Manual - EH Wachs
Contents
1. RSEN EC ERES 11 Optional Equipment zoo Us ML ed d p ne HOw PRESUL qs 11 O 15 Trailer Assembly sa 2 2 M S EM 15 Engine eps igh ee ica sad en 18 Hydraulic Power Umit 5 S PES 19 ERV 750 Extended Reach Valve Exerciser 21 Storage Dr 22 KETTE ett PUR Re wae ADR 22 Storage Basket rain ni aaa 23 Optional Equipment ran SER MEG EROR E Sw M e Rope PA Sd 24 Hydraulic Hose Reel 44 23 2244 b RE E NA 24 Erud ri AME m 25 Chapter 4 Operating Instructions 27 Trailer Features 2 ya 2422 22 2a aree onte ave eene quts dried ca ol seta eee waren 27 Tome the pa Ce CC 27 Starting and Running the Engine 4 els exe E SU EE SED EY ER 28 Using the Hydraulic System 1 4 Sus PEE he 29 Valve Exerciser aan br hie 31 Light Bar Oper at ons at ea ye ete OE 34 Wachs Part No 79 MAN 20 Rev 1 0911 Trailer System Chapter 5 Routine 37 Hydraulc Sysie2. Wachs 600 Knightsbridge Parkway Lincolnshire IL 60069 www ehwachs com ERV Trailer System User s Manual E H Wachs Part No 79 MAN 20 Rev 1 0911 September 2011 Revision History Original November 2009 Revision 1 September 2011 Copyright 2011 Wachs All rights reserved This manual may not be reproduced in whole or in part without the written consent of E H Wachs Trailer System This page intentionally left blank Part No 79 MAN 20 Rev 1 0911 E H Wachs Table of Contents Table of Contents Chapter 1 About This Manual 1 Purpose Mantal sesers E ten Ge ED 1 Howto Use The sus eee ede qas LIO d 1 Symbols and Warnings aa oro Ee ee RR EG e ae 2 Manual Updates and Revision Tracking 2 2 1 2 a ee 3 Component Manuals 51 2 pris i ku RA FK REX EUR E DER RET Gg 3 Chapter 2 Safety aussen 5 Operator Safety sa ese o UR E M dp ee od Ud UR IR E db A iA 5 Salety Symbols AO ate ERO LEES den rer EN I EE 6 Protective Equipment Requirements 7 Safety Labels eel eats esi ku eee 7 Chapter 3 Introduction to the Equipment 11 Standard Equipri epibe 3 os ox ue Geet
3. A description of the problem or the work to be done An estimate of the work to be performed and the associated cost will be provided prior to commencement of service or repairs WARRANTY INFORMATION Enclosed with the manual is a warranty card Please com plete the registration card and return it to E H Wachs Retain the owner s registration record and warranty card for your information RETURN GOODS ADDRESS Use the following address to return equipment for repair E H Wachs 600 Knightsbridge Parkway Lincolnshire Illinois 60069 USA Part No 79 MAN 20 Rev 1 0911 E H Wachs Chapter 6 Parts List and Ordering Information Parts Lists Drawings PARTS LISTS AND DRAWINGS The following pages illustrate components of the ERV Trailer System Refer to the figures to identify parts for ordering Table 1 ERV Trailer System Parts List Part No Description 59 080 00 Tire Wheel Assembly 59 097 00 Reflector Amber 77 213 20 Hub Cover 79 020 01 00 Weldment Tongue Straight 77 520 01 03 Tail Light RH 77 520 01 04 Tail Light LH 79 020 03 00 Weldment Fender RH 79 020 04 00 Weldment Fender LH 79 020 05 00 Hose Assembly ERV Return 79 020 06 00 Hose Assembly ERV Pressure 79 120 04 00 Basket 79 120 05 01 Hose Assembly Return 79 120 05 02 Hose Assembly Pressure 79 120 05 03 Machine Return 79 220 01 00 Hose Assembly Reel Return 79
4. Figure 4 11 The light bar controller is inside a box on the right side of the trailer 1 To access the controller turn the lock counterclock wise and pull the top of the front cover forward Figure 4 12 Turn the lock counterclockwise to open the controller box 34 Part No 79 MAN 20 Rev 1 0911 E H Wachs Chapter 4 Operating Instructions Light Bar Operation 2 Usethe POWER switch to turn on the light bar Press the switch at the top to select high intensity light mode press at the bottom to select low intensity light mode 3 Set the function knob to select the light bar display LEFT Left arrow RIGHT Right arrow SPLIT Alternating right and left arrows FLASH All lights alternate on and off in unison LEDs mimics lightbar display OCC ON INDICATOR Figure 4 13 Turn the function knob on the lightbar controller to select the display 4 Close the front cover after the controller 1s set To turn off the light bar toggle the POWER switch to the cen ter position E H Wachs Part No 79 MAN 20 Rev 1 0911 35 ERV Trailer System This page intentionally left blank 36 Part No 79 MAN 20 Rev 1 0911 E H Wachs Chapter 5 Maintenance Chapter 5 Routine Maintenance HYDRAULIC SYSTEM q Check the hydraulic oil level prior to using the hydraulic power unit Add oil if necessary Keep the oil level at the full mark on the gauge Hydraulic oil level and temperature indica
5. 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 79 MAN 20 Rev 1 0911 E H Wachs Chapter 2 Safety Safety Labels 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 Personal hearing protection is mended when operating or working near this tool Hearing protectors are required in high noise areas i e 85 dBA or greater Noise level can be increased by the opera tion of other tools and equipment in the area reflective sur faces process noises and resonant structures For additional information on hearing protection refer to Federal OSHA regulations 29 Code of Federal Regulations Section 1910 95 Occupational Noise Exposure and ANSI S12 6 Hearing Protectors SAFETY LABELS The following safety labels are included on the ERV Trailer System Some labels are associated with optional equip men
6. the knob labeled PULL REEL PUSH ERV 2 Touse the optional hose reel push in the knob labeled PULL AUX PUSH ERV REEL pull out the knob labeled PULL REEL PUSH ERV Selector knob pull for hose Port selector knob push for reel push for ERV 750 ERV 750 and hose reel Figure 4 3 To use the ERV 750 or optional hose reel first push in the port selector knob then also either pull or push the selector knob labeled PULL REEL PUSH ERV as appropriate E H Wachs Part No 79 MAN 20 Rev 1 0911 29 Trailer System To use the auxiliary ports connect the hoses to the hydraulic ports and pull out the port selector knob labeled PUSH ERV REEL PULL AUX Hydraulic Port selector knob ports turn tank pressure pull for auxiliary Figure 4 4 To use the auxiliary ports connect hoses to the hydraulic ports and pull out the port selector knob 30 Part No 79 MAN 20 Rev 1 0911 E H Wachs Chapter 4 Operating Instructions Valve Exerciser VALVE EXERCISER The engine must be running in order to operate the valve exerciser This section describes how to set up the ERV 750 for use Detailed instructions on operating the ERV 750 are in the ERV 750 Extended Reach Valve Exerciser User 5 Manual which is provided with the ERV 750 The ERV 750 is plumbed directly to the hydraulic tank The ERV 750 does not require any additional hoses or connec tors 1 To enable hydraulic flow through the valve e
7. 220 02 00 Hose Assembly Reel Pressure 68 177 21 Volt Meter 68 179 02 Switch Work Light Table 2 Optional Equipment List Part No Description 79 220 00 Hose Reel Kit 79 420 00 Light Bar Kit 11 408 00 Telescoping Key 11 409 00 Telescoping Key Short E H Wachs Part No 79 MAN 20 Rev 1 0911 45 Trailer System AT8W3SSV 133HM 3AlL 00 260 6S 00 080 65 5 g ak 7 EZ 4 li 00 L0 020 62 IHOIVALS INDNOL INIWTIIM MOIS EUN o 02 612 72 33AOO 00 0020 6 AJANI INGWGHM 00 90 020 64 3385344 ATAWASSV 35 00 10 02 6 1333 A18W3SSV ISOH L AT8W3SSV avd 20 50 001 6 24055344 ATHW3SSV ISOH 10 90 020 67 NANY ATaW3SSV ISOH 00 111 21 ISOH TVNG 2 1 00 00 002 6 3anss3ald 1444 18 355 ISOH 00 70 02 L 64 131579 1001 1 00 0 020 6 INIWCTM 00 50 020 6 NANA Ada 18 355 ISOH 00 0 00 6 20 IHOMLOdS Figure 6 1 Parts Drawing E H Wachs Part No 79 MAN 20 Rev 1 0911 46 Chapter 6 Parts List and
8. N 20 Rev 1 0911 E H Wachs Chapter 4 Operating Instructions Chapter 4 Operating Instructions This chapter provides instructions for towing the ERV Trailer System and starting the engine to power the trailer s equipment Specific sections of the chapter provide instructions for operating the following standard and optional components of the ERV Trailer System e gas engine hydraulic system valve exerciser light bar TRAILER FEATURES Towing the Trailer Before towing the trailer Remove the key from the engine keyswitch e Ensure that the hitch is properly attached and the safety chains attached to the vehicle trailer tail lights brake lights and turn signals are functional jack stand on the trailer hitch is raised tires are properly inflated all hoses and attachments are securely stored on the trailer the ERV 750 is secured to the trailer bed with the latches remove the controller from its cradle and put it in its storage case Store the case in the vehicle In This Chapter TRAILER FEATURES STARTING AND RUNNING THE ENGINE USING THE HYDRAULIC SYSTEM VALVE EXERCISER LiGHT BAR OPERATION E H Wachs Part No 79 MAN 20 Rev 1 0911 27 ERV Trailer System En NOTE The engine MUST be running to operate the valve exerciser or auxiliary hydraulic equip ment s CAUTION Use short starting cycles with the keyswitch Prolonged cranking more than 15 se
9. ND 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 greatly decrease the chance 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 In This Chapter OPERATOR SAFETY SAFETY LABELS Look for this sym AN bol throughout the manual It indicates a personal injury hazard E H Wachs Part No 79 MAN 20 Rev 1 0911 ERV Trailer System KEEP CLEAR OF MOVING PARTS Keep hands arms and fingers clear of all rotating or moving parts Always turn machine off before doing any adjustments or service 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 per sonnel 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 Z WARNING This safety alert indicates a potentially hazardous situation that if not avoided could result in death or serious injury N CAUTION This
10. Ordering Information Parts Lists Drawings ud 77785 87387 4 RELAY p n 932 332209150 TERMINAL Be 30 30 86 87 85 87a CONNECTOR OREN p n 930 534485007 LIGHT BAR FEED YLW ENG L REGULATOR 12VDC DC TAP IGN SW TERM A TO ERV 930 12015792 TO SYSTEM GROUND em RED 7 BLK 7 BLK 2 Lu OIL COOLER 930 12015798 gt THERMOSTATIC CONTROL C B n CONNECTOR 930 12015024 TO SENSOR BLK 79 120 00 WD ERV TRAILER SYSTEM Mrz sr BUILD DATE 6 6 11 WIRING DIAGRAM VIN 1E9PT1014BC297537 Figure 6 2 Wiring Diagram E H Wachs Part No 79 MAN 20 Rev 1 0911 47 ERV Trailer System This page intentionally left blank 48 Part No 79 MAN 20 Rev 1 0911 E H Wachs
11. POWER UNIT ERV 750 EXTENDED REACH VALVE EXERCISER STORAGE OPTIONAL EQUIPMENT E H Wachs Part No 79 MAN 20 Rev 1 0911 Trailer System Figure 3 1 The right side of the ERV Trailer System 12 Part No 79 MAN 20 Rev 1 0911 E H Wachs Chapter 3 Operating Instructions Standard Equipment E H Wachs Part No 79 MAN 20 Rev 1 0911 13 ERV Trailer System ERV 750 exerciser Storage box Hydraulic hose reel Hydraulic tank EE eR NN Figure 3 3 The rear view of the ERV Trailer System 14 Part No 79 MAN 20 Rev 1 0911 E H Wachs Chapter 3 Operating Instructions Trailer TRAILER The ERV Trailer System is a single axle trailer featuring all steel construction with a box beam frame and steel deck Specifications Curb Weight 1200 lbs Tongue Weight 200 Ibs Length 10 ft Width 5 5 ft Height 6 ft Trailer Assembly To reduce shipping volume when shipped via common car rier the trailer package is typically delivered without the tongue installed Unpack and inspect all components for damage If any damage is found immediately report the damage to the shipping company and your sales representa tive Do not use shipping material and or shipping supports to support any part of the trailer during tongue installation or trailer service Use ONLY purpose built jack stands and jacks Use the following procedure to install th
12. al and become familiar with all instructions Also read the manual for the gas engine that powers the hydraulic power unit this manual describes how to service and main tain the engine How TO USE THE MANUAL This manual is organized so that information can be found quickly and easily Each chapter describes a specific topic on using or maintaining your equipment Each page is designed with two columns The 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 defini In This Chapter PURPOSE OF THIS MANUAL How TO USE THE MANUAL SYMBOLS AND WARNINGS MANUAL UPDATES AND REVISION TRACKING COMPONENT MANUALS Throughout this manual refer to this column for warnings cautions and notices with supplementary information E H Wachs Part No 79 MAN 20 Rev 1 0911 ERV Trailer System 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 AN CAUTION A CAUTION alert with the safety alert symbol indicates a potentially hazardous situa tion that could result in minor or moderate injury CAUTION A CAUTION alert with the damage alert symbol indi cates a situation that will result in damage to the equipment t
13. c onds can damage the starter motor STARTING AND RUNNING THE ENGINE 1 Ensure that there is sufficient fuel in the gas tank 2 Pullthe throttle halfway out 3 If the engine is cold pull the choke out Figure 4 1 To start the engine pull the throttle half way out If the engine is cold also pull the choke out 4 the keyswitch on the front panel to START When the engine starts release the keyswitch back to the RUN position ENGINE POWER PULL AUX Figure 4 2 Turn the key to START then release to RUN when the engine starts 5 Allow the engine to run at least a minute to warm up Push the choke back in 28 Part No 79 MAN 20 Rev 1 0911 E H Wachs Chapter 4 Operating Instructions Using the Hydraulic System UsiNG THE HYDRAULIC SYSTEM Only one hydraulic circuit operates at a time The ERV 750 is connected directly to the power unit no hose connections are required When equipped with the optional hose reel auxiliary tools may be connected to either the hose reel hose or the auxiliary ports located on the front panel To avoid damage to the equipment ensure that the hydraulic fluid is clean and that there is no air in the hydraulic system the engine has oil and is running properly Follow the engine maintenance schedule in the engine manual all hydraulic connections are secure 1 To use the ERV 750 push in the knob labeled PULL AUX PUSH ERV REEL push in
14. e sys tem includes an auxiliary power port relief valve and an oil cooler with an electric fan Hydraulic supply 8 gpm at 2000 psi Engine performance 16 horsepower 4 hour fuel endurance Hydraulic reservoir 10 gallons 37 8 Filtration 10 micron canister filter Finish Powder coated white The hydraulic power unit is shown in the following figures Figure 3 9 components of the hydraulic power unit Figure 3 10 front panel controls and Figure 3 11 engine controls Engine Hydraulic reservoir cap Engine gas tank Hydraulic fluid filter Figure 3 9 Components of the hydraulic power unit E H Wachs Part No 79 MAN 20 Rev 1 0911 19 ERV Trailer System Selector knob pull Engine Hydraulic Hydraulic for hose reel push hours pressure oil level for ERV 750 gauge temp gauge Engine keyswitch Hydraulic Port selector knob pull for ports leturn tank pressure ports push for ERV 750 and hose reel Figure 3 10 Front panel of the hydraulic power unit Electrical port to ERV 750 Figure 3 11 Front panel engine controls 20 Part No 79 MAN 20 Rev 1 0911 E H Wachs Chapter 3 Operating Instructions ERV 750 Extended Reach Valve Exerciser ERV 750 EXTENDED REACH VALVE EXERCISER The ERV 750 is an extended reach hydraulic valve exer ciser mounted on a pivoting telescoping arm It can reach valves up to 13 ft from the curb side of the trailer and pro vid
15. e tongue and connect the wiring harness for the trailer lights 1 Position tongue such that the jack is on the left side of the tongue with the safety chain label facing up 2 Carefully insert the tongue into the receiver wires first Take care not to damage the wire and connectors N WARNING Use ONLY purpose built jacks and jack stands when assembling or servicing the trailer AN CAUTION The tongue assembly weighs 65 Ibs and should be installed using two people E H Wachs Part No 79 MAN 20 Rev 1 0911 ERV Trailer System 3 Lineup the holes in the tongue with the holes in the receiver Insert bolts and tighten supplied nuts to 80 Ib ft Figure 3 4 Tighten nuts to secure tongue to trailer 4 Route tongue wires through frame hole as shown in Fig 3 5 Fold ground wire white back and insert the four wire connector through the hole Use care to avoid breaking the locking tab on the connector Once the large connector is through pull the wire harness through until the ground wire and connector clears the frame Figure 3 5 Route tongue connectors through frame 16 Part No 79 MAN 20 Rev 1 0911 E H Wachs Chapter 3 Operating Instructions Trailer Place the ground wire on the stud welded to the frame Install and tighten the lock nut Figure 3 6 Attach ground wire to stud 6 Connect the four wire connectors A click should be heard indicating the connection is co
16. es up to 750 Ib ft of torque 1131 1 Figure 3 12 The ERV 750 valve exerciser extends on a pivoting telescoping arm The ERV 750 includes a ruggedized handheld controller data logger for operating the machine and collecting valve exercising data The controller is available with optional GPS capability either standard or submeter resolution for automated valve locating and logging The controller is available separately 79 410 00 if a spare or replacement is needed The ERV 750 is supplied with a separate manual for operat ing instructions and parts service information s CAUTION Do not move the ERV 750 from the stow position for operation or service without the trailer connected to a tow vehicle E H Wachs Part No 79 MAN 20 Rev 1 0911 21 Trailer System STORAGE Key Storage Additional storage for valve keys is located beneath the trailer decking on both the left and right sides of the trailer Access the storage compartments by pulling the knob up and opening the cover toward the inside of the trailer mag Figure 3 14 Access key storage by pulling the knob up and opening the cover toward the inside of the trailer 22 Part 79 20 Rev 1 0911 E H Wachs Chapter 3 Operating Instructions Storage Storage Basket A storage basket for holding valve keys and other tools is mounted at the rear of the trailer frame 1 Figure 3 15 The storage bas
17. ions Refer to the narrow column for safety notes and other information SYMBOLS AND WARNINGS The following symbols are used throughout this manual to indicate special notes and warnings They appear next to the section that they refer to in the outside column of the page It is important to understand what each symbol means and follow all instructions for cautions and warnings This is the safety alert symbol and is used to notify the user of potential per sonal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death This is the equipment damage alert symbol and is used to notify the user of potential equipment damage situa tions Obey all messages that follow this symbol to avoid damaging the equipment or work piece on which it is operating Part No 79 MAN 20 Rev 1 0911 E H Wachs Chapter 1 About This Manual Manual Updates Revision Tracking 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 manuals will be updated with improved oper ation or maintenance procedures or with corrections if nec essary Revised manuals will include an updated revision history on the title page If factory service or upgrades are performed on the equip ment and that service changes any technical data or opera tion and main
18. ket is mounted at the rear of the trailer E H Wachs Part No 79 MAN 20 Rev 1 0911 23 Trailer System En NOTE The hydraulic hoses are 45 feet long Thehose reelhasa ratchet lock pull the desired length of hose then stop when the ratchet clicks OPTIONAL EQUIPMENT The following equipment items are options available with the ERV Trailer System The trailer can be equipped with any combination of these options Hydraulic Hose Reel The hose reel supplies 45 ft of 1 2 hydraulic hose rated 2000 psi for operating auxiliary equipment It is plumbed directly to the hydraulic tank and includes quick disconnect fittings to connect to auxiliary tools Hydraulic hose reel Figure 3 16 The hydraulic hose reel is mounted at the rear of the trailer 24 Part No 79 MAN 20 Rev 1 0911 E H Wachs Chapter 3 Operating Instructions Optional Equipment Light Bar An overhead light bar with work lights and a programmed arrow board is available The light bar includes an elec tronic control panel in a watertight enclosure m E 5 gt EN sd n 1 Figure 3 17 The optional direction control and work light a Figure 3 18 The light bar controller is housed in a water tight enclosure above the hydraulic unit E H Wachs Part No 79 MAN 20 Rev 1 0911 25 ERV Trailer System This page intentionally left blank 26 Part No 79 MA
19. m 442 22 oe tacere es Uta Nes EF que nb ed ui eden Fre edat 37 ane oe 38 Replacing Switches and Fuses 1 45242 TERRI MEE sete as 39 Replacing Light Bar and Work Light Bulbs 41 Light Bar Flashers ia 24 soe nhs ta RES 41 Work Lights ovs oo Gases XV IAE 42 Chapter 6 Parts List and Ordering 43 Ordering Replacement Parts 122 NX MESS init 43 Repair Information 224x243 ee wee ra 44 Warranty Information 44 Return Goods Address alt ss zu ce Le EX LEAL e lou 44 Paris Lists and Drawinss css wr ex Eb NE SERERE 45 ii Part No 79 MAN 20 Rev 1 0911 E H Wachs Chapter 1 About This Manual Chapter 1 About This Manual PURPOSE OF THIS MANUAL This manual explains how to operate and maintain the ERV Trailer System and hydraulic power unit It includes instructions for set up operation and maintenance in addi tion to parts lists diagrams and service information to be used when ordering replacement parts and performing user serviceable repairs Before operating the ERV Trailer System read through this manu
20. mplete The green weather seal should be fully encased in the mat ing connector leaving only a thin ring visible Figure 3 7 Connect four wire connectors 7 Verify proper operation of the trailer lights 8 Safely remove jack stands and lower the trailer E H Wachs Part No 79 MAN 20 Rev 1 0911 17 ERV Trailer System ENGINE The trailer s equipment is powered by a 16 HP Briggs amp Stratton Vanguard V Twin gasoline engine This overhead cam horizontal crankshaft engine is equipped with an elec tric starter The engine operates the ERV 750 and hydraulic pump The engine operates on 87 octane unleaded gasoline or on 10 ethanol 90 gasoline gasohol blend Use a winter blend fuel when running the engine in cold weather The engine is provided with an Owner Manual a Refer to the manual for operating guidelines maintenance and ser vice of the engine Figure 3 8 The gasoline engine for the ERV Trailer System 18 Part No 79 MAN 20 Rev 1 0911 E H Wachs Chapter 3 Operating Instructions Hydraulic Power Unit HYDRAULIC POWER UNIT The hydraulic power unit is designed to supply hydraulic power to the ERV 750 valve exerciser other Wachs utility tools except the Trav L Cutter or any HTMA Class II hydraulic tool It supplies 8 gallons per minute gpm flow at a pressure of 2000 psi The 10 gallon hydraulic oil reser voir has a sight gauge for oil level and temperature Th
21. n age Figure 2 4 This label is on the hydraulic hose reel When retracting the hose walk it back to the reel Do not let the hose snap back into the reel Contact the manufacturer Cox Reels for replacement labels Figure 2 5 This caution label is on the hydraulic hose reel Do not disassemble the spring from the reel WARNING DO NOT MOVE THE ERV 750 FROM THE STOW POSITION FOR OPERATION OR SERVICE WITHOUT THE TRAILER CONNECTED TO A TOW VEHICLE Figure 2 6 This warning label is on the ERV head Before moving the ERV from the stow position ensure that the trailer is connected to a tow vehicle Part no 79 020 00 01 E H Wachs Part No 79 MAN 20 Rev 1 0911 ERV Trailer System This page intentionally left blank 10 Part No 79 MAN 20 Rev 1 0911 E H Wachs Chapter 3 Operating Instructions Chapter 3 Introduction to the Equipment STANDARD EQUIPMENT The following standard equipment is provided with the basic 79 000 20 gas engine configuration of the ERV Trailer System trailer e ERV 750 valve exerciser gas engine e storage basket hydraulic system Optional Equipment The following optional equipment is available for the ERV Trailer System hose reel with 45 of hydraulic hose direction control and worklight bar These components are described in the following sections In This Chapter STANDARD EQUIPMENT TRAILER ENGINE HYDRAULIC
22. over switches are on the bottom cover the fuse block is on the top E H Wachs Part No 79 MAN 20 Rev 1 0911 39 ERV Trailer System Fuse block Voltage Work light switch Figure 5 4 Voltage meter and work light switch com ponents and fuse block 4 To remove a switch or gauge first disconnect the wires Use a screwdriver if necessary to loosen the junction screws 5 Toreplace a fuse identify the blown fuse in the fuse block Pull out the blown fuse and press in a new fuse Ensure that the new fuse is the correct amperage rat ing 40 Part No 79 MAN 20 Rev 1 0911 E H Wachs Chapter 5 Maintenance Replacing Light Bar Work Light Bulbs REPLACING LiGHT BAR AND WORK LIGHT BULBS The light bar uses eight individual bulbs that are easy to replace Light Bar Flashers 1 Using a Phillips screwdriver remove the screws hold ing the cover on the burned out bulb Pull the cover off On 27 Y 44 alal ant ARK vb Figure 5 5 Remove the two screws and pull the cover off the burned out bulb 2 Twist the bulb in the socket and pull it out Figure 5 6 Remove the light bulb from the socket 3 Insert a new bulb and twist it into the socket 4 Replace the cover Do not overtighten the screws The light bar uses ECCO model R3000BH 35 W halo gen bulbs available from most industrial lighting suppli ers E H Wachs Par
23. t Ensure that all labels are in good condition and legi ble Replace any damaged or missing labels To order replacements refer to the part numbers in this section and see the ordering instructions in Chapter 6 E H Wachs Part No 79 MAN 20 Rev 1 0911 ERV Trailer System LIII NO STEP 7 7 7 7 7 7 7 Figure 2 1 This warning label is on the top of both trailer fenders Do not step on the trailer fender to reach any part of the equipment Part no 59 084 00 A WARNING ALWAYS use safety chains Chains hold trailer if connection fails You must 1 CROSS chains underneath coupler 2 ALLOW slack for trailer to turn 3 ATTACH chain hooks securely to tow enicie trame Figure 2 2 The safety chain warning label is on the tongue of the trailer Part no 77 106 20 Tire wheel or lug nut failure can cause loss of control Before towing you must CHECK 1 Tire pressure and tread 2 Tires and wheels for damage 3 Lug nuts for tightness For new and remounted wheels re tighten lug nuts at the first 10 25 and 50 miles of driving 2002 NATM Figure 2 3 This warning label is on the back of both trailer fenders Prior to each use of the trailer check tire condition and lug nut tightness Part no 77 160 15 Part No 79 MAN 20 Rev 1 0911 E H Wachs Chapter 2 Safety Safety Labels Hose or cable n walked back to USt pe prevent injury a
24. t No 79 MAN 20 Rev 1 0911 41 ERV Trailer System Work Lights 1 Remove the cover by pulling back the rubber seal around the lamp housing 2 Pull the bulb out of the rubber seal Figure 5 7 Pull the cover and bulb out of the rubber seal around the lamp housing 3 Remove the wire leads from the bulb 4 Connect the leads to the new bulb and press it back into the rubber seal 42 Part No 79 MAN 20 Rev 1 0911 E H Wachs Chapter 6 Parts List and Ordering Information Chapter 6 Parts List and Ordering Information To place an order request service or get more detailed information on any E H Wachs product please contact us at one of the following numbers 5 800 323 8185 International 847 537 8800 Or visit our Web site at www ehwachs com ORDERING REPLACEMENT PARTS When ordering parts please provide the part description and part number for all parts to be ordered In This Chapter ORDERING REPLACEMENT PARTS REPAIR INFORMATION WARRANTY INFORMATION RETURN GOODS ADDRESS PARTS LISTS AND DRAWINGS E H Wachs Part No 79 MAN 20 Rev 1 0911 43 ERV Trailer System REPAIR INFORMATION Please call for an authorization number before returning any equipment for repair or factory service We will advise you of shipping and handling Include the following information when returning equipment e Your name company name e Your address e Your phone number
25. tenance procedures on the equipment a revised manual will be returned with the equipment COMPONENT MANUALS The following manufacturers manuals are supplied for components of the ERV Trailer System Engine Owner s Manual for gas engine Dexter Hubs Drums Bearings manual IMPORTANT An IMPORTANT alert with the damage alert symbol indi cates a situation that may result in damage to the equipment 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 ehwachs com E H Wachs Part No 79 MAN 20 Rev 1 0911 ERV Trailer System This page intentionally left blank 4 Part No 79 MAN 20 Rev 1 0911 E H Wachs Chapter 2 Safety Chapter 2 Safety E H Wachs takes great pride in designing and manufactur ing 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 ERV Trailer System It contains important safety instructions and recommendations Also refer to safety information in the gas engine manual OPERATOR SAFETY Follow these guidelines for safe operation of the equip ment READ THE OPERATING MANLAL Make sure you understand all setup and operating instructions before you begin INSPECT MACHINE A
26. tor Figure 5 1 Use the sight gauge to check oil level and temperature 2 Change the hydraulic oil filter once per year In This Chapter HYDRAULIC SYSTEM ENGINE REPLACING SWITCHES AND FUSES REPLACING LIGHT BAR AND WoRK LIGHT BULBS E H Wachs Part No 79 MAN 20 Rev 1 0911 37 ERV Trailer System 3 Change the hydraulic oil Mobil DTE Light or equiv alent every two years 4 Check the oil temperature as the pump is operating If the temperature exceeds 180 F the oil will break down and continued operation will damage the pump Replace the oil if it exceeds 180 F and check to make sure that the cooler is working ENGINE Check the engine oil level prior to using the ERV Trailer System and add oil if necessary Engine oil dipstick Figure 5 2 Use the dipstick to check engine oil level Change the oil every 100 hours of operation Change the oil filter every 200 hours of operation Refer to the manufac turer s manual supplied with the engine for maintenance schedules and instructions 38 Part No 79 MAN 20 Rev 1 0911 E H Wachs Chapter 5 Maintenance Replacing Switches Fuses REPLACING SWITCHES AND FUSES Open the cover for the voltage and work light controls to replace damaged switches and fuses 1 Tum off power at the engine keyswitch 2 Usea flathead screwdriver to open the cover Figure 5 3 Insert a screwdriver to open the cover Open the c
27. xerciser ports push in the knob labeled PULL AUX PUSH ERV REEL and push in the knob labeled PULL REEL PUSH ERV Selector knob Port selector knob PUSH for ERV 750 PUSH for ERV 750 Figure 4 5 Push in both selector knobs to enable hydraulic flow to the ERV 750 CAUTION Do not move the ERV 750 from the stow position for operation or service without the trailer connected to a tow vehicle E H Wachs Part No 79 MAN 20 Rev 1 0911 3l Trailer System When not in use the ERV arm is secured to the trailer with a latch and a quick pin Figure 4 7 Move the latch down while pulling the knob out 59322170716 releasing the knob under lip of the arm 32 Part No 79 20 Rev 1 0911 E H Wachs Chapter 4 Operating Instructions Valve Exerciser Figure 4 10 Pull the quick pin to release the ERV 750 Let the pin hang behind the arm when released to prevent entanglement of the lanyard 3 Operate the ERV 750 according to the instructions in the ERV 750 Extended Reach Valve Exerciser User s Manual 4 When finished using the ERV 750 return the arm to the storage position and fasten it with both the latch and the quick pin E H Wachs Part No 79 MAN 20 Rev 1 0911 33 Trailer System LiGHT BAR OPERATION The light bar controller is mounted in a box on the right side of the trailer above the hydraulic unit Controller box
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