Wachs ERV-750 User manual

ERV-750 Extended Reach
Valve Operator
User’s Manual
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.
E.H. Wachs
600 Knightsbridge Parkway
Lincolnshire, IL 60069
www.ehwachs.com
E.H. Wachs Part No. 79-MAN-01
Rev. 3-0409, April 2009
Revision History:
Original January 2008
Rev. 1 February 2008
Rev. 2 December 2008
Rev. 3 April 2009

ERV-750 Extended Reach Valve Operator
Part No. 79-MAN-01, Rev. 3-0409 E.H. Wachs

Table of Contents
E.H. Wachs Part No. 79-MAN-01, Rev. 3-0409 i
Table of Contents
Chapter 1: About the ERV-750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
How to Use The Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Symbols and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Manual Updates and Revision Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Connecting the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installing the ERV-750 on Existing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 2: Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Protective Equipment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Chapter 3: Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Setting Up the Valve Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Performing the Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Starting the Vitals Data Logging Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Running the Wachs Controller Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Chapter 4: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Chapter 5: Parts List and Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Return Goods Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Layout Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

ERV-750 Extended Reach Valve Operator
ii Part No. 79-MAN-01, Rev. 3-0409 E.H. Wachs
Parts Lists and Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Mechanical Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Chapter 1, About the ERV-750
E.H. Wachs Part No. 79-MAN-01, Rev. 3-0409 1
Chapter 1
About the ERV-750
PURPOSE OF THIS MANUAL
This manual explains how to operate and maintain the
ERV-750 extended reach valve operator. It includes instruc-
tions for set-up, operation, and maintenance. It also con-
tains parts lists and diagrams to help you order replacement
parts and perform user-serviceable repairs.
HOW TO USE THE MANUAL
Throughoutthismanual,refer
to this column for warnings,
cautions, and notices with
supplementary information.
This manual is organized to help you quickly find the infor-
mation you need. Each chapter describes a specific topic on
using or maintaining the equipment.
Each page is designed with two columns. Thislarge 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-
tions. Refer to it 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 in the out-
side column of the page, next to the section they refer to.
In This Chapter
PURPOSE OF THIS MANUAL
HOW TO USE THE MANUAL
SYMBOLS AND WARNINGS
MANUAL UPDATES AND
REVISION TRACKING
EQUIPMENT DESCRIPTION
INSTALLING THE ERV-750 ON
EXISTING EQUIPMENT

ERV-750 Extended Reach Valve Operator
2 Part No. 79-MAN-01, Rev. 3-0409 E.H. Wachs
Make sure you understand what each symbol means, and
follow all instructions for cautions and warnings.
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 alert with the
safety alert symbol indicates
a potentially hazardous situa-
tion that could result in
minor or moderate injury.
A CAUTION alert with the
damage alert symbol indi-
cates a situation that will
result in damage to the
equipment.
An IMPORTANT alert with
the damage alert symbol indi-
cates a situation that may
result in damage to the
equipment.
A NOTE provides supple-
mentary information or oper-
ating tips.
WARNING
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.
CAUTION
CAUTION
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.
IMPORTANT
NOTE
NOTE
This symbol indicates a user note. Notes
provide additional information to supple-
ment the instructions, or tips for easier
operation.

Chapter 1, About the ERV-750: Manual Updates and Revision Tracking
E.H. Wachs Part No. 79-MAN-01, Rev. 3-0409 3
MANUAL UPDATES AND REVISION TRACKING
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
[email protected].
Occasionally, we will update manuals with improved opera-
tion or maintenance procedures, or with corrections if nec-
essary. Revised manuals will be available for customers.
When a manual is revised, we will update the revision his-
tory on the title page and at the bottom of the pages.
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 we return the equipment to you.
EQUIPMENT DESCRIPTION
The ERV-750 is an automated, medium-duty valve operator
mounted on an extension arm to reach valves up to 13 feet
from the pedestal mount. With the ERV-750 mounted on
your truck or utility trailer, you can reach many valves when
parked curbside. It operates on hydraulic power, using a
ruggedized, computer-based controller that can store and
transfer valve operation data.
The standard configuration is provided on a Wachs Swivel-
Vac heavy-duty trailer; the system’s components can also be
mounted on a truck or pickup bed with the optional installa-
tion kit.
Specifications
• Operates all valves 6”-60”
• 750 lb-ft maximum torque
• 0-30 rpm
• 13 ft arm (on Swivel Vac trailer, reaches 11 ft to the curb
side and 9 ft to the driver side) with locking extension
• swivel mounting pedestal with position lock
• microprocessor control system
• Vitals Recon controller, a Windows CE-based handheld
pendant with operating and data logging software
• 4-9 ft telescoping valve key (3 ft extensions available)

ERV-750 Extended Reach Valve Operator
4 Part No. 79-MAN-01, Rev. 3-0409 E.H. Wachs
System Components
The following figures illustrate the components of the ERV-
750.
Figure 1-1. The photo shows the ERV-750 mounted
on the Wachs Swivel Vac trailer.
Figure 1-2. The photo illustrates the components of
the ERV-750.
ERV-750
Pedestal
mount
Upper
arm
Lower
arm
Telescoping
extension arm
Head Valve key
adapter

Chapter 1, About the ERV-750: Equipment Description
E.H. Wachs Part No. 79-MAN-01, Rev. 3-0409 5
Figure 1-3. The photo illustrates the ERV-750 head.
Figure 1-4. The ERV-750 controller has a touch-
screen for operation.
Hydraulic
motor Control
pendant
Positioning
handle
Control
connector

Torque—Displays current
operating torque. Touch to
change torque limit
Highest—Displays aximum
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.
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 ERV-750 when
startup is complete).

ERV-750 Extended Reach Valve Operator
6 Part No. 79-MAN-01, Rev. 3-0409 E.H. Wachs
Operation Overview
This section briefly describes the ERV-750 controls. See
Chapter 3 for detailed operating instructions.
1. For an ERV-750 installed on the Swivel Vac trailer,
turn on power to the unit using the switch on the con-
trol box. The engine must be running to power up the
ERV.
Figure 1-5. Push the power switch on the control box
down to turn on power to the ERV-750.
2. When power is enabled to the ERV, brakes in both
swivel joints of the arm lock the arm in its current
location. To move the arm, hold down the brake
release button on the positioning handle and move the
arm to its desired location.

Chapter 1, About the ERV-750: Equipment Description
E.H. Wachs Part No. 79-MAN-01, Rev. 3-0409 7
Figure 1-6. Press and hold the brake release button to
move the arm. When you release the button, the brakes
will re-engage and hold the arm stationary.
NOTE
There are two
holes in the arm
extension for the locking pin,
one at each end. Do not hold
the pin when you are sliding
the extension out. The pin
snaps intothe hole to prevent
the extension from coming all
the way out of the arm.
3. To extend thelength of the telescoping lower arm, turn
the locking knob counter-clockwise and pull out the
locking pin. Pull the arm extension out to the position
you want, then tighten the locking knob to secure it.
When you pull the extension out to the end of travel,
the locking pin will snap into the hole at the end of the
extension.
Figure 1-7. To extend the arm, (A) loosen the locking
knob, (B) pull out the locking pin, and (C) pull the
extension out. When you have the extension at the
desired position, tighten the locking knob (A).
4. To operate the ERV-750, remove the controller from
its storage cradle.
Brake release
button
ABC

ERV-750 Extended Reach Valve Operator
8 Part No. 79-MAN-01, Rev. 3-0409 E.H. Wachs
Connecting the Controller
The ERV-750 controller is connected to the machine with a
specialized cable.
Figure 1-8. The photo shows the controller cable.
Figure 1-9. The ERV-750 controller connections are
shown.
Connector to
ERV-750 head
Serial connector
to ERV controller
Power connector
to ERV controller
USB connector
(for data transfer)
Power connector Serial connector

Chapter 1, About the ERV-750: Installing the ERV-750 on Existing Equipment
E.H. Wachs Part No. 79-MAN-01, Rev. 3-0409 9
Figure 1-10. To connect the controller cable to the
ERV-750 head, unscrew the connector cap and then
screw on the cable connector.
INSTALLING THE ERV-750 ON EXISTING
EQUIPMENT
NOTE
A parts list for the
installation kit is
included in Chapter 5.
You can install the ERV-750 on your truck or trailer. An
installation kit (part number 79-401-00) is provided.
Hydraulic Requirements
Hydraulic system parameters are critical to the proper oper-
ation of the ERV-750. It must be operated by a hydraulic
system with the correct performance.
• PTO driven hydraulic pumps often can deliver pressures
and flows that exceed those required for the ERV-750.
This can result in malfunctions and premature compo-
nent failure.
• A hydraulic system with insufficient flow or pressure
will result in poor performance or logic errors.
The ERV-750 requires the following hydraulic parameters:
Operating Pressure: 1500 -1800 psi
Return Line Pressure: 110 psi max

ERV-750 Extended Reach Valve Operator
10 Part No. 79-MAN-01, Rev. 3-0409 E.H. Wachs
NOTE
Flows greater than
10 gpm require the
use of a pressure compen-
sated flow control valve such
as Prince model #RD-100.
Excess flow must be ported
back to the reservoir.
Hydraulic Flow: 6-10 gallons per minute
Oil Viscosity: ISO Grade 32 or equal, Mobil
DTE 24 or equal
System return line pressure must be kept as low as possible.
Excessive return line pressure will prevent release of the
ERV-750 brakes. If the return hose length for the ERV-750
exceeds four feet, it is recommended that -12 (3/4”) or
larger hose is used.
Installation Instructions
IMPORTANT: The bed or deck of the vehicle must be at
least 1/4” thick at the location where you are mounting the
ERV-750 pedestal.
At least two people should install the ERV-750. One person
will need to hold the machine in place while the other
attaches the fasteners.
The installation kit includes two mounting brackets and a
mounting spacer, illustrated in Figure 1-11. If possible, it is
preferable to attach the mounting brackets to a beam or
channel on the underside of the vehicle bed. This beam must
be 3” wide to properly space the mounting brackets. If you
mount the brackets in this way, you will omit the spacer.
Figure 1-11. The spacer (1) can be omitted if there is
a 3” beam or channel on the underside of the deck
where you can attach the mounting brackets (2).
1. Set the pedestal of the ERV-750 base at the location
you want to install it on the equipment.

Chapter 1, About the ERV-750: Installing the ERV-750 on Existing Equipment
E.H. Wachs Part No. 79-MAN-01, Rev. 3-0409 11
2. Mark the location of the 4 holes in the ERV-750 base.
Make sure you can drill into the equipment at these
locations without causing damage to the equipment.
3. Refer to Figure 1-12 for dimensions and hole sizes.
Measure the locations for the arm latch holes and
make sure you can drill into the equipment there.
Figure 1-12. The drawing shows the top-view layout
for mounting the ERV-750 on a vehicle.
4. Remove the ERV-750 and drill the four hole locations
using a 5/8” drill.
5. Measure the locations for the two holes for the arm
latch, as shown in Figure 1-12. Drill the two holes
using a 3/8” drill.
6. Assemble the two mounting brackets and the mount-
ing spacer as shown in Figure 1-13.
ERV-750
pedestal
Arm latch

ERV-750 Extended Reach Valve Operator
12 Part No. 79-MAN-01, Rev. 3-0409 E.H. Wachs
Figure 1-13. Attach the two mounting brackets (2) to
the mounting spacer (1) using the two 1/2”-13 x 4.5”
HHCS (9) provided with the mounting kit.
7. Set the ERV-750 base in place and insert the four 1/2”-
13 x 2.25” HHCS through the pedestal and the drilled
holes.
8. Position the mounting bracket assembly under the
vehicle bed so that the four bolts go through the holes
in the mounting brackets, as shown in Figure 1-14.
Figure 1-14. Insert the four 1/2”-13 x 2.25 HHCS
(10) through the ERV-750 pedestal, the vehicle deck,
and then through the holes in the mounting bracket
assembly.
9. Attach the washers and nuts and tighten them securely.

Chapter 1, About the ERV-750: Installing the ERV-750 on Existing Equipment
E.H. Wachs Part No. 79-MAN-01, Rev. 3-0409 13
10.Install the arm latch at the location illustrated above in
Figure 1-12. Insert the fasteners as shown in Figure 1-
15, with the nuts and washers on the underside of the
vehicle deck.
Figure 1-15. Install the arm latch using two 3/8”-16 x
1.75” HHCS (12).
Installation Troubleshooting Tips
Every ERV-750 is factory tested to verify proper operation.
If the ERV-750 is not functioning as expected after you
install it, follow these troubleshooting steps to isolate the
cause.
• Supply hydraulic power from a separate, properly sized
hydraulic unit (ideally, a Wachs TM7 or similar con-
nected to the auxiliary hose connections).
• Reconnect to system hydraulic power. If malfunction
continues, diagnose hydraulic system failure. Install cal-
ibrated gauges to verify system pressures and flow.
Return line pressures must not exceed 25 psig. If neces-
sary, route a dedicated return line from the ERV-750 to
the hydraulic reservoir, or increase hose size.
• Routing a temporary return line to an empty oil drum
will verify brake release with low return line pressure.

ERV-750 Extended Reach Valve Operator
14 Part No. 79-MAN-01, Rev. 3-0409 E.H. Wachs

Chapter 2, Safety
E.H. Wachs 79-MAN-01 15
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-750.
It contains important safety instructions and recommenda-
tions.
OPERATOR SAFETY
Follow these guidelines for safe operation of the equip-
ment.
Look for this sym-
bol throughout the
manual.Itindicates
a personal injury
hazard.
•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 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 Company.
•KEEP CLEAR OF MOVING PARTS. Keep hands,
arms, and fingers clear of all rotating or moving parts.
In This Chapter
OPERATOR SAFETY

ERV-750 Extended Reach Valve Operator
16 79-MAN-01 E.H.Wachs
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.
•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
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.
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.
NOTICE
This alert indicates a situation that, if not avoided, will
result in damage to the equipment.