TM-6 Truck Mounted Valve Operator User Manual
Contents
1. WOS HOLIMS AZL HJONASNYHL oj S IN HOLIMS OND I S rio OND 1OIH QON 8 O AG L 3TOIH3A AZ L GON 2 gr I dO1S a HIS Flava TOHINGD SNQILO NNQO q HHYO8 19411995 YIMOd 2 dO1S IHM u 5 NH S Fr 6 Hole 8 Mp S ete 13 519 TE ans lt _ lt qe lt 3 WOO IN IN _ ji 7 IHM HOLIMSOYDIN NYYDVIG ONIAIM II WL YJONASNTUL TM 6 TRUCK MOUNTED VALVE OPERATOR VALVE EXERCISING LOG VALVE VALVE GATE OPEN TO NUMBER DATE OPERATED LOCATION SIZE DEPTH POSITION LEFT OR RIGHT OF TURNS COMMENTS TM 6 TRUCK MOUNTED VALVE OPERATOR VALVE EXERCISING LOG VALVE VALVE GATE OPEN TO NUMBER LOCATION SIZE DEPTH POSITION LEFT OR RIGHT OF TURNS DATE OPERATED COMMENTS TM 6 TRUCK MOUNTED VALVE OPERATOR SECTION X ORDERING INFORMATION ORDERING To place an order or to get more detailed information on any E H Wachs products call us at 1 800 323 8185 ORDERING REPLACEMENT PARTS Please use parts list provided in manual Have part description and part number ofrequired replacement part or parts to help expedite order and insure proper parts are being ordered REPAIR INFORMATION Please call E H Wachs Company prior to returning any equipment for repair2. Head retracted and latched but display Adjust Micro Switch in housing to switch stays on off when head is retracted and latched Charge battery No display Dead battery See above No power to head Pull out head to engage Micro Switch Disconnected or defective cable Check cable and power connections see wiring diagrams Test control cable leads to insure continuity Replace defective cables Machine does not operate Pump not engaged Engage pump or PTO Auxilliary circuit engaged Push auxilliary valve in completely to dis engage Encoder error Pump not engaged Engage pump or PTO Verify drive hub rotation by pressing JOG keys in both di rections Poor electrical connection Check electrical connections see wiring diagram Encoder failure Replace Encoder Defective Solenoid Valve Using JOG keys rotate drive hub in both directions While jogging observe indica tor lights on top of valve If either light fails check electrical connections and power control board If both lights illumi nate but head fails to rotate in one or both directions replace valve 14 TM 6 TRUCK MOUNTED VALVE OPERATOR SECTION VI Trouble Encoder Error TRANSDUCER ERR displayed EMERGENCY STOP ERR displayed Low Power Possible Cause Relay failure Defective control unit Damaged Cable Poor electrical connection Pressure transducer failure Defective control unit Damaged Cable Electrical noi
3. PACKAGE PART NO 07 404 00 Consisting of Pressure Relief Valve Shut Off Valve and piping installed on Truck Mounted Valve Operator to provide power for auxiliary hydraulic equipment such as the Wachs Pump and Portable Valve Actuator A Change hydraulic filter on tank once a year replace ment filter can be purchased from WACHS B Change hydraulic oil Mobil DTE light or equivalent every two years Note tank drain ref Fig 2 Letter B 5 No lubrication attention is required on the two hydraulic motors as they are adequately lubricated by the hydraulic oil 6 CheckALL electrical connections regularly For problems other than these refer to Trouble Shooting section or call the E H WACHS COMPANY at 1 800 323 8185 THROTTLE CONTROL PART NO 07 405 00 Locking T handle type for controlling truck engine speed EXTRA VALVE KEYS PART NO 07 406 00 Heavy duty 2 square keys drilled both ends to accept socket or key adaptor Customer to specify length desired KEY ADAPTOR PART NO 07 407 00 Male union for joining keys including two detent pins EXTRA UNIVERSAL SOCKET PART NO 07 408 00 2 square ductile iron socket to fit Wachs 2 square keys and standard A W W A nut EXTRA FILTER ELEMENT PART NO 07 139 00 11 TM 6 TRUCK MOUNTED VALVE OPERATOR Section VI TM 6 TM 6B TROUBLE SHOOTING TM 6 TRUCK MOUNTED VALVE OPERATOR SECTION VI TM 6 TROUBLESHOOTING Trouble Possible Cause Dead battery
4. We will advise you of shipping and handling Please enclose with equipmentto be repaired your name address phone number and a brief description of problem or work to be done or estimated All repair work done at our plant will be estimated and the customer advised of cost and time required to complete repair WARRANTY INFORMATION Enclosed with the manual is a warranty card Please fill out the registration card and return to Wachs Retain the owners registration record and warranty card for your information RETURN GOODS ADDRESS E H Wachs Company 600 Knightsbridge Parkway Lincolnshire IL 60069 PIPE amp VALVE MAINTENANCE PRODUCTS Mod TM 6 6B Sn E H Wachs Company 600 Knightsbridge Parkway Lincolnshire IL 60069 847 537 8800 FAX 847 520 1147 847 520 1168 Toll Free 1 800 323 8185 36
5. experience gathered from utilities worldwide and has programmed this safe and accepted method into the TM 6 Now even the inexpe rienced operator has the ability to turn hard to operate valves without knowing direction loosen seized valves and exercise valves safely and efficiently MICROPROCESSOR CONTROLLER TheTM 6 Microprocessor Controller is a hand held pendant type utilizing a powerful 9 216 MHz Z180 processor to run Wachs copyrighted valve exercis ing program for safe and easy valve turning Built in a durable cast aluminum housing which is watertight and impact resistant the TM 6 features a backlit LCD display for easy visibility day or night It also provides a tactile key pad for positive feel data input The pendant when not in use is secured in a snap in closure at the front of the machine for easy access TM 6 TRUCK MOUNTED VALVE OPERATOR SAFETY INSTRUCTIONS SECTION II Since 1883 EHWachs has built a reputation for quality and a commitment to consumer satis faction In accordance with this Wachs must take on the added responsibility of doing our bestto assure the safest use of our equipment We have assembled a list of safety reminders to aid in creating the safest possible working environment We recommend that the precautionary steps listed there be closely observed Read the Following thoroughly before proceeding 1 READ THE OPERATING MANUAL Reading the setup and operating instructi
6. 7 214 00 07 215 00 07 216 00 07 217 00 07 218 00 07 219 00 07 220 00 07 221 00 07 222 00 07 223 00 11 004 00 17 028 00 17 029 00 17 030 00 17 032 00 17 033 00 90 001 06 90 050 07 90 051 05 90 059 25 90 501 39 90 901 09 26 k N er Se NJ at ee ee MN mM Nm PINION COUNTER ENCODER PHOTOCRAFT STAND TMC2CONTROLLER CONNECTOR 3 8x90 PIN ROLL 3 32 X 5 8 PLATE SIN TAG HANDLE STAND OFF ENCLOSURE MOD PLUG ENCLOSURE BRACKET ENCODERMTG SWITCH MOD PUSHBUTTON E STOP BLOCK CONTACT GROMMET SEAL ENCODER O RING ENCODER HOLDER FUSE FUSE 6 AMP CORD POWER STRIP FOAM CONNECTOR CORD BOARD POWERCONTROL GROMMET BATTERY CABLE CONTROL GRIP CABLE SHCS 6 32 x 5 8 1 4 20 3 4 HHCS 1 4 20X 1 2 RHMS 1 4 20x 1 2 TERM SREDFORK WIRE 18GAWHITE TM 6 TRUCK MOUNTED VALVE OPERATOR TM 6 TRUCK MOUNTED VALVE OPERATOR SECTION IX TM 6 PARTS LISTS amp EXPLODED VIEW DRAWINGS earn fore semen __ 07 089 00 HOSE PRESSURE 90 208 51 ADAPTOR 5 8 x 5 8 JIC 07 090 00 HOSE RETURN 90 501 06 TERMINAL 1 4 MALE 07 020 00 BASE SLIDING 90 501 00 FEMALE SPADE 250 07 023 00 PIN SLIDE LOCKING 90 501 11 TERMINAL 6 RED 07 024 00 WIRE RETAINING 90 501 37 TERMINAL 6 RED 07 025 00 PLATE HP HOSE 90 501 39 TERMINAL 8 RED 07 029 00 FILTER ASSEMBLY 90 901 05 WIRE 14 GA RED 07 045 00 SLEEVE RETAINING WIRE 90 901 06 WI
7. ATOR Section VIII PARTSLISTS AND EXPLODED VIEW DRAWINGS 21 22 TM 6 TRUCK MOUNTED VALVE OPERATOR TM 6 Head Assembly REF PARTNO ary 70 001 00 70 002 00 07 003 00 07 005 01 07 006 01 07 006 02 07 009 00 07 036 00 07 037 00 07 100 00 07 072 00 07 008 00 07 018 00 Ay NS aa po 1 2 3 4 5 6 7 8 9 10 57 78 79 DESCRIPTION GEAR HUB DRIVE PIN DRIVE HUB GEAR BUSHING UPPER THURST WASHER LOWER THRUST WASHER BULL GEAR TOP HOUSING BOTTOM HOUSING RETAINING RING MOTOR HYDRAULIC GEAR PINION RETAINING RING FASTENERS REF PARTNO QTY 90 056 03 90 060 06 90 070 07 90 070 17 90 070 12 90 070 25 90 095 02 90 500 03 037 90 092 12 069 90 062 07 gt O O O DESCRIPTION PIN DOWEL 1 4 x 3 8 SHCS 5 16 18 x 5 8 SHCS 3 8 16 x 314 SHCS 3 8 18 x 1 3 4 SHCS 3 8 16 x 1 1 4 SHCS 3 8 16 x 2 1 2 HEX NUT 1 2 20 GREASE FITTING 1 8 BHCS1 2 13 x 1 1 4 5 16 18 x 1 2 BHCS TM 6 TRUCK MOUNTED VALVE OPERATOR 23 TM 6 TRUCK MOUNTED VALVE OPERATOR TM 6 Manifold Assembly DESCRIPTION 07 085 00 07 169 00 07 172 00 07 171 00 07 170 00 07 173 00 07 174 00 07 089 00 07 090 00 07 176 00 11 004 00 62 138 00 WIRE NUT MANIFOLD VALVE TRANSDUCER RELIEF CARTRIDGE HOSE HOSE HOSE PRESSURE N S HOSE RETURN N S CONNECTOR CONNECTOR CORD TUBING 3 8 ek GJ 243 Sak ask ASTENERS PARTNO DES
8. CRIPTION SHCS 1 4 20 x 1 1 2 SHCS 5 16 18 x 1 4 PLUG NPT 1 4 EL w SWVL 3 4 90 NIPPLE 3 4 x 6 HP ELBOW w SWVL 1 90 NIPPLE 1 x 6 1 2 LP TERMINAL 8 BLU N S TERMINAL 6 RED N S 90 501 39 TERM INAL 8 RED N S 90 901 01 WIRE 18 GA RED N S 90 901 02 WIRE 1 8GA BLACK N S 90 901 03 WIRE GA BLUE N S 90 901 04 WIRE 18GA YELLOW N S 90 050 15 90 060 32 90 059 62 90 218 54 90 218 59 90 238 51 90 238 72 90 501 08 90 501 11 co Oo TM 6 TRUCK MOUNTED VALVE OPERATOR TM 6 Housing Assembly REF PARTNO DESCRIPTION PINION COUNTER ENCODER PLATES N ENCLOSURE PANEL RELAY PIGTAIL EMERGENCY SWITCH CONNECTOR CONTROL PAD HOLDER 07 050 00 07 093 00 07 106 00 07 177 00 07 178 00 07 179 00 07 180 00 07 195 00 62 137 00 07 182 00 k ap lt FASTENERS PARTNO QTY 90 009 01 90 016 56 90 020 06 90 040 03 90 045 03 90 049 01 DESCRIPTION RHMS 6 32 x 1 4 ROLL PIN 3 32 x 5 8 SHCS 8 32 x 5 8 SHCS 10 24x3 8 NUT HEX 10 24 SCREW 3 16 3 NOTE If your Valve Excerciser has been upgraded to a TM 6B or a TM 6DT please also refer to pages 26 27 which is a supplement to this page TM 6 TRUCK MOUNTED VALVE OPERATOR TM 6B UPGRADE 07 307 01 02 PARTNO DESCRIPTION 07 050 00 07 093 00 07 182 00 17 304 00 62 137 00 90 016 56 07 106 00 07 198 00 07 209 00 07 210 00 07 224 00 07 211 00 07 212 00 0
9. R Ep LS ta fe TM 6 TRUCK MOUNTED VALVE OPERATOR Section IX WIRING DIAGRAMS AND VALVE EXCERCISING LOG 31 TM 6 TRUCK MOUNTED VALVE OPERATOR 32 BLK L EVIRGENCY 7 STOP SMTC I ERN RED RED WET BLK BLACK RED WHT WHITE GRN GREEN BLU BLUE SOLENOID VALVE 5 El TRANSDUCER YEL YELLOW 2 i Ne BRN BROWN 7 BLU ORG ORANGE f vF E BED pai 2 5 AMP FJSE 7TTTE7 J YEL nik ru fro 7 BLA D RELAY REAY G fa gt Pa WARNING USE 14 GA WIRE MINIMUM HIRECTLY CONNECTED TO BATTERY POSITIVE TERMINAL WARNING MAKE A CLEAN SOLID CONNECTION DIRECTLY TO VEHICLE CHASIS GROUND 17m BA FR TM 6 WIRING DIAGRAM NOI1O IIQ JATYA NOLLO33910 IATYA OND IATYA 4015 34 4015 9 o TAM LO Mco qm L LOO AH Ola g INO AH 21 LNO AH 21 21 NI VLSI 21 NI SOTvNV Old Old MIISHS HFIONISNYAL OND H30NASNYYL TYNDIS H3DCNASNYHL T NO TWO OM aM 33 TM 6 TRUCK MOUNTED VALVE OPERATOR
10. RE 14 GA BLACK 07 055 00 PLATE VALVE MOUNTING 90 238 52 1 ST ELW SWIVEL 07 056 01 TANK ASSEMBLY 90 218 17 3 4 x 90 ELBOW 07 057 00 FRAME ASSEMBLY 90 075 53 3 8 FLAT WASHER 07 150 00 CRATE SHIPPING 07 406 08 8 VALVE KEY 07 034 00 UNIVERSAL SOCKET 07 035 00 CENTER BLOCK 07 134 00 UNIVERSAL SOCKET PIN 14 124 00 FILLER CAP ASSEMBLY 14 125 00 OIL LEVEL GUAGE 07 062 00 TANK GASKET 07 139 00 FILTER CANISTER 07 041 00 SWITCH MICRO 07 046 00 CLAMP CABLE 07 140 00 FUSE HOLDER 07 143 00 5 AMP FUSE 07 142 00 POWER CORD 07 008 00 GEAR PINION 07 018 00 RETAINING RING 07 072 00 HYDRAULIC MOTOR 07 304 00 CONTROL PAD ASSEMBLY R 24 DR 1 1 4 1 1 1 1 1 2 1 2 1 1 1 1 1 1 1 1 36 1 2 2 1 FASTNERS 90 218 54 90 218 51 90 054 02 90 079 21 90 051 01 90 055 01 90 055 52 90 072 07 90 075 01 90 092 10 90 092 12 90 095 01 90 218 01 90 218 05 90 218 07 90 238 01 90 238 02 90 238 05 ELBOW W SWIVEL 3 4 90 ELBOW W SWIVEL 1 90 SSS 1 4 20 x 1 4 PIN FAST 3 8 x 2 7 8 1 4 20 x 1 HEX NUT 1 4 20 LOCK WSHR SPLT RING 1 4 BHCS 3 8 16 x 3 4 NUT HEX 3 8 16 BHCS 1 2 13x1 BHCS 1 2 13 x 1 1 4 NUT HEX 3 8 16 NIPPLE CLOSE 3 4 LP PLUG SQUARE HEAD 3 4 ELBOW 3 4 90 NIPPLE CLOSE 1 LP NIPPLE 1x2 1 2 ELBOW 1 90 CONTROL PAD CONTAINS NO USER SERVICEABLE COMPONENTS 28 TM 6 TRUCK MOUNTED VALVE OPERATO
11. Truck Mounted Valve Model TM 6 6 DD PIPE amp VALVE MAINTENANCE PRODUCTS Mod 6 6 S N J E H Wachs Company 600 Knightsbridge Parkway Lincolnshire IL 60069 Part Number 07 MAN 01 Revision No 2 Revised April 98 TM 6 TRUCK MOUNTED VALVE OPERATOR SECTIONI SECTION II SECTION III SECTION IV SECTION V SECTION VI SECTION VII SECTION VIII SECTION IX SECTION X TABLE OF CONTENTS INTRODUCTION SAFETY INSTRUCTIONS MACHINE SPECIFICATIONS SET UP 8 OPERATION A TM 6 Installation Instructions TM Controller C Operation Instructions MAINTENANCE TM 6 TROUBLESHOOTING TM 6B TROUBLESHOOTING OPERATION MODE COMPARISON TABLE PARTS LISTS AND EXPLODED VIEW DRAWINGS WIRING DIAGRAMS AND VALVE EXCECISE LOG PARTS ORDERING INFORMATION 7 10 7 8 10 11 14 15 16 17 20 22 29 32 35 36 TM 6 TRUCK MOUNTED VALVE OPERATOR The E H Wachs TM 6 truck mounted valve operator is a permanently mounted heavy duty hydraulic valve turner to Automatically operate 6 through 96 valves The TM 6 offersthe same rugged design power and reliability as it s TM 2 TM 3 and TM 5 predeces sors Now combined with a new Automatic Control System the TM 6 is designed to make valve turning easy for all utilities and assures maximum valve protec tion The E H Wachs company has taken 50 years of valve turning and exercising
12. and remove it from the valve nut 12 Remove the valve key from the power head and slide it back into truck until locking pins can be replaced Once head is secured disengage PTO and move onto next valve TM 6 TRUCK MOUNTED VALVE OPERATOR SECTION V MAINTENANCE Routine 1 Keep slide bars greased to prevent rust and facilitate easy sliding of power head 2 Useasoftautomotive grease in gear box applied at grease fitting 3 Check oil level on gauge of hydraulic oil tank Add oil if necessary Keep hydraulic oil level at full mark on gauge 4 Oil temperatures should not exceed 180 F under pro longed or hard operating If this temperature is exceeded the hydraulic oil will break down and damage pump The ample storage tank on the Wachs valve operator should assure proper oiltemperature under normal conditions If excessive temperatures are encountered check oil level If reservoir is full and high oil temperatures continue consult E H WACHS CO ACCESSORIES POWER TAKE OFF PART NO 07 401 00 2 gear type extra heavy duty to accept flange mounted hydraulic pump Customer to provide truck model year and transmission model when ordering HYDRAULIC PUMP PART NO 07 402 00 To supply power for Truck Mounted Valve Operator Customer to specify either flange mount for direct mount to PTO listed above or foot mount for remote mounting and connection through Universal Joint and shaft to customer s PTO AUXILIARY POWER
13. ate pump until system is filled with oil Set valve operator in truck at desired location Keep as close as possible to opening on side of body to assure maximum reach of power head when extended Layout and drill eight 8 9 16 mounting holes in truck bed for securing unit to the truck frame Ref Fig 2 Letter Con page 8 Layout and cut two access holes in bed of truck 1 3 8 access hole for 1 high pressure line ref 2 letter D on page 8 2 acess hole for 1 1 4 low pressure return line ref Fig 2 Letter A on page 8 If access holes cannot be cut beneath connecting points on machine because of frame members cut where clearance is available Extra piping from access holes to connecting points may be needed See Step 6 Figure 3 shows suggested hose assemblies which should be purchased High pressure hole should be 1 two wire braid capable of at least 1500 PSI working pressure Return hose should be 1 1 4 rayon braid capable of at least 300 PSI working pressure Hose ends should be male pipe thread In figure 3 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 connec 10 TE 12 13 14 tions Note that a swivel connection is necessary at one end of each hose Bolt Valve Operator to truck bed using 1 2 bolts through mounting holes ref 2 Letter C on pa
14. auxilliary valve in completely to disengage Replace fuse see Kohler engine manual Engage pump or PTO Verify drive hub rotation by pressing JOG keys in both di rections Check electrical connections see wiring diagram Replace Encoder Using JOG keys rotate drive hub in both directions While jogging observe indica tor lights on top of valve If either light fails check electrical connections and power control board If both lights illumi nate but head fails to rotate in one or both directions replace valve TM 6 TRUCK MOUNTED VALVE OPERATOR SECTION VI Trouble COUNTER ERR displayed TRANSDUCER ERR displayed BYPASS ACTV displayed Possible Cause Power control board failure Damaged cable Defective control unit Poor electrical connection Pressure transducer failure Defective control unit Damaged Cable Electrical noise Power Control Board failure Defective Control Unit TM 6B TROUBLESHOOTING cont Unplug and replace power control board Replace Cable Replace or return for service Check electrical connections see wiring diagram Check transducer voltage output at green wire Voltage should read between 5 and 5V Replace if not within tolerance Replace or return for service Replace Cable Press STATRT If message clears problem is false signal caused by electrical noise Consult your factory representative if problem persists Unplug and repla
15. ce Power Control Board Replace or return for service 17 TM 6 TRUCK MOUNTED VALVE OPERATOR Section VII OPERATION MODE COMPARISON TABLE TM 6 TRUCK MOUNTED VALVE OPERATOR SECTION VII OPERATION MODE COMPARISON TABLE Valve Type Yes Geared Yes No Ka Torque limit increases always available Torque limit increment 50 ft lb 100 ft lb 100 ft lb 100 ft lb 100 ft lb when available Automatic torque limit 50 ft lb per 50 ft lb per None None None decrement rate 0 5 turns 1 5 turns Automatic set point increment 50 ft lb NN ft lb rote ft lb 100 ft lb Automatic set point 50 ft lb per 50 ft lb per 50 ft lb per 50 ft lb per La decrement rate 0 5 turns 1 5 turns 0 5 turns 1 5 turns Attempts required at each set point Number of turns during 0 5 3 1 5 10 0 5 1 5 None forced reverse Condition to require operator Set point reaches limit and attempts required is satisfied input Limit will decrement if the difference between limit and set point is more than two set point increments exercise mode only Set point will decrement if the difference between set point and operating torque is more than 100 ft Ib In exercise mode when set point is less than limit reverses are short and intended only to clear valve nut and stem threads first number shown above applies In emergency mode all reversing is intended only to clear valve nut and stem threads 20 TM 6 TRUCK MOUNTED VALVE OPER
16. djustable has a factory default at 200 ft lbs The exercise or break loose procedure begins with operat ing torque programmed at 50 ft Ibs If this torque is not suffi cient to turn the valve stem the direction of operation will reverse and apply torque This procedure the No Assump tion method which allows the microprocessor to determine direction of rotation continues uninterrupted increasing torque gradually until the stem begins to turn or operating torque reaches the factory set torque limit If the valve has not started to turn the operator can increase the TORQUE LIMIT in increments of 50 ft Ibs per operating cycle Once the valve stem has started turning operating torque is reduced to the minimum torque required to keep it turning The TORQUE LIMIT is the maximum torque the TM 6 will apply to the valve during operation When operating torque reaches the TORQUE LIMIT exercising will stop automati cally This is usually an indication that the valve is fully opened or fully closed If additional torque increases are necessary the limit may be increased once by pressing the limit key TORQUE LIMIT in creases are available only when operating torque has reached the TORQUE LIMIT When operating torque drops well below the LIMIT the LIMIT will decrease automatically When tuberculation calcification or other deposits have built up on the valve stem or slides rotation may become tight requiring increased operat
17. ge 8 cutin Step 4 If mounting bolts do not ground operator to frame of truck connect ground strap from one bolt to frame Install piping and hoses assembled in Step 6 Use pipe tape on all connections Use one to three hose clips to secure hose to underside of truck Connect red wire coming off of micro switch directly to battery positive terminal Ground or black wire must make SE 14 Gi WIRE VINIVLIV LY GONNEG A Fr VEHICLE C ESIS GROUND asolid connection directly to vehicle chassis See diagram above A 14 guage wire minimum should be used to make these connections Fill tank to full mark on gauge approximately 22 gallons Use hydraulic oil Mobil DTE light or equivalent Purchase and install hand throttle if truck is not equipped with one Test system by engaging PTO Allow truck to idle for several minutes to purge air from system and check for hydraulic oil leaks See OPERATING INSTRUCTIONS before proceeding with operation Mosttruck body and equipment installers are familiar with installations of the type described above This includes PTO pump hose lines and throttle controls If a door is cut in side of truck body for access to Valve Operator make it at least 25 wide and 17 1 4 high 14 high with direction control handle shortened to allow power head to slide in and out SECTION IV SET UP AND OPERATION cont opening in truck pane
18. ing torque The TM 6 will stop and automatically reverse direction temporarily This helps to flush loosened debris from the stem threads and slides Operation resumes automatically with increased operating torque Op erating torque never exceeds the factory set TORQUE LIMIT When rotation becomes easier and less torque is required to turn the valve operating torque automatically decreases to the lowest torque needed to maintain rotation OPERATION MODES Three modes are available for valve exercising with the TM 6 EXERCISE MODE provides the safest and most thourough valve excercising method The torque limit may be increased only if the current limit is insufficient to turn the valve When rotation becomes easier and operating torque decreases the limit will decrement back to its original value This ensuresthat the TM 6 uses only the minimum required torque 10 EMERGENCY MODE is available when a valve must be closed in a hurry while still enforcing safe valve operation Fewer reverses are induced and the torque limit remains at set point At this point the operator has full control of the set torque point MANUAL MODE is intended for the experienced operator The torque set point is not in effect and operation stops only when operating torque reaches the torque limit No forced reverses occur and the operator has full control of the torque limit this feature available only by request VALVE TYPE SELECTION Geared valves requ
19. ire a special consideration for proper exer cising To effectively clean the stem and slides any up and down motions of the gate must occur through a greater num ber of turns than on a non geared valve Selecting a geared valve type will account for this by backing up further during temporary direction changes 1 Position truck next to valve box Engage PTO and set engine speed 3 Remove locking pins located to either side ofthe power head and pullthe head out over the valve 4 Insert the valve key into the power head Use the right and left JOG keys if necessary to align the socket over the valve nut 5 Byusingthe TM 6controlpad initializethe valveturning sequenceby selectingthe VALVE TYPE either geared or non geared to be turned 6 Selectthe MODE ofoperation Choose from emergency or exercise 7 Press the START button to begin exercise Exercise will automatically stop when operating torque reaches the TORQUE LIMIT 8 If TORQUE LIMIT has been reached and valve has not yet started to move the control pad will flash the insufficienttorque message Atthistime the TORQUE LIMIT may be adjusted by using the limit keys 9 When machine stops check COUNTER to determine if the valve has reached the full open or full closed position 10 Press the DIRECTION and the START buttons to exercise the valve in the opposite direction 11 When complete use the JOG keys if necessary to release the valve key
20. l ink minimum 171 44 TM 6 TRUCK MOUNTED VALVE OPERATOR opening vertical 2 3 4 SIDE PANEL OF TRUCK 14 with shortened handle TRUCK BED 67 1 2 overall extended opening truck panel minimum opening vertical 287 overall 30 overall with accessory package SIDE PANEL OF TRUCK with accessory package FIGURE 2 A bene A En 1 TM CONTROLLER CURRENT LIMIT 750 127 8 R No Exer COUNT GEARED MODE FESET ee EH SE o 9 DIRECTION MODE JOG D MICROPROCESSOR CONTROLLED TRUCK MOUNTED VALVE OPERATOR B TMCONTROLLER Pens ao TM 6CONTROLLERPAD LCDREADOUTDISPLAY CURRENT Torque being applied at that moment HIGHEST Highest torque required to turn valve during cycle LIMIT Indicates torque limit setting TORQUE LEVEL INDICATOR BAR Measures torque being applied TORQUE INDICATOR LEVEL Indicates maximum allow able torque being applied during acycle DIRECTION Primary turning direction chosen by program GEARED Valve type selected geared or non geared COUNT Revolution counter counts in 10th s of a turn MODE Operation mode selected exercise or emergency RESET COUNT Reset counter to zero STOP Stop exercise LIMIT Manually increase torque LIMIT Manually decrea
21. ons prior to beginning the setup procedures can save valuable time and help prevent injury to operators or damage to machines 2 INSPECT MACHINE amp ACCESSORIES Prior to machine setup physically inspect the machine and it s accessories Look for worn tool slides loose bolts or nuts lubricant leakage excessive rust etc properly maintained machine can greatly decrease the chances for injury 3 ALWAYS READ PLACARDS amp LABELS All placards labels and stickers must be clearly legible and in good condition Replacement labels can be purchased from the manufacturer ALWAYS WEAR PROTECTIVE EQUIPMENT WARNING Impact resistant eye pro tection must be worn while operating or working near this tool 4 KEEP CLEAR OF ROTATING PARTS Keep hands arms and fingers clear of all rotating or moving parts Always turn machine off before attempt ing any adjustments requiring contact with the machine or it s accessories 5 SECURE LOOSE CLOTHING amp JEWELRY Loose fitting clothing jewelry long unbound hair can get caught in the rotating parts on machines By keepingthese things secure or removing them you can greatly reduce the chance for injury 6 KEEP WORK AREA CLEAR Be sure to keep the work area free of clutter and nonessential materials Only allow those personnel directly associated with the work being performed to have access to the area if possible CAUTION Personal hearing protection is requi
22. red at all times when operating or working near this tool TM 6 TRUCK MOUNTED VALVE OPERATOR CAPACITY SPEED SPEEDCONTROL DRIVE MICROPROCESSOR TORQUE RETROFIT CONTROLVALVE DIMENSIONS OILTANK FILTRATION VALVE KEY SOCKET MISALIGNMENTCAPABILITY FRAME HEADEXTENSION WEIGHT FINISH AUXILIARYHYD CIRCUIT WARRANTY PRODUCTSUPPORT PRODUCT LIABILITYINS COMMERCIALLYPROVEN Operates all gate valves through 96 510 30 revolutions per minute Speed controlled by hydraulic flow at source Dual self lubricating hydraulic motor drive to single ring gear Balanced power load Pendant type Water and shock resistant Automatically operates valves in an exercising sequence compatible with industry standards LCDreadoutdisplaysrevolutioncount intenths operatingtorque peak torque torque limit and direction Variable from 0 to 2500 ft lbs Retrofit available for Wachs TM 2 TM 3 and TM 5 Solenoid operated hydraulic directional control valve On off and direction 25 wide x 51 long x 23 high Requires 9 2 square feet of bed space 19 gallon steel fabricated with sight guage 10 micron canister type easy change filter 2 square high strength cold rolled tubing 2 square AWWA standard universal type 12 degrees at power head Structural steel channel fabricated 21 from frame to center of head 28 maximum 370 lbs dry weight Acrylic enamel paint yellow Integral power supply p
23. rovides 2000 psi 8 gpm 1 year factory warranty against all defects in materials and workmanship OEM training available on site or at manufacturers facility Manufacturer shall maintain product liability Manufacturer shall provide upon request evidence that the valve operator to be furnished has been commercially provento the industry for notlessthan 1 yearandreplacementparts are readily available TM 6 TRUCK MOUNTED VALVE OPERATOR SECTION IV SET UP AND OPERATION A 1 INSTALLATION INSTRUCTIONS Install a power take off on truck transmission See manufacturer s instructions included with power take off Be certain that rotation of power take off shaft matches rotation of Hydraulic Pump as indicated by arrow on pump PTO supplied by Wachs is normally installed on right passenger side of transmission unless specified other wise Connect PTO control cable and mount red engagement knob assembly in desired location on dashboard Control should be installed so that PTO will become engaged when pulled out The most satisfactory pump installation is direct flange mounted onto the PTO eliminating universal joints and drive shafts from PTO to remote mounted pump If Wachs supplies the pump it will be a flange mounted with splined shaft for direct mount to PTO unless otherwise specified If pumpis purchased by customer from other than Wachs it must be capable of producing 14 GPM at 1200 RPM at 2000 PSI NOTE Do not oper
24. se Defective Relay Defective Control Unit Damaged Encoder Poor electrical connection TM 6 TROUBLESHOOTING cont Replace Relay Replace or return for service Replace Cable Check electrical connections see wiring diagram Check transducer voltage output at green wire Voltage should read between 5 and 5V Replace if not within tolerance Replace or return for service Replace Cable Turn off vehicle accessories Replace Relay Replace or return for service Replace Encoder Repair connection Make sure proper installation procedure was followed 15 TM 6 TRUCK MOUNTED VALVE OPERATOR Trouble Dead battery No display Machine does not operate COUNTER ERR displayed Possible Cause Machine stored with head e xtended Head retracted and latched but displaystays on Dead battery No power to head Disconnected or defective cable Pump not engaged Auxilliary circuit engaged Blown fuse Pump not engaged Poor electrical connection Encoder failure Defective Solenoid Valve Retract and latch head for storage Charge battery Adjust Micro Switch in housing to switch off when head is retracted and latched Charge battery See above Pull out head to engage Micro Switch Check cable and power connections see wiring diagrams Test control cable leads to insure continuity Replace defective cables Engage pump or PTO Close auxilliary valve Push
25. se torque RESET SYSTEM Clear all data START Start exercise VALVE TYPE Select valve type geared or non geared MODE Select mode exercise or emergency DIRECTION Reset direction once operation cycle has beencompleted JOG LEFT Rotate power head left slightly TM 6 TRUCK MOUNTED VALVE OPERATOR SECTION IV SET UP AND OPERATION cont 22 23 JOG RIGHT Rotate power head right slightly LIGHT Display light on off Other controls 1 Power Take Off Control The Valve Operator gets its power from the truck transmis sion through a hydraulic pump Before operating a valve the PTO knob must be actuated to engage the power take off and start the hydraulic pump Always push clutch in on standard transmission vehicles before engaging the PTO Truck Throttle The speed of the Valve Operator is adjusted by changing the truck engine speed The truck should have a lockable throttle in the cab either original equipment or added later The speed range of the Valve Operator is 5 to 30 RPM When the truck is idling the Valve Operator should turn about 5 RPM Emergency Stop The TM 6 is equipped with an emergency stop button located on top of the encoder counter assembly housing TM 6 TRUCK MOUNTED VALVE OPERATOR SECTION IV SET UP AND OPERATION cont C TM 6 OPERATION INSTRUCTIONS The TM 6 is programmed to operate at the lowest torque re quired to maintain valve stem rotation The torque limit though a
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