Wachs RS-2 User manual

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RS-2
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PIPE & VALVE
MAINTENANCEMACHINERY
Mod. RS-2 S/N:
E.H. WACHS COMPANY
100 Shepard St. Wheeling, IL 60090
Patent Pending
PART NUMBER: 78-MAN-01
REVISION NO: R1_1
Revised:
Jan.2004
E.H. Wachs Water Utility Products
600 Knightsbridge Parkway, Lincolnshire, IL 60069

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TABLE OF CONTENTS
SECTION I INTRODUCTION&SPECIFICATIONS...................................................................3-4
SECTION II SAFETYINSTRUCTIONS............................................................................................5
SECTION III SETUP&OPERATINGPROCEDURES............................................................6-16
SECTION IV CHARTS&SCHEMATICS..................................................................................17-19
ElectricRS-2...............................................................................................................19
HydraulicRS-2............................................................................................................19
PneumaticRS-2..........................................................................................................19
SECTION V BILLOFMATERIALS...........................................................................................20-33
MainHeadAssembly............................................................................................21-22
RevolutionCounterAssembly..............................................................................21-22
HydraulicDriveAssembly.....................................................................................21-22
PneumaticDriveAssembly..................................................................................23-24
ElectricDriveAssembly........................................................................................25-26
ACCESSORIES...................................................................................................27-30
UniversalHandwheel............................................................................................27-28
1”InchDriveAdapter............................................................................................27-28
HandwheelAdaptorPlate....................................................................................27-28
GeneralAccessories............................................................................................29-30
ClecoAirMotor......................................................................................................31-33
SECTION VI ORDERINGINFORMATION......................................................................................34

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SECTION I INTRODUCTION-SPECIFICATIONS
INTRODUCTION:
TheRS-2 PortableValveOperator for rising
andnon-rising stemvalvesoffers reliable
openingand closing of water, wastewater,
pipelineand petroleumvalves.
The RS-2 offers these advantages:
!Available in Hydraulic, Pneumatic or
Electric Drive.
!Operate all Rising & Non-Rising Stem
valves. From 6” to 60”.
!4” Opening for operating Rising Stem
Valves.
!Mount to any Hand Wheel with
“Universal Hand Wheel Adapter”.
!Forward and Reverse operation.
!Variable Speed Control.
!Built in easy view LCD counter.
Universal Handwheel Adaptor
OPERATE YOUR RS-2 AND OTHER
VALVE TURNING AND PIPE
CUTTING EQUIPMENT WITH....
WACHSWACHS
WACHSWACHS
WACHS
HYDRAHYDRA
HYDRAHYDRA
HYDRAULIC POULIC PO
ULIC POULIC PO
ULIC POWER UNITWER UNIT
WER UNITWER UNIT
WER UNITS
!Cart Mounted / Electric Start
!9 to 15 H.P. Gas or Diesel Engines
!8 to15 G.P.M. units Available
Electric Hydraulic Pneumatic

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CAPACITY:Operate all rising and non-rising stem valves from 6” to 60”, which require mechanized turning.
DRIVE: Lightweight Aluminum gear box. Two stage reduction.
Planetary motor drive. Steel Ring and Pinion secondary drive.
DRIVEHUB: 4” opening for rising stem valve operation.
REVOLUTION
COUNTER: Built in “easy view” LCD Counter. Push button reset counts 1/10 revolution increments, forward and
reverse automatically.
FINISH: Aluminum gear housing, Zinc plated handle.
DIMENSIONS: 42” length, 4.75” width, 10.3” height
WEIGHT:40-45 lbs.
AIR ELECTRIC HYDRAULIC
Electric, 110 volt AC
(15 amps or 3500 watt generator)
2 Speed gear box
Forward and reverse control knob.
POWER
REQUIREMENTS: Air drive, 60 cfm @ 90 psi.
MOTOR Adjustable speed.
CONTROLS: Forward and reverse dial.
Hydraulic, 8 gpm @ 1800 psi
Variable speed.
Adjustable torque control.
Forward and reverse control valve
SPECIFICATIONS
OPTIONAL Universal Handwheel Adaptor (pn: 09-405-00) Dedicated Handwheel Adapter Plate (pn: 09-404-00)
ACCESSORIES: 1” Square drive adopter (pn: 09-402-00) 8 ft. Valve Key (pn: 05-402-00)
SECTION I INTRODUCTION-SPECIFICATIONS
*NOTE: SEE PAGE 19 FOR PEAK TORQUE AND MAXIMUM RPM OUTPUT

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1. READ THE OPERATING MANUAL!!
Reading the setup and operating instructions prior to
beginning the setup procedures can save valuable time
and help prevent injury to operators or damage to ma-
chines.
2. INSPECT MACHINE & ACCESSORIES!
Prior to machine setup physically inspect the machine
andit'saccessories.Lookforworntoolslides,loosebolts
ornuts,lubricantleakage,excessiverust,etc.Aproperly
maintained machine can greatly decrease the chances
for injury.
3. ALWAYS READ PLACARDS & LABELS!
All placards, labels and stickers must be clearly legible
and in good condition. Replacement labels can be pur-
chasedfromthemanufacturer.
4. KEEP CLEAR OF ROTATING PARTS!
Keep hands, arms and fingers clear of all rotating or
movingparts.Alwaysturnmachineoffbeforeattempting
anyadjustmentsrequiringcontactwiththemachineorit's
accessories.
5. SECURE LOOSE CLOTHING & JEWELRY!
Loosefittingclothing,jewelry;long,unboundhaircanget
caught in the rotating parts on machines. By keeping
these 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 nones-
sential materials. Only allow those personnel directly
associatedwiththeworkbeingperformedtohaveaccess
to the area if possible.
ALWAYSWEARPROTECTIVEEQUIPMENT:
Since 1883, EH Wachs has built a reputation for
quality and a commitment to consumer satisfaction.
In accordance with this, Wachs must take on the
added responsibility of doing our best to assure the
safest use of our equipment.
We have assembled a list of safety reminders to
aid in creating the safest possible working environ-
ment. We recommend that the precautionary steps
listed there be closely observed.
Foradditonalinformationon eye andfaceprotection,refer to
federal OSHA regulations, 29 Code of Federal Regulations,
Section 1019.133., Eye and Face Protection and American
National Standards Institute, ANSI Z87.1, Occupational and
Educational Eye and Face Protection. Z87.1 is available
from the American National Standards Institute, Inc., 1430
Broadway, New York, NY 10018
Hearing protectors are required in high noise areas, 85dBA
or greater. The operation of other tools and equipment in the
area, reflective surfaces, process noises and resonant
structures can substantionally contribute to and 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, Occupa-
tional Noise Exposure and ANSI S12.6 Hearing Protectors.
Personal hearing protection is re-
quired at all times when operat-
ing or working near this tool.
CAUTION
WARNING
Impact resistant eye protection
must be worn while operating or
working near this tool.
CAUTION
Some individuals are suseptible to
disorders of the hands and arms
when exposed to tasks which in-
volve repetitive motions and/or vi-
bration. Disorders such as Carpal
Tunnel Syndrome and Tendonitis
can be caused or aggravated by
repetitious, forceful exertions of the
hands and arms.
!Use minimum hand grip force.
!Keep wrists straight
!Avoid prolonged, continuous vibration exposure
!Avoid repeated bending of wrists and hands.
!Keep arms and hands warm and dry.
Read the Following thoroughly before proceeding
SECTION II SAFETY INSTRUCTIONS

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Section III
Set Up
&
OperatingProcedures

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Valve Maintenance Procedure
Avalve that hasnotbeen operatedfora number of
years needs to be closed by using a series of up
anddown motions.Occasionally,crews attempting
toclosea difficultvalve useaT-handleor a cheater
bar, applying a great deal of pressure in one direc-
tionsimply to forcethe valve closed.The correct
waytoexercise a valve is to beginwithasteady
amountof torque inthedirection necessary toclose
thevalve,movingthroughfivetoten rotations,then
thedirection should bereversedfortwo or three
revolutions,followed byfive ortenmoreturnsin the
closingdirection.This procedure shouldbere-
peateduntil fullclosureis attained.
Thereason for thecautiousapproach isthat
tuberculationand sedimenthaveprobablybuiltup
onthegates, stem, and slides. Byusingtheproce-
duredescribed, waterinthe systemcanflush the
debristhathas broken awayfromthegate slide.
Thestemis exercised throughtheseries of
upand downmotions. Oncethe valvehas beenfully
closed,itshould be openedafew turns so thatthe
highervelocity waterflowingunderthegates can
movethe remainderofthe sedimentdownstream.
Afterthe valve isreopened,it shouldbeturned in
theclosing directiononeortworevolutions. Thus,
thenext time thevalveisoperated, it willnotbe
SECTION III SET-UPANDOPERATION
necessaryto startwitha nutandstem
jammedagainst the bonnet,andthere willbe
noguesswork aboutwhich wayto turn
thenut because thevalve will befree.Also,if
itis inadvertentlyturned thewrong way,one
or two turns can be made before a positive
stopsoccurs, andbyreversing direction,full
operationof the valvecanbe effected.
Usingthe RS-2 machinestooperate valves
iseasieronthe valve because a steady
turningtorque isappliedrather thanjerky
motions.This prevents thestem breakage
thatis sometimes causedbyturning the
valveby hand.Also,morevalves canbe
turnedin lesstime.Afurther advantageis that
informationabout eachvalvecan be gener-
atedautomaticallybytherevolutioncounter
andtorque gauges forinclusionon perma-
nentrecords.
HOW TO DETERMINE AN
UNKNOWN VALVE ROTATION:
Whenthedirectionto turnthe valve
stemis not known,selectarotation
directionand proceed withcaution.If
resistanceis felt, immediatelyreverse
therotation. Continuethis procedure,
reversingdirection when resistanceis
felt,until a freeturning direction is
achieved.Document thedirection,
openorclosed position, andnumber
ofturns required.

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I. SET UP PROCEDURE (Valve Key & Socket):
1.Insert1”driveadaptor intoRS-2drivehub,secure
with1/420x5/8”SHCS.(Ref. 1)
2.Insertvalvekeyandsocket into valve.(Ref.2)
3.Installstopcollaratacomfortable operatingheight
tosupport theweightof the RS-2.
4.MounttheRS-2on thevalvekeyandreston stop
collar. Connect thepowersource.
5.Zerothecounterwhenvalve isreadytobeturned
bypressingthered resetbuttononthe counterface.
Alwaysusethecounter to determinethenumberof
rotationsthevalvehasturned.
6.Determinedirectionofvalverotationandwhich
sideofRS-2to operatefrom.Theoperatorshould
standonthe sideofthe machine whichallowsthe
torquetoPULL the machinehandleawayfrom his
body.
II. OPERATOR POSITIONING
Standing on the wrong side of the machine will allow
the handle to PUSH against the operator and can
knock him off balance or pin him against an obstacle if
torque suddenly increases. When positioned properly,
an increase in torque will PULL the handle and control
out of the operator’s hand and stop the machine (See
illustrations below).
IMPORTANT: Always refer to the manual or the valve
direction decal located on valve handle for correct
operation positions.
SECTION III SET-UPANDOPERATION
CAUTION: The RS-2 is capable of producing up
to 800 ft./lbs. of torque to turn valves. It is very
important that proper procedure be exercised
when using the valve operating machine.
!
!
Operatorshould always changesides foroppositerotation
Valve Key & Socket
Valve Operator
Extension Handle
Stop Collar
1” Square DriveAdaptor
Ref.1
Ref.2
Valve KeyOperation

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SECTION III SET-UPANDOPERATION
I. SET UP PROCEDURE
(Universal Handwheel Adapter)
1. Installthe4handwheelfingersonto the RS-2
rotatingdrivehubslotswiththeprovided1/420x1”
sockethead capscrews.
2. Measurethevalvehandwheeltodeterminethe
correctlengthtorquearm requiredtomounttothe
universalhandwheel.Installthetorquearmsusing
theprovidedflathead screws andnuts.
3. Settheassembly overtherisingstemvalve. Center
theopeningoftheuniversalhandwheeladapter
overthe rising stemscrew.
4. Mountthe3 straddle clampsoverthetorquearms
andunderthevalvehandwheelandsecurethe
assemblywiththe 1/213x2”squarehead screwsin
thestraddleclamps.
UniversalHandwheelAdapter Assembly
5. PlacetheRS-2ontotheUniversal hand wheel
adopterbyinsertingthe4drive fingersintothe4
mountingslotsontheUniversalhandwheeladopter.
Inserttheswing bolt assembliesintothe slotsand
tightenthenutstosecure theassembly.
I. SET UP PROCEDURE
(Mounting Dedicated Handwheel
Adaptor Plate)
1. Thededicatedadaptorplatemust be mountedto
risingstemvalvewithU-bolts supplied withyour
dedicatedadaptorplate. Holesmustbedrilledinto
adapterplatetoboltplatetohandwheelspokes.
DedicatedHandwheelAdapterAssembly
2. Aftermountingadapterplate,boltfingersto RS-2
drivehubusingtheslots providedforthispurpose,
locatedonbottomofactuator, using1/420x5/8”
sockethead capscrews.
3. PlaceRS-2onadapter dedicated platesothat
fingersrestinadapter plateslots.
4. Insert“fast-pins”inholes provided tolockactuator
onadapterplate.
NOTE: Center dedicated handwheel plate
hole over center of rising stem screw.
""
""
"
Adapter Plate Drive Fingers
Straddle Clamps
Torque Arms
Drive Fingers
Universal Handwheel
UniversalHandwheelAssembly

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SECTION III SET-UPANDOPERATION
CONTROLS AND COMPONENTS
ELECTRIC RS-2
INTRODUCTION
Itisimpossible to determinehowmuch torque a
valvestemcan take before breaking.Size,age,
condition,tuberculation,and period oftimesince
lastoperation willhavean effecttothis. The
recommendedstart-up procedure foroperatinga
valveisto set theRS-2toits lowest torquesetting.
Forward/Reverse
Switch
ElectricMotor
1/10th Counter
w/ResetButton
Power Head
ResetButton
On/Off
Trigger
High/Low
Torque
Setting
Switch
GFI
GroundFault
Interrupter
!
!LiftingHandles
CAUTION: DO NOT connect or disconnect hoses
to valve operator or power source while power
source is operating.
Universal Handwheel Operation
Dedicated Handwheel Operation
Valve Operator
Extension Handle
Valve Socket Stop Collar
Valve Key Operation
Drive Plate Drive Fingers
Straddle Clamps
Long, Medium, Short Torque Arms
Drive Fingers
Universal Handwheel
1” Drive Adapter

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OPERATING PROCEDURE:
ELECTRIC RS-2
SECTION III SET-UPANDOPERATION
CAUTION:Beforebeginning turningsequence,
know which direction to turn the valve to avoid
breaking the valve stem.
1.Afterplugginginpower cord,pushreset button
onGFIto power up unit.
2.Setspeed control knob to highspeed/low
torquesetting(see illustration below).
3.If the valvedoes not moveineither direction,
switchspeed control tolowspeed/high torque
setting.
Oncethevalvehasstarted turning,returnthe
speedcontrol switch tothehigh speed/low torque
setting.This procedurewillassureyouthat the
machinestopsoperating as soon as anytypeof
obstructionis encounteredorwhen thevalve is
seated.
DURING OPERATION:
Whenoperating a valve,abuild up oftorquecan
befeltby the operator.Whenthis occurs, it is a
signofeither build up ofmaterialin the valve gate
slidesor that the endoftravel is approaching.The
operatorshould change sidesandreverse the
valvedirection for afewturns, doingthiseach
timeresistanceis felt. This methodofexercising
cleansout tuberculinand othercontaminant build
up.The counterwill keeptrack ofhowmanyturns
youhaveputonthevalve.
NOTE: If the motor overload circuit breaker
pops while attempting to free a frozen valve,
reset the circuit breaker by pressing the
reset button and attempt to free the valve
again before switching to the low speed/
high torque setting.
""
""
"
NOTE: More torque will be required to seat,
unseat or clear tuberculin from the valve.
""
""
"
CAUTION: Only use extension cords rated
for 10 AMPS or higher.

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Ì
!
SECTION III SET-UP AND OPERATION
CONTROLS AND COMPONENTS
HYDRAULIC RS-2
INTRODUCTION
It is impossible to determine how much torque a
valve stem can take before breaking. Size, age,
condition, tuberculation, and period of time since
last operation will have an effect to this. The
recommended start-up procedure for operating a
valve is to set the RS-2 to its lowest torque setting.
Lifting Handles
CAUTION: DO NOT connect or disconnect hoses
to valve operator or power source while power
source is operating.
Supply Inlet
Torque Control Knob
Torque Gauge
Hydraulic Motor
1/10th Counter
w/Reset Button
Power Head
Universal Handwheel Operation
Dedicated Handwheel Operation
Valve Operator
Extension Handle
Valve Socket Stop Collar
Valve Key Operation
Drive Plate Drive Fingers
Straddle Clamps
Long, Medium, Short Torque Arms
Drive Fingers
Universal Handwheel
1” Drive Adapter
Forward/Reverse
Lever

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Ì
!
SECTION III SET-UP AND OPERATION
CAUTION: Before beginning turning sequence,
know which direction to turn the valve to avoid
breaking the valve stem.
1. Rotate torque control knob counterclockwise
to the lowest torque setting.
2. Engage the “power on” handle in either forward
or reverse direction. If valve does not turn, release
handle and engage in the opposite direction.
3. Continue this process, increasing the torque value
1/2 turn on the torque control until valve stem
breaks free. This method ensures that only enough
torque is supplied to turn the valve. Once the valve
has started turning, reduce the torque setting to the
lowest setting which will keep the machine operat-
ing. This procedure assures you that the machine
will stop operating as soon as any type of obstruc
tion is encountered or valve begins to seat.
DURING OPERATION:
When operating a valve, a build up of torque can be
felt by the operator. When this occurs, it is a sign of
either build up of material in the valve gate slides or
that the end of travel is approaching. The operator
should change sides and reverse the valve direction
for a few turns, doing this each time resistance is felt.
This method of exercising cleans out tuberculin and
other contaminant build up. The counter will keep track
of how many turns you have put on the valve.
""
""
"NOTE: When lever is depressed, torque
indicator will read the torque value being
applied to valve stem.
NOTE: More torque will be required to seat,
unseat or clear tuberculin from the valve.
""
""
"
OPERATING PROCEDURE:
HYDRULIC RS-2

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CONTROLS AND COMPONENTS
PNEUMATIC RS-2
INTRODUCTION
It is impossible to determine how much torque a
valve stem can take before breaking. Size, age,
condition, tuberculation, and period of time since
last operation will have an effect to this. The
recommended start-up procedure for operating a
valve is to set the RS-2 to its lowest torque setting.
SECTION III SET-UP AND OPERATION
Ì
!
Lifting Handles
CAUTION: DO NOT connect or disconnect hoses
to valve operator or power source while power
source is operating.
Air Inlet
Torque Gauge
Forward/Reverse
Ring
1/10th Counter
w/Reset Button
Power Head
Torque Adjustment Universal Handwheel Operation
Dedicated Handwheel Operation
Valve Operator
Extension Handle
Valve Socket Stop Collar
Valve Key Operation
Drive Plate Drive Fingers
Straddle Clamps
Long, Medium, Short Torque Arms
Drive Fingers
Universal Handwheel
1” Drive Adapter
On/Off
Trigger
Pneumatic Motor

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SECTION III SET-UP AND OPERATION
1. Rotate torque control knob counterclock wise to the
lowest torque setting
2. Press the power on lever in either forward or re-
verse direction. If valve does not turn, release lever
and rotate motor direction ring on motor body and
repeat procedure.
3.Continue this process, increasing the torque value
1/4 turn on the torque control until valve stem breaks
free. This method ensures that only enough torque
is supplied to turn the valve. Once the valve has
started turning, reduce the torque setting to the
lowest setting which will keep the machine operat-
ing. This procedure assures you that the machine
will stop operation as soon as any type of obstruc-
tion is encountered or valve begins to seat.
NOTE:
1. More torque will be required to seat, unseat
or clear tuberculin from the valve.
2. Maximum torque cut-off can be reset by
free running RS-2 with no load and
adjusting torque control until torque indicator
gauge reads desired torque cut-off.
""
""
"
OPERATING PROCEDURE:
PNEUMATIC RS-2
""
""
"NOTE: When lever is depressed, torque
indicator will read the torque value being
applied to valve stem.
CAUTION: RS-2 Must be used with an inline
filtration system to stop water and air borne
contaminents. FAILURE TO COMPLY WILL
DAMAGE MOTOR AND VOID WARRANTY.
Ì
!
DURING OPERATION
When operating a valve, a build up of torque can
be felt by the operator. When this occurs, it is a
sign of either build up of material in the valve gate
slides or that the end of travel is approaching. The
operator should change sides and reverse the
valve direction for a few turns, doing this each time
resistance is felt. This method of exercising cleans
out tuberculin and other contaminant build up. The
counter will keep track of how many turns you have
put on the valve.
USE OF AIR LINE OIL:
An in-line oiling system should be utilized when
operating the pneumatic Pow-R-Drive II to lubricate
motor on a continuous basis.
When continuous load and high torque settings
are required, the use of an antifreeze oil to
lubricate the motor will reduce ice buildup and
maintain motor performance. (Kilfrost Anti-
Freeze Solution, Wachs Part No. 02-403-00)

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SECTION III SET-UP AND OPERATION
TWO OPERATOR OPERATION:
An extension handle is provided with each
RS-2. It is designed to be inserted into the end
of the handle assembly near the powerhead.
A convenient quick release pin attached to the
extension handle is inserted through the handle
and extension to secure them.
An extension handle should be used when the
torque required to turn a valve is more than one
operator can control easily.
The second operator should stand on the
opposite side of the RS-2 as the primary
operator. (see photograph) The torque should
be pulling the machine handle away from both
the secondary and primary operator.

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Section IV
Charts & Schematics

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SECTION IV CHARTS & SCHEMATIC
EIBENSTOCK MOTOR SWITCH SCHEMATIC
REVOLUTION COUNTER CONNECTION

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Torque Charts
SECTION IV CHARTS & SCHEMATIC

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Section V
Bill of Materials