 59 NPT JIC 1 Adapter 90 501 42 16 Ga Bullet M Terminal 90 501 43 16 Ga Bullet F Terminal 051 7 AUXILLIARY COOLER ASSEMBLY HEAD FRAME ASSEMBLY indicates part not shown in exploded view REF NO PART DESCRIPTION QUANTITY 17 001 00 Knuckle 17 002 00 Hub Gear 17 003 00 Lock Ring 17 005 00 Bearing 17 006 00 Upper Housing 17 007 00 Lower Housing 17 008 00 75 Dia Drive Ball 17 00
15. filter is accessible through the side of the TM 7 enclosure The filter will be easier to replace if you disconnect and move the hoses e Change the hydraulic oil every two years Use Mobile DTE Light or equivalent If the oil temperature ever exceeds 180 F 82 C change it immediately to pre vent damage to the hydraulic pump Figure 6 5 The hydraulic reservoir drain plug is accessible through the back of the TM 7 enclosure 46 Part No 17 MAN 00 Rev 6 0309 E H Wachs Chapter 7 Service Repair Chapter 7 Service and Repair REPLACING THE COUNTER PROXIMITY SENSOR The counter proximity sensor is accessible from beneath the power head The sensor may wear out or malfunction and need to be replaced 1 Make sure the power switch on the control box is turned OFF 2 Release the extension latch lever and pull the exten sion slide out 3 From beneath the power head remove the proximity sensor and disconnect the electrical cable sor is threaded into power head E Figure 7 1 Remove the proximity sensor and discon nect the cable In This Chapter REPLACING THE COUNTER PROXIMITY SENSOR REPLACING THE TRANSDUCER CONTROL BOX SEAL E H Wachs Part No 17 MAN 00 Rev 6 0309 47 7 Truck Mounted Valve Operator Screw the new sensor into the power head and connect the cable REPLACING THE TRANSDUCER The transducer is mounted on the hydrauli
16. greatly decrease the chances for injury ALWAYS READ PLACARDS AND LABELS Make sure all placards labels and stickers are clearly legible and in good condition You can purchase replacement labels from E H Wachs KEEP CLEAR OF MOVING PARTS Keep hands arms and fingers clear of all rotating or moving parts In This Chapter OPERATOR SAFETY SAFETY LABELS Look for this sym N bol throughout the manual Itindicates a personal injury hazard E H Wachs Part No 17 MAN 00 Rev 6 0309 7 Truck Mounted Valve Operator Always turn machine off before doing any adjustments or service e SECURE LOOSE CLOTHING AND JEWELRY Secure or remove loose fitting clothing and jewelry and securely bind long hair to prevent them from getting caught in moving parts of the machine e KEEP WORK AREA CLEAR Keep all clutter and nonessential materials out of the work area Only people directly involved with the work being performed should have access to the area Safety Symbols A This icon is displayed with any safety alert that indicates a personal injury hazard WARNING This safety alert indicates a potentially hazardous situation that if not avoided could result in death or serious injury Z CAUTION This safety alert with the personal injury hazard symbol indicates a potentially hazardous situation that if not avoided could result in minor or moderate injury Part No 17 MAN 00 Rev 6 0
17. hex nuts secure the exten sion to the TM 7 frame Lift the TM 7 into the pickup bed and position it at the desired location Install the adjustable angle brackets They require two 1 2 13 x 1 1 2 HHCS four flat washers two lock washers amp two 1 2 13 hex nuts each which are sup plied Butt the adjustable angle brackets against the bed wall lip and tighten the fasteners Install the two rear engine side J hooks and snug with two flat washers two lock washers and two 3 8 16 hex nuts Install the two forward J hooks and snug fasteners _ Tighten all four J hooks equally until unit is firmly secured to bed Using the angle bracket as a template mark inside of truck bed for mounting hole locations Drill through truck bed inside wall and bolt angle bracket to truck bed Fasteners not included IMPORTANT After the first operation of the TM 7 recheck the tightness of the J hooks Check their tightness every month Y NOTE The J hooks mount on the adjust able angle brackets They clamp to the upper wall between the inside lip and the outside wall of the pickup bed E H Wachs Part No 17 MAN 00 Rev 6 0309 25 7 Truck Mounted Valve Operator Figure 4 1 The drawing illustrates top mounted installation of the TM 7 on a pickup bed 26 Part No 17 00 Rev 6 0309 E H Wachs Chapter 5 Operating Instructions Chapter 5 Operating Instructions
18. mounting bolts do not interference electrically ground the TM 7 to the frame of the truck connect a ground strap from one bolt to the frame Install piping and hoses assembled in Step 5 Use pipe 6 joint compound on all NPT connections Use one to three hose clips to secure hose to underside of truck E H Wachs Part No 17 MAN 00 Rev 6 0309 23 7 Truck Mounted Valve Operator 2 Use minimum 14 gauge wire to connect the 7 10 fuse is recommended at the positive battery terminal CAUTION Make sure the fuel line does not contact the exhaust sys tem or any sharp objects 10 11 Connect the white wire from the TM 7 control box directly to the positive terminal of the battery Connect the black wire from the TM 7 control box directly to the negative terminal of the battery Fill the hydraulic reservoir to full mark on gauge approximately 10 gallons Use Mobil DTE light or equivalent hydraulic oil Test the system by engaging the PTO Allow the truck to idle for several minutes to purge air from the hydraulic system and check for hydraulic oil leaks Refill the hydraulic reservoir Read the Operating Instructions Chapter 5 before proceeding with opera tion Gas Engine Option 1 Set valve operator in truck bed at desired location Keep TM 7 as close as possible to side of truck body to assure maximum reach of power head when extended Lay out
19. needed to access the TM 7 disconnect electrical power and other related work will differ by installation 3 Phillips head screwdriver Medium flat head screwdriver 2mm Precision Jeweler s flathead screwdriver Ve ud 1 Wrenches for 2 4 hex nuts or suitable adjustable 3 3 NPT Tap and driver Paper and pen pencil to note wire positions and color Read through these directions before beginning Because multiple wires of the same color are used work on one fitting at a time to avoid wiring mistakes Note wire color and position at the connector BEFORE removing Some terminals are not used note these positions as OPEN to ensure correct wire placement in the connector when reassembling Disconnect 12 volt power to the TM 7 Access and remove the lid from the enclosure If moisture or standing water is found inside the enclosure make sure all components are dry before reassembly Verify that water is not entering from the directional control valve conduit If this situation is found install repair kit part number 17 416 00 to correct Evaluate the condition of the lid seal If necessary replace with new seal When installing the lid 3 8 PIPE THREADS SMALL O RING P N 71 033 01 LARGE O RING P N 17 132 02 REPLACE WITH NEW FITTING P N 17 033 00 PLASTIC SEAL RING P N 17 132 01 NOTE O RINGS ARE SHOWN REMOVED FOR CLARITY
20. you will be performing service or repairs make sure you read and understand these chapters e Chapter 1 About This Manual e Chapter 4 Assembly and Disassembly e Chapter 6 Routine Maintenance e Chapter 7 Service and Repair In This Chapter PURPOSE OF THIS MANUAL How TO USE THE MANUAL SYMBOLS AND WARNINGS MANUAL UPDATES AND REVISION TRACKING E H Wachs Part No 17 MAN 00 Rev 6 0309 7 Truck Mounted Valve Operator Throughout this manud refer to this column for warnings cautions and notices with supplementary information N WARNING A WARNING alert with the safety alert symbol indicates a potentially hazardous situa tion that could result in seri ous injury or death A CAUTION A CAUTION alert with the safety alert symbol indicates a potentially hazardous situa tion that could result in minor or moderate injury You will also want to refer to Chapter 8 Parts Lists and Drawings TO USE THE MANUAL This manual is organized to help you quickly find the infor mation you need Each chapter describes a specific topic on using or maintaining your equipment Each page is designed with two columns This large column on the inside of the page contains instructions and illustra tions Use these instructions to operate and maintain the equipment The narrower column on the outside contains additional information such as warnings special notes and definitions Refer to it for sa
21. 07 409 04 4 Aluminum Valve Key 07 409 06 6 Aluminum Valve Key 07 409 08 8 Aluminum Valve Key 07 409 10 10 Aluminum Valve Key 07 409 12 12 Aluminum Valve Key 07 412 00 Valve Key Adaptor 2 to 1 07 407 00 2 male union for joining keys with 07 408 00 Universal 2 Socket to fit standard A W W A nut 17 078 00 Adapter Drive 17 074 02 2 Low Clearance Valve Key 17 074 04 3 1 2 Low Clearance Valve Key 17 074 06 5 1 2 Low Clearance Valve Key 17 074 08 7 1 2 Low Clearance Valve Key 17 MAN 00 TM 7 Manual 76 Part No 17 MAN 00 Rev 6 0309 E H Wachs Chapter 10 Ordering Information Chapter 10 Ordering Information To place an order request service or get more detailed information on any E H Wachs products call us at one of the following numbers US 800 323 8185 International 847 537 8800 You can also visit our Web site at www ehwachs com ORDERING REPLACEMENT PARTS When ordering parts refer to the parts lists in this chapter Please provide the part description and part number for all parts you are ordering REPAIR INFORMATION Please call us for an authorization number before returning any equipment for repair or factory service We will advise you of shipping and handling When you send the equip ment please include the following information e Your name company name e Your address e Your phone number A description of the problem or the work to be done In This
22. 309 E H Wachs Chapter 2 Safety Operator Safety Protective Equipment Requirements WARNING Always wear impact resistant eye pro tection while operating or working near this equipment For additional information on eye and face protection refer to Federal OSHA regulations 29 Code of Federal Regula tions Section 1910 133 Eye and Face Protection and American National Standards Institute ANSI Z87 1 Occu pational and Educational Eye and Face Protection Z87 1 is available from the American National Standards Institute Inc 1430 Broadway New York NY 10018 CAUTION Personal hearing protection is recom mended when operating or working near this tool Hearing protectors are required in high noise areas 85 dBA or greater The operation of other tools and equipment in the area reflective surfaces process noises and resonant struc tures can increase the noise level in the area For additional information on hearing protection refer to Federal OSHA regulations 29 Code of Federal Regulations Section 1910 95 Occupational Noise Exposure and ANSI 512 6 Hearing Protectors E H Wachs Part No 17 MAN 00 Rev 6 0309 7 Truck Mounted Valve Operator SAFETY LABELS The following safety labels are on TM 7 units mounted on swivel trailers or vehicles Figure 2 1 The rotation clamps on the swivel rail must be tightened securely before operating the TM 7 Figure 2 2 Keep hands clea
23. 7 degree swivel e We recommend the use of 1 heavy wall pipe and 1 1 4 standard wall pipe for all connections through bed of truck Pipe should extend under truck bed far enough to allow straight hose connections e A swivel connection is necessary at one end of each hose 1 Install a power takeoff on the truck transmission See manufacturer s instructions included with power take NOTE off Be certain that the rotation of the power takeoff shaft matches the rotation of the TM 7 hydraulic pump as indicated by arrow on pump It is recom mended that the PTO be installed on the right passen ger side of transmission unless specified otherwise Purchase and install a hand throttle if the truck is not equipped with one 2 Set the TM 7 in the truck bed at the desired location Keep it as close as possible to the side of the truck body for maximum extension of the power head 3 Layoutand drill eight 8 9 16 mounting holes in the truck bed for securing the TM 7 to the truck frame Layout and cut two access holes in bed of truck 1 3 8 access hole for 3 4 high pressure line and a 2 Y NOTE access hole for 1 low pressure return line Cut where clearance is available Extra piping from access holes to connecting points may be needed Do not cut access holes beneath connecting points of the machine frame because 5 Boltthe TM 7 to the truck bed using 1 2 bolts of rotating head slide path through mounting holes If
24. 9 00 Micro Switch 17 010 00 Frame Weldmount 17 011 00 Rail 17 012 00 Slide Bearing 17 013 00 Clamp Locking Lever 07 006 01 Upper Thrust Washer 58 046 00 Proximity Switch 90 050 05 1 4 20 x 1 2 SHCS 90 056 03 1 4 x 3 8 Dowel Pin 90 060 22 5 16 18 x 2 1 4 SHCS 90 065 01 5 16 18 Hex Nut 90 070 05 3 8 16 x 1 2 SHCS 90 070 15 3 8 16 x 1 1 2 SHCS 90 500 05 1 4 28 Straight Grease Fitting 90 500 07 1 4 28 x 90 Grease Fitting 90 901 20 22 Ga 2 Condensor Wire PON BR WH AH NN AH N AH TM 7 HEAD FRAME ASSEMBLY RAIL EXTENSION ASSEMBLY REF NO PART NO DESCRIPTION QUANTITY 17 037 00 Slide Weldmount 17 038 00 Adjustable Bracket 58 023 00 J Bolt 90 075 01 3 8 16 Hex Nut 90 075 53 3 8 Flat Washer 90 091 15 1 2 13 x 1 1 2 HHCS 90 091 40 1 2 13 x 4 HHCS 90 095 01 1 2 13 Hex Nut 90 095 52 1 2 Flat Washer 90 095 58 1 2 Lock Washer 90 075 52 3 8 Lock Washer 1 2 4 4 4 4 4 8 16 8 4 MIEGWASSV 4 IVY ZNL TANK ASSEMBLY REF NO PART DESCRIPTION QUANTITY 17 042 00 Tank Assembly 17 044 00 Label 17 045 00 Manifold 17 046 00 Relief Valve 17 047 00 Auxilliary Valve 17 043 00 Pressure Gauge 17 014 00 Grommet Strip 17 048 00 Pressure Hose 17 049 00 Supply Hose 17 050 00 Return Hose 17 029 00 Filter Assembly 90 075 17 3 8 16 x 1 3 4 Coupling 90 058 04 1 4 Galvanized LP Coupling
25. Chapter E H Wachs Part No 17 MAN 00 Rev 6 0309 77 7 Truck Mounted Valve Operator Before we perform any repair we will estimate the work and inform you of the cost and the time to complete it WARRANTY INFORMATION Enclosed with the manual is a warranty card Please fill out the registration card and return to E H Wachs Retain the owner s registration record and warranty card for your information RETURN GOODS ADDRESS Return equipment for repair to the following address E H Wachs 600 Knightsbridge Parkway Lincolnshire Illinois 60069 USA 78 Part No 17 MAN 00 Rev 6 0309 E H Wachs E H Wachs 600 Knightsbridge Parkway Lincolnshire IL 60069 847 537 8800 www ehwachs com
26. Mounted Valve Operator drive system microprocessor control for torque and direc tion of rotation electronic revolution counter an integral auxiliary hydraulic circuit 8 long valve key with 2 univer sal socket operating manual and installation instructions TM 7 Heavy Duty Mechanical Controls PN 17 000 03 Wachs Model TM 7 Truck Mounted Valve operator com plete with heavy duty 2500 ft 15 torque hydraulic drive system manual control for torque and direction of rotation electronic revolution counter an integral auxiliary hydraulic circuit 8 long valve key with 2 universal socket operating manual and installation instructions TM 7 Heavy Duty Microprocessor Control PN 17 000 04 Wachs Model TM 7 Truck Mounted Valve operator com plete with heavy duty 2500 ft 15 torque hydraulic drive system microprocessor control for torque and direction of rotation electronic revolution counter an integral auxiliary hydraulic circuit 8 long valve key with 2 universal socket operating manual and installation instructions EQUIPMENT DESCRIPTION Figure 3 land Figure 3 2 illustrate the major components of the TM 7 valve operator Figure 3 4 shows the control panel features The following sections describe the available con figurations 10 Part No 17 MAN 00 Rev 6 0309 E H Wachs Chapter 3 Introduction to the Equipment Equipment Description Hydraulic oil reservoir Control panel with Vitals R
27. O RINGS MUST BE INSTALLED ON FITTINGS PRIOR TO INSTALLATION SMALL O RING TOP HOLE P N 71 033 01 LARGE O RING BOTTOM RH 17 132 02 Rev 1 0908 E H Wachs Utility Products Division seal locate the joint in the middle of a straight section of the groove Lightly press the seal into the groove without stretching or bunching Work away from the joint in both directions finishing on the opposite side of the lid At this point the seal should not need to be bunched or stretched to fit If required remove the seal and re insert Remove the connectors from the circuit board Pull ONLY on the connector body not the wires Do NOT remove any wires from the connectors at this time Only remove the wires of the fitting being sealed and re connect as each fitting is completed Special Instructions The replacement fitting part number 17 033 00 is provided as replacement for the fitting installed in the threaded hole as indicated in the figure on page 1 The threads of the old fitting may be damaged and the fitting should be discarded Before removing the old fitting note whether the body hex contacts the enclosure For proper sealing the hex must be within 1 turn of the enclosure wall If more than one thread is exposed then chasing of the threads is required Use a 3 8 NPT pipe tap to enlarge the thread to obtain the correct offset Chasing of the threads will produce metal chips that must be removed These chips wil
28. See the detailed instructions for valve operator control for using Vitals Mobile in the Vitals Help File provided on the Vitals software disk E H Wachs Part No 17 MAN 00 Rev 6 0309 15 7 Truck Mounted Valve Operator Torque Displays current operating torque Touch to change torque limit Highest Displays maxi mum torque during current activity Count Displays valve rota tions during current activity START STOP Touch to start or stop the valve exer ciser Displays STOP if the exerciser is operating Back Touch to return to Vitals Mobile program Reset Touch to start a new activity Vitals Mobile Limit Displays current torque limit Touch to change torque limit Direction Displays current turn ing direction Touch to set turning direction Mode Displays current operat ing mode Exercise or Manual Touch to change mode Jog LH Touch and hold to jog left hand counter clockwise Jog RH Touch and hold to jog right hand clockwise Settings Touch to change valve operating settings Waiting to connect Displays current operating status reads Connected to TM 7 when startup is complete Figure 3 6 The illustration describes the features of the Wachs Controller program Connecting the Controller The Vitals Recon controller is connected to the TM 7 with a specialized cable Serial connector to Vitals Recon controller Powe
29. and drill eight 8 9 16 mounting holes in truck bed for securing unit to the truck frame Bolt the TM 7 to the truck bed using 1 2 bolts through mounting holes cut in Step 1 If mounting bolts do not ground operator to frame of truck con nect ground strap from one bolt to frame The gas tank should be mounted to the bed of truck Using the universal anchors supplied drill a 3 4 hole in two locations approximately 14 apart Install the anchors and secure Place the tank between the anchors Attach the spring cord through the tank handle and to the anchors Attach the quick disconnect fuel line and fill 24 Part No 17 MAN 00 Rev 6 0309 E H Wachs Chapter 4 Assembly Disassembly and Storage Installation on Customer Equipment Top Mounted Installation Gas Engine Only Have the frame extension angle brackets and installation hardware ready before you begin installation These items are ordered and shipped separately from the TM 7 unit See the illustration on the next page 1 11 12 Measure the width of truck bed Slide the frame extension into the TM 7 main frame from the rear The frame extension has been drilled for multiple mounting locations Align the mounting holes that allow the overall length of the frame and extension be equal to or slightly lon ger than the outside maximum width of your truck bed walls Using the supplied four 1 2 13 x 4 HHCS 8 flat washers and four 1 2 13
30. ase Tac WMG as ta wD eS EEE 12 PTO ren De EE Din hrsg eee 13 Gas Engine Option S sur RES NAMES ee Te SEAS u A X EDS 13 Control Options ieee ae ea aed 13 Vitals Recon Computer Control ea on 13 Manual Control e 13 TM 7 Controller eo fatu tus ete iesu ua vie qued ee 15 Connecting the Controller erre 14 ne eas hod ee Ne 16 Specifications and Dimensions 18 Chapter 4 Assembly Disassembly and 5 21 Preparing Tor Use gen dee Agee Ra 21 5301826 se a ahem ee MO 22 Installation on Customer Equipment 22 Bed Mount Installation nen eet ote a eR tb ee 22 PTO Powered pion eo McLeod Mero ctore a 22 Gas Engine esee uy ee en ur ar ux ev EEE 24 Top Mounted Installation Gas Engine Only 25 Chapter 5 Operating 5 27 Setting Up the Valve Operatori os desde A er OS es
31. ase unit Table 2 TM 7 Performance Specifications Configuration Standard Duty Drive Heavy Duty Drive PTO 1500 Ib ft at 2000 psi 2500 Ib ft at 2000 psi 6 68 rpm at 2 20 gpm 4 62 rpm at 2 30 gpm 27 rpm at 8 gpm 25 rpm at 13 gpm Gas engine 15 HP 20 HP 1500 Ib ft at 2000 psi 2500 Ib ft at 2000 psi 4 27 rpm at 600 3600 23 rpm at 13 gpm engine rpm 4 hour fuel endurance 8 hour fuel endurance at 300 Ib ft and 2800 at 450 Ib ft and 2600 rpm rpm With cooler 8 gpm at 2000 psi at 12 gpm at 2000 psi at 120 120 18 No 17 MAN 00 Rev 6 0309 E H Wachs Chapter 3 Introduction to the Equipment Equipment Description Dimensions FITS 48 67 BED WIOTH WITH HCH MOUNT EXTENSION RAL Figure 3 10 The drawing illustrates the TM 7 oper ating dimensions E H Wachs Part No 17 MAN 00 Rev 6 0309 19 7 Truck Mounted Valve Operator 20 Part No 17 MAN 00 Rev 6 0309 E H Wachs Chapter 4 Assembly Disassembly and Storage Chapter 4 Assembly Disassembly and Storage This chapter includes instructions for unpacking the TM 7 for first time use preparing the TM 7 for storage and installing the TM 7 on a customer supplied vehicle PREPARING FOR USE Follow these guidelines to put the TM 7 in service 1 Remove all wrapping and packaging from the unit If installing the TM 7 on your own vehicle install it ac
32. ating speed For PTO driven configurations engage the PTO Reset the counter to zero Always use counter to deter mine the number of rotations the valve has turned Make sure the pressure relief knob on the hydraulic manifold is set to minimum Turn it all the way coun NOTE ter clockwise for the minimum setting It is impossible to know before operating a valve the amount of torque that the WIEN USING TM CONTROLLER valve stem can withstand N MANUAL FOR DETARS before breaking Size age condition tuberculation and period of time since last oper ation all affect this Therefore recommended procedure for operating a valve is to start with the torque control at the N 1 lowest setting Figure 5 13 Turn the pressure relief knob all the way counter clockwise to start at minimum pressure when operating the TM 7 using the manual controls 6 Engage the directional control lever If the valve does not turn stop and reverse the direction 7 Ifthe valve doesn t turn in either direction return the valve handle to the neutral position E H Wachs Part No 17 MAN 00 Rev 6 0309 37 7 Truck Mounted Valve Operator is CAUTION Do not increase the torque while holding the directional control lever open i CAUTION It is important to operate the valve at the minimum torque required If you reach the end of travel using high torque setting you may damage the valve Increase the torque setting
33. by turning the pressure relief knob 1 2 turn clockwise Figure 5 14 To increase the torque turn the pressure knob clockwise Each turn increases the torque by approximately 250 lb ft Do not increase the pressure more than 1 2 turn at a time 9 Try to turn the valve again by engaging the directional control lever If the valve will not turn in either direc tion increase the torque again by 1 2 turn of the pres sure knob 10 Once you have started the valve turning release the directional control lever and reduce the torque to the minimum required to keep the valve turning You may have to stop and adjust the torque several times 11 If the power head stops rotating before the valve 15 seated there may be corrosion or dirt on the valve stem and slides Reverse the machine 3 to 5 turns to clear any debris then continue operating 12 When you have finished exercising the valve log the valve location the normal gate position right or left hand thread and the number of turns to open or close the valve 38 Part No 17 MAN 00 Rev 6 0309 E H Wachs Chapter 5 Operating Instructions Operating Auxiliary Equipment OPERATING AUXILIARY EQUIPMENT You can use the TM 7 s hydraulic system as a power unit to operate other hydraulic tools If you will be operating Class II tools you should have the optional hydraulic cooler installed 1 Connect the hydraulic hoses to the auxiliary circuit ports on the front of th
34. c manifold The transducer may wear out or malfunction and need to be replaced 1 Make sure the system is turned off and is not under pressure 2 Remove transducer from manifold The trans ducer is threaded into its port connector 7 Em Figure 7 2 Remove the transducer from the hydraulic manifold and disconnect the cable 37 Disconnect the cable to transducer 4 Thread new transducer into manifold and nect the cable CONTROL Box SEAL KIT If you will be using the TM 7 where the control box is repeatedly exposed to the elements or water spray you should install the seal kit part number 17 027 SK The fol lowing pages describe the procedure 48 Part No 17 MAN 00 Rev 6 0309 E H Wachs 7 Power Board Installation Guide Enclosure Seal Kit Seal Kit Part Number 17 027 SK This seal kit helps protect against water entry into the TM 7 Power Board enclosure It should be installed when extended exposure to the elements i e outdoor storage is expected repeated exposure to water spray or anytime moisture or standing water is found inside the enclosure High pressure water should never be directed at the enclosure whether sealed or not This seal kit only provides protection from exposure to weather and low pressure water spray Expected Time Requirement Less than 1 hour Tools Required The tools listed are for work on the enclosure only tools
35. cording to the directions later in this chapter 3 the hydraulic reservoir using Mobile DTE or equivalent hydraulic oil The reservoir holds approxi mately 10 gallons 4 Lubricate the unit according to the instructions in Chapter 6 5 Checkthe engine oil level Units with gas engine 6 Checkthe engine coolant level Units with gas engine 7 the engine fuel tank Use a standard automotive gasoline Units with gas engine 8 Connect the battery to the cables The TM 7 is pro vided with a maintenance free battery which does not require you to fill the battery or perform other service In This Chapter PREPARING FOR USE STORAGE INSTALLATION ON CUSTOMER EQUIPMENT E H Wachs Part No 17 MAN 00 Rev 6 0309 21 7 Truck Mounted Valve Operator By NOTE If you are storing the machine in cold weather you may want to remove the battery and store it indoors Ay NOTE Do not operate the pumpuntil you have filled the system with hydraulic oil STORAGE Prepare the TM 7 for storage by following this procedure 1 Lubricate the unit according to the instructions in Chapter 6 2 Drain the fuel tank and close the fuel shut off valve Units with gas engine 3 Hf storing in sub freezing weather make sure the engine coolant has the appropriate antifreeze mix Units with gas engine 4 Disconnect the cables from the battery Units with gas engine 5 Disconnect the Vital
36. e TM 7 Auxiliary circuit ports return tank pressure Figure 5 15 Connect the hydraulic hoses to the front connectors on the TM 7 2 Pullthe port selector knob on the front panel out ENGINE POWER Figure 5 16 Pull out the port selector knob to oper ate the auxiliary circuit E H Wachs Part No 17 MAN 00 Rev 6 0309 39 7 Truck Mounted Valve Operator There is no flow control vided for the auxiliary circuit other than setting the engine speed You will have to pro vide external flow control if your tool requires it s CAUTION Charging or jump starting the battery with the control box powered on will damage the TM 7 s electronic compo nents 3 Connectthe other ends of the hoses to the tool you are operating 4 Start the engine and set the throttle to operating speed If using a PTO drive configuration engage the PTO 5 When you are finished using the auxiliary circuit shut down the TM 7 Press the port selector knob back in ENGINE POWER Figure 5 17 Push the port selector knob back in when you are finished using the auxiliary circuit CHARGING OR JUMP STARTING THE BATTERY CAUTION Make sure the power switch on the control box is OFF before jump starting It is recommended that you disconnect the control box before you connect charging or jumper cables to the battery 40 Part No 17 MAN 00 Rev 6 0309 E H Wachs Chapter 5 Operating
37. e valve needs to be turned touch the Direction button until either LH left hand or RH right hand is displayed If you don t know the valve direction leave the Direction set to The valve exercising program will attempt to deter mine the freely turning direc tion E H Wachs Part No 17 MAN 00 Rev 6 0309 33 7 Truck Mounted Valve Operator Press the Start button The button will turn red and will display Stop Press the button again if you need to stop the valve operation The valve operator head will turn the valve until the torque limit is reached When the torque limit is reached the head will stop and the controller will increment the limit up by 50 Ib ft The head will reverse and turn until it reaches the new limit Once the valve operator finds the free direction of rotation it will turn the valve all the way to the end of travel It will stop when the torque limit is reached If you do not want the valve operator to exceed a cer tain torque for example if you know the valve may be damaged by a high torque touch the Mode button to change the mode to MAN manual You will then have to set the direction and manually reverse the direction and increase the torque limit When the valve operation is complete you can touch the Back button to return to the Vitals Mobile program if you are logging data If you are not logging data you can touch the Reset button to clea
38. econ and fill cap auxiliary ports controller Manual over Hydraulic Extension ride controls motor slide Power head Figure 3 1 The photo illustrates major components of the TM 7 valve operator engine not shown Engine Engine Side hydraulic ports Hydraulic gas tank 7 pressure return reservoir cap Hydraulic fluid filter Figure 3 2 The photo shows the 7 configured with a gas engine Shown with TM 7 hoses discon nected from side hydraulic ports E H Wachs Part No 17 MAN 00 Rev 6 0309 11 7 Truck Mounted Valve Operator Front hydraulic ports Port selector knob return tank pressure pull for front ports push for side ports T Engine hours gt Hydraulic Engine Hydraulic oil gauge pressure gauge keyswitch level temp gauge Figure 3 3 The photo shows the panel controls Throttle Choke Electrical port to valve operator Figure 3 4 The photo shows the front panel engine controls Base Machine The following items are included with all configurations Valve turning power head on extension slide 10 gallon hydraulic reservoir Manual or computerized torque control Power head position locking lever e Auxiliary hydraulic circuit for operating other tools with switchover control 12 Part No 17 MAN 00 Rev 6 0309 E H Wachs Chapter 3 Introduction to the Equipment Equipment Description e Integrated microswitch for automated po
39. er LUBRICATION ENGINE HYDRAULIC SYSTEM E H Wachs Part No 17 MAN 00 Rev 6 0309 43 7 Truck Mounted Valve Operator Figure 6 2 Grease the 2 fittings on the power head ENGINE Check the oil and coolant levels in the engine each time you operate the TM 7 Refer to the manual supplied with the engine for mainte nance schedules and procedures HYDRAULIC SYSTEM Perform the following checks each time you use the TM 7 e Check the oil level in the hydraulic oil gauge Add oil if necessary using Mobile DTE Light or equivalent Part No 17 MAN 00 Rev 6 0309 E H Wachs Chapter 6 Routine Maintenance Hydraulic System I lt 0 A gt E Figure 6 3 Check the oil level in the hydraulic oil gauge The gauge also indicates temperature While the TM 7 is operating check the hydraulic oil temperature to make sure it does not exceed 180 F 82 C Temperatures above 180 F will break down the oil leading to hydraulic pump damage If the oil temperature exceeds 180 F change the hydraulic oil You should also consider installing a Wachs cooling unit e f your TM 7 has a cooler installed make sure it is func tioning properly Oil and Filter e Change the hydraulic oil filter every year You can order the filter from E H Wachs E H Wachs Part No 17 MAN 00 Rev 6 0309 45 7 Truck Mounted Valve Operator Figure 6 4 The hydraulic oil
40. fety notes and other information SYMBOLS AND WARNINGS The following symbols are used throughout this manual to indicate special notes and warnings They appear in the out side column of the page next to the section they refer to Make sure you understand what each symbol means and follow all instructions for cautions and warnings This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Part No 17 MAN 00 Rev 6 0309 E H Wachs Chapter 1 About This Manual Manual Updates and Revision Tracking This is the equipment damage alert symbol It is used to alert you to poten tial equipment damage situations Obey all messages that follow this sym bol to avoid damaging the equipment or workpiece on which it is operating NOTE This symbol indicates a user note Notes provide additional information to supple ment the instructions or tips for easier operation MANUAL UPDATES AND REVISION TRACKING Occasionally we will update manuals with improved opera tion or maintenance procedures or with corrections if nec essary When a manual is revised we will update the revision history on the title page You may have factory service or upgrades performed on the equipment If this service changes any technical data or operation and maintenance procedures we will include a revised manual when
41. g the 2mm flat screwdriver turn the clamping screws in the connector body counter clockwise to release the wire end Remove the cable from the enclosure Install Seal Each fitting has a small groove to accept an o ring seal This groove is located on the flat face of the body hex opposite the grip nut Inspect this groove and the mating surface on the enclosure for anything that might affect the ability to obtain a seal Select and install the appropriate seal as indicated in the figure on page 1 Avoid twisting or excessive stretching of the seal during installation The seal ring p n 17 132 01 fits loosely on the fitting Install fitting and reconnect wires to connector Install fitting in enclosure with lock nut where required tighten by rotating body hex clockwise sufficiently to compress seal Referring to noted locations insert wire ends in connector Tighten by turning the clamping screws clockwise Verify a good connection by pulling lightly on the wire Tighten Grip Nut The grip nut contains a rubber seal that is compressed by tightening the grip nut The grip nut must be tightened to ensure adequate sealing of the enclosure Position the cable so a different section of the jacket is compressed by the grip nut Reconnect Power and Replace Lid Reconnect connectors to the cicuit board Verify operation of the machine after completing task E H Wachs Utility Products Division Chapter 8 Parts Lists and Drawings
42. l damage the circuit board if not removed If a lock nut is used at this location either the new or original fitting may be used but an o ring must be installed Removal of the fitting located in the bottom of the enclosure requires removal of the circuit board for access to the lock nut It is recommended that this fitting be sealed before replacing the 17 033 00 fitting Leave the circuit board removed until any thread cutting is completed to prevent metal chips from collecting on the circuit board In some installations removal of the 17 033 00 fitting may ease removal of the circuit board If required loosen the grip nut to prevent twisting of the cable then remove the fitting by turning the body hex counter clockwise 2 Rev 1 0908 FOR EACH FITTING Loosen the grip nut of the fitting This is the outer rounded hex on each fitting Loosening this will prevent twisting of the cable during removal of the fitting To keep internal rubber sealing rings in place the grip nut should not be removed from the fitting body Remove the fitting from the enclosure Using the proper size wrench remove the fitting from the enclosure by turning the body hex counter clockwise On fittings with a lock nut restraint of the lock nut is required Remove the fitting from the enclosure Remove wires from connector Only for the cable passing through the removed fitting carefully note the color and position of the wires in the connector Usin
43. lack Wire 90 901 07 6 Ga Red Wire 90 901 08 6 Ga Black Wire 90 901 09 18 Ga Whire Wire 90 901 10 14 Ga Yellow Wire N O ROO 1 2 3 4 5 6 7 8 9 10 0 02 0 Qa Sn O1 90 AITENASSV ANISNA SVD Z WL 20HP GAS ENGINE ASSEMBLY indicates part not shown in exploded view REF NO PART DESCRIPTION QUANTITY 14 136 00 9AL Battery 59 033 01 Kohler CH20S 59 034 00 Kohler CH20 Muffler 59 035 00 Tach Hourmeter 59 071 00 Muffler Guard 59 072 00 Exhaust Deflector 17 068 00 Cable Clamp 17 069 00 Clamp Screw 17 058 00 Wiring Harness 17 071 00 PTO Adapter 17 072 00 Hydraulic Pump 17 073 00 Drive Coupling 17 062 00 Pump Hose 17 063 00 Tank Hose 17 064 00 Choke Cable 17 065 00 Throttle Cable 17 066 00 Tie Down 14 Strap 17 067 00 Tie Down 19 Strap 17 070 00 Tie Down Anchor 59 036 00 Fuel Tank 59 060 00 Terminal Cover 59 093 00 Fuse Holder 67 204 00 7 5 AMP Fuse 59 078 00 1 4 Fuel Hose 59 079 00 1 2 Hose Clamp 90 057 10 1 4 Sq x 1 Key 90 065 06 5 16 18 Wing Nut 90 069 37 CRG 5 16 18 x 3 4 Bolt 90 071 15 3 8 16 x 1 1 2 HHCS 90 075 06 3 8 16 Flange Nut 90 078 11 3 8 x 6 LP Nipple 90 078 16 3 8 HP Coupling 90 081 17 7 16 14 x 1 3 4 HHCS 90 218 95 ORB x JIC 3 4
44. ls Recon controller 7 On the controller touch screen press the Start menu button and then press Vitals Mobile to start the pro gram The Vitals Mobile startup screen appears Exit 2008 Wachs Company Figure 5 7 From the Vitals Mobile startup screen you can start a new activity list saved activities or review and change program Settings 8 To start a new valve exercising activity touch the New Activity button 32 Part No 17 MAN 00 Rev 6 0309 E H Wachs Chapter 5 Operating Instructions Performing the Valve Operation 10 You will be prompted to select an existing valve or enter a new valve Refer to the Vitals Help File on the Vitals disk for detailed instructions on using the Vitals Mobile software Once you have selected or entered the required valve information refer to the next section to use the valve exerciser controller program Running the Wachs Controller Program This section briefly describes the operating features of the Wachs Controller program Refer to the Vitals Help File on the Vitals disk for detailed instructions on using the Vitals Mobile software Vitals Mobile Torque Figure 5 8 Touch the buttons on the controller pro gram screen to change settings and operate the valve exerciser Set the torque limit by touching the Limit button and then touching the up or down arrow The arrows change the torque limit in increments of 50 If you know the direction th
45. n Clockwise lever left head rotates clockwise Counter clockwise lever right head rotates counter clockwise Torque Control Adjustment Increase torque by turning the adjustment knob in clock wise Decrease torque by turning the adjustment knob out coun terclockwise e Torque Gauge The torque gauge indicates torque output in Ib ft at the power head e Revolution Counter The revolution counter counts in hundredths of a turn A reading of 100 on the counter equals 1 complete revolution of a valve When changing valve rotation direction the counter will automatically reverse the count To zero the counter press the reset button on the counter face 14 Part No 17 MAN 00 Rev 6 0309 E H Wachs Chapter 3 Introduction to the Equipment Equipment Description TM 7 CONTROLLER The TM 7 is operated using the Vitals Recon controller The controller is a rugged handheld computer running the Win dows Mobile operating system It features a touchscreen interface for data entry and machine control Figure 3 5 The Vitals Recon controller is used to operate the TM 7 and other E H Wachs valve opera tors The controller stores valve exercising data for valve logging and analysis using the Vitals Desktop software program The controller runs the Vitals Mobile software for managing valve activity data and operating the TM 7 Figure 3 6 En NOTE shows the interface of the Wachs Controller program used
46. n damage the starter motor E H Wachs Part No 17 MAN 00 Rev 6 0309 29 7 Truck Mounted Valve Operator s CAUTION Use the maximum setting only when operating the TM 7 with the Vitals Recon con troller For manual operation see Operating the TM 7 with Manual Override Controls later in this chapter Ib ft of torque It reverses direction again trying to turn the valve with 50 Ib ft If unsuccessful it will reverse again and increase torque to 100 Ib ft The operator will continue this back and forth procedure increasing torque in 50 Ib ft increments up to the torque limit until it finds the valve s free turning direction At this point the Direction button will change to RH or LH The con troller will lower the torque limit to the minimum required to keep the valve turning When the valve operator meets resistance and reaches the torque limit it stops and reverses a few rotations then tries to rotate forward again If it can t turn the controller dis plays Insufficient Torque Check the Count button to see if you have reached the valve s expected end of travel If you think the valve should turn further increase the torque limit and tap the START button again See if the valve turns any further You may have to increase the torque limit additional steps Starting the Valve Activity 1 TM 7 up at the valve location as described above in Setting Up the Valve Operator 2 your TM
47. r connector to Connector Vitals Recon controller to TM di Figure 3 7 The photo shows the controller cable 16 Part No 17 MAN 00 Rev 6 0309 E H Wachs Chapter 3 Introduction to the Equipment Equipment Description Power connector Serial connector USB connector for data transfer Figure 3 8 The Vitals Recon controller connections are shown CAUTION MOT LJ rence Figure 3 9 To connect the controller cable to the TM 7 unscrew the connector cap and then screw on the cable connector E H Wachs Part No 17 00 Rev 6 0309 17 7 Truck Mounted Valve Operator SPECIFICATIONS AND DIMENSIONS Table 1 TM 7 Physical Specifications Feature Specification Head extension 27 686 mm Misalignment capability 15 Hydraulic reservoir 10 gallons 37 8 1 Drive system Single hydraulic motor Controls Computerized or manual computerized systems have manual override capability Auxiliary circuit Standard Class II cooler option available Hydraulic oil filtration 10 micron canister Door clearance Width 19 483 mm Height 13 330 mm Frame 3 76 mm square tube module design Mounting methods Wachs trailer mount customer vehicle mount to bed or across bed side panels Finish Powder coated white Weight 370 Ib 170 kg b
48. r of the swivel rail when positioning the TM 7 Part No 17 MAN 00 Rev 6 0309 E H Wachs Chapter 3 Introduction to the Equipment Chapter 3 Introduction to the Equipment The E H Wachs TM 7 truck mounted valve operator is a permanently mounted heavy duty hydraulic valve turner designed to operate 6 through 96 valves It is designed to make valve turning easy for all utilities and assures maxi mum valve protection The TM 7 allows computer controlled or manual exercis ing of valve Computer control is provided with the Wachs Vitals Recon controller which can store valve activity data and transfer it to the Vitals Desktop program on your PC for analysis TM 7 CONFIGURATIONS TM 7 Standard Duty Mechanical Controls PN 17 000 01 Wachs Model TM 7 Truck Mounted Valve operator com plete with standard duty 1500 Ib ft torque hydraulic drive system manual control for torque and direction of rotation electronic revolution counter an integral auxiliary hydrau lic circuit 8 long valve key with 2 universal socket oper ating manual and installation instructions TM 7 Standard Duty Microprocessor Control PN 17 000 02 Wachs Model TM 7 Truck Mounted Valve operator com plete with standard duty 1500 ft Ib torque hydraulic In This Chapter TM 7 CONFIGURATIONS EQUIPMENT DESCRIPTION TM 7 CONTROLLER SPECIFICATIONS AND DIMENSIONS E H Wachs Part No 17 MAN 00 Rev 6 0309 7 Truck
49. r the screen to start another valve opera tion Operating the TM 7 with Manual Override Controls If the Vitals Recon controller or the TM 7 electronics fail you can still operate valves using the manual override con trols Turn off the switch on the control box before operat ing manually 1 Set the valve operator up as described at the beginning of this chapter 2 Startthe engine and set the throttle to operating speed For PTO driven configurations engage the PTO 3 sure the pressure relief knob on the hydraulic manifold is set to minimum Turn it all the way coun ter clockwise for the minimum setting 34 Part No 17 MAN 00 Rev 6 0309 E H Wachs Chapter 5 Operating Instructions Performing the Valve Operation PRESSURE SET TO MAJUMUM WHEN USING TM CONTROLLER T 70 MINIMUM WHEN USING MANUAL CONTROL REFER TO OPERATION MANUAL FOR 5 Figure 5 9 Turn the pressure relief knob all the way counter clockwise to start at minimum pressure when operating the TM 7 using the manual controls 4 To turn the valve operator in the left hand counter clockwise direction press in on the left flow control Figure 5 10 Press in the left flow control to turn the valve counter clockwise 5 To turn the valve operator in the right hand clock wise direction press in on the right flow control E H Wachs Part No 17 MAN 00 Rev 6 0309 35 7 Truck Mounted Valve Operator
50. ration Install the socket on the bottom of the key and insert the pin 7 Lowerthe valve key down into the valve vault and position the socket end of the key on the valve nut Starting the Engine Use the following procedure for a TM 7 equipped with the gas engine 1 Check that there is enough fuel in the gas tank for the job you are performing Open the fuel valve on the engine fuel line Pull the throttle halfway out If the engine is cold pull the choke out AU N Turn the keyswitch on the front panel to START When the engine starts release the keyswitch back to the ON position 6 Allow the engine to run for a minute or so to warm up Push the choke back in PERFORMING THE VALVE OPERATION TM 7 with Vitals Recon Controller When you perform the valve operation you can operate the TM 7 only in controller mode without logging valve data or you can use the Vitals data logging program to record valve operating information Intelligent Reverse and Turn Valve Exercising When you run the valve operator using the Vitals Recon controller in EXER mode it uses the Intelligent Reverse and Turn exercising protocol to determine direction of valve rotation The valve operator starts with a break loose procedure It turns in one direction stopping if it meets resistance of 50 s CAUTION Use short starting cycles with the keyswitch Prolonged cranking more than 15 sec onds ca
51. s Recon controller and store it in its case Screw the cap on the connector on the TM 7 control box 6 Anoptional weatherproof cover is available for the TM 7 If you have the cover put it over the unit and secure it with the provided straps The cover is highly recommended for long term outdoor storage INSTALLATION ON CUSTOMER EQUIPMENT Bed Mount Installation Follow the instructions below for either a PTO driven TM 7 or for a unit with its own gasoline engine PTO Powered Option The most satisfactory installation for the TM 7 pump is direct flange mounted onto the PTO which eliminates uni versal joints and drive shafts from the PTO to the pump The pump must be capable of producing 10 gpm at 2000 PSI running at 1200 RPM Most truck body and equipment installers are familiar with installations of the type described in this section This includes PTO pump hose lines and throttle controls 22 Part No 17 MAN 00 Rev 6 0309 E H Wachs Chapter 4 Assembly Disassembly and Storage Installation on Customer Equipment If a door is cut in side of truck body for access to the TM 7 make it at least 19 wide and 13 high to allow the power head to slide in and out Hose and Fitting Guidelines The high pressure hose should be 1 two wire braid capable of at least 2000 PSI working pressure e The return hose should be 1 1 4 rayon braid capable of at least 300 PSI working pressure Hose ends should be SAE 3
52. we return the equipment to you s CAUTION A CAUTION alert with the damage alert symbol indi cates a situation that will result in damage to the equipment is IMPORTANT An IMPORTANT alert with the damage alert symbol indi cates a situation that may result in damage to the equipment En NOTE A NOTE provides supple mentary information or oper ating tips Current versions of E H Wachs manuals are also available in PDF format You can request an electronic copy of this manual by email ing customer service at sales wachsco com E H Wachs Part No 17 MAN 00 Rev 6 0309 7 Truck Mounted Valve Operator 4 Part No 17 MAN 00 Rev 6 0309 E H Wachs Chapter 2 Safety Chapter 2 Safety The E H Wachs takes great pride in designing and manu facturing safe high quality products We make user safety a top priority in the design of all our products Read this chapter carefully before operating the TM 7 It contains important safety instructions and recommenda tions OPERATOR SAFETY Follow these guidelines for safe operation of the equip ment READ THE OPERATING MANUAL Make sure you understand all setup and operating instructions before you begin INSPECT MACHINE AND ACCESSORIES Before starting the machine look for loose bolts or nuts leaking lubricant rusted components and any other physical conditions that may affect operation Properly maintaining the machine can
53. wer on off e Panel indicator for hydraulic oil level and temperature e System pressure gauge PTO Drive Option The TM 7 is provided with components described in the Base Machine section above Customer must supply power take off and throttle control Gas Engine Option The gas engine option includes all components described in the Base Machine section above plus the following 15 HP standard or 20 HP heavy duty gasoline engine e Panel controls for engine Off Run Start throttle speed and choke Operating and maintenance manuals are provided with the engine Before using the TM 7 read these manuals to famil iarize yourself with the engine s features and operation Control Options The standard control option for the TM 7 is the Vitals Recon controller a hand held computer for machine control and valve activity data storage Manual machine control is available as an option Vitals Recon Computer Control For units equipped with the Vitals Recon computer control ler all machine controls and settings are performed using the Vitals Mobile program on the controller The next sec tion describes the control features of Vitals Mobile Manual Control Manually controlled units offer the following controls Directional Control Valve E H Wachs Part No 17 MAN 00 Rev 6 0309 13 7 Truck Mounted Valve Operator Off center position oil bypasses motor machine head does not tur
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