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BADGER FAMILY SELF ROTARY SWIVELS USER MANUAL *EXCLUDES BA-H6 4” 40K MODEL 2 INCH 6 INCH 4 INCH PL 663 REV B (05/2018) TABLE OF CONTENTS .MANUFACTURER’S INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIFICATIONS FOR ALL MODELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 KEY FEATURES FOR ALL MODELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL JETTING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2” BADGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TOOL DESCRIPTION AND INTENDED USE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TOOL SERVICE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ASSEMBLY AND PARTS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4” BADGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 TOOL DESCRIPTION AND INTENDED USE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 WARNING AND SAFETY INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 TOOL SERVICE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 FLUID REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 PART NAMES/NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 SERVICE KITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 6” BADGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 TOOL DESCRIPTION AND INTENDED USE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 WARNING AND SAFETY INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 TOOL SERVICE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 FLUID REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 PART NAMES/NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 SERVICE KITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 TERMS AND CONDITIONS AND WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 This manual must be used in accordance with all applicable national laws. The manual shall be regarded as a part of the machine and shall be kept for reference until the final dismantling of the machine, as defined by applicable national law(s). 2 866-795-1586 • WWW. SEWERNOZZLES.COM MANUFACTURER’S INFORMATION StoneAge Inc. 466 S. Skylane Drive Durango, CO 81303, USA Phone: 970-259-2869 Toll Free: 866-795-1586 www.stoneagetools.com StoneAge Europe Unit 2, Britannia Business Centre Britannia Way Malvern WR14 1GZ United Kingdom Phone: +44 (0) 1684 892065 Badger Model Specifications Tool Size Tool Model Number Pressure Range Flow Range Inlet Connection Weight Rotation Speed Max Water Temperature BA-LK-P4 BA-LK-BSPP4 2–15k psi 140–1000 bar 3–20 gpm 11–76 l/min 1/4 NPT or 1/4 BSPP 0.45 lb 0.20 kg High Speed 250 ºF 120 ºC BA-LK-MP9L BA-LK-MP9R 12–22k psi 830–1500 bar 3–15 gpm 11–57 l/min 9/16 MP or M24 0.45 lb 0.20 kg High Speed 250 ºF 120 ºC BA-P6 BA-BSPP6 2–15k psi 140–1000 bar 13–30 gpm 49–110 l/min 3/8 NPT 3/8 BSPP 3.0 lbs 1.4 kg 20-100 rpm (Slow Fluid) 75-250 rpm (Fast Fluid) 250 ºF 120 ºC BA-TM12 12–22k psi 830–1500 bar 12–25 gpm 45–95 l/min 3/4 Type M Male 3.0 lbs 1.4 kg 20–100 rpm (Slow Fluid) 75–250 rpm (Fast Fluid) 250 ºF 120 ºC BA-H6 (Not included in this manual) 44k psi 3000 bar 4.5–12 gpm 17–45.5 l/min 3/8 HP Female 4.0 lbs 1.8 kg 100–400 rpm 250 ºF 120 ºC BA-MP9 BA-M24 12–22k psi 840–1500 bar 14–43 gpm 53–163 l/min 9/16 MP or M24 8.0 lbs 3.6 kg 50–300 rpm (Adjustable) 250 ºF 120 ºC BA-P8 2–15k psi 140–1000 bar 15–55 gpm 57–208 l/min 1/2 NPT 8.0 lbs 3.6 kg 50–300 rpm (Adjustable) 250 ºF 120 ºC 2” 4” 6” Badger Model Features 2” 4” 6” • The only self-rotary tool on the market that can navigate 2 in. (50 mm) pipes with bends and comes with head locking technology for increased safety • Multiple jetting options allow the tool to be optimized for a variety of pump pressures and flows - unplug, polish, or run longer lines based on jetting • Optional fairing available to streamline tool during retrieval • • • • Different jetting configurations allow for more or less pull and forward hitting power Navigates elbows as small as 4 in. (102 mm) at up to 43.5k psi (3000 bar) Self-rotary, speed controlled head provides complete internal coverage with optimum jet delivery Two speeds to choose from to maximize cleaning by choosing slower speeds for hard to clean or plugged pipes, and faster speeds for polishing easy to clean pipes with a single tool • Multiple jetting options optimize the tool for a variety of pumps pressures and flows - unplug, polish, or run longer lines based on jetting • Designed to easily pair with the AutoBox ABX-500 hose tractor for hands-free pipe cleaning. • Only rotary pipe cleaning tool on the market with adjustable speed control for fine-tuning to specific requirements • Different jetting configurations allow for more or less pull and forward hitting power and optimize the tool for a variety of pumps pressures and flows. • Navigates elbows as small as 6 in. (152 mm) • Speed controlled rotary tools provide complete internal coverage with optimum jet delivery • Maximize cleaning by choosing slower speeds for hard to clean or plugged pipes, and faster speeds for polishing easy to clean pipes with a single tool • Centralizer options for larger pipe sizes available 866-795-1586 • WWW.SEWERNOZZLES.COM 3 GENERAL JETTING INFORMATION DETERMINING JET SIZES: Badger tools come from the factory with installed nozzles, selected based on customer pressure and flow requirements. Jet thrust is used to pull the tool through the pipe. An estimate of the amount of pulling force required is useful and depends on the number of elbows and any vertical climbs that must be made. On a horizontal run with no elbows, 1 pound of pull is required for every ten feet. When climbing vertically, the pulling force must equal the weight of the tool and the hose. Typically, larger jet sizes using 50 to 80 percent of the total flow are used in the back ports. As little as 10 percent of the total flow is given to the front jet, because it pushes the wrong direction and is only used to open up blockages. The remaining flow goes to the side ports, which help pull as well as clean. Jetting assistance is available on our jetting app at: http://jetting.stoneagetools.com or through one of our StoneAge customer service reps at 1-866-795-1586. See the “Assembly” section of this manual for instructions on to how to install new nozzles. 4 866-795-1586 • WWW. SEWERNOZZLES.COM 2” BADGER TOOL DESCRIPTION AND INTENDED USE 2” BADGER MODELS DESCRIPTION AND INTENDED USE The BA-LK-P4 / BA-LK-BSPP4 / BA-LK-MP6R / BA-LK-MP9L / BA-LK-MP9R is a self-rotating swivel designed for cleaning 2” to 4” tubes and pipes with bends and long radius elbows, such as U-Tubes and process lines. The P4 and BSPP4 tools can be used at operating pressures up to 15,000 psi (1035 bar) and the MP6R, MP9L and MP9R tools at up to 22,000 psi (1500 bar). The P4 and BSPP4 have either a 1/4” NPT or 1/4” BSPP female pipe thread inlet. If a standard 1/4” NPT or BSPP hose end is used, they can pass through elbows in 3” and larger pipe. If using the tool in 2” pipe a special shorter hose end is required to allow tool to travel through elbows. Contact StoneAge for more information on the hose requirements. The MP6R tool has a 3/8” female right-hand medium pressure inlet. The MP9L tool has a 9/16” female left-hand medium pressure inlet and the MP9R has a 9/16” female right-hand medium pressure inlet. The tools do not use any bearings, seals, or lubricating fluid. Rotation is powered by the jet thrust. The nozzle inserts used in the head determine the flow rate and the pulling force. *An OPTIONAL BA 530 Fairing Assembly is available for all 2” Badger models when using hose sizes up to 6mm. The fairing is designed to be attached to the back of the 2” Badger to help prevent the rear edge of the tool from getting caught on obstructions during withdrawal from tubes or pipes. BA 530 FAIRING 866-795-1586 • WWW.SEWERNOZZLES.COM 5 2” BADGER OPERATION NOTICE The most important items in maintaining the Badger tool; - Keep debris from entering the tool and preventing it from rotating by flushing high pressure hoses before use. OPERATION • Make sure the operator has a controlled dump in the system and it is operated by the person closest to the job. Test the dump prior to beginning the job. • Flush out the high pressure hoses before connecting the Badger to eliminate debris. • Attach tool to the end of the hose. Use Parker Thread Mate and Teflon tape on all pipe thread connections (P4, BSPP4); use anti-seize on all straight thread connections (MP6R, MP9L, MP9R) to the swivel inlet. • The 2” Badger has a large O-Ring (WV 008) around the inlet. This O-Ring helps prevent the tool from getting caught on the rear edge when pulling the tool back out of the line. An optional Fairing Assembly (BA 530) will also help prevent snagging during tool removal. BA 530 FAIRING • It is recommended that the hose be marked a few feet from the end with a piece of tape so the operator knows when to stop on the way back out. • Position the tool in the pipe opening. • Close the dump and slowly bring the pump up to pressure the first time to make sure no nozzles are plugged and the jet thrust is correct. The Badger™ should begin to slowly rotate. • Once operating pressure is reached, feed the tool into the pipe to begin the cleaning job. • Allow the jets time to do their work by feeding the hose out at a controlled rate. • 2” BADGER ONLY- After the Badger is removed from the hose, blow out water with compressed air and spray a light oil such as WD-40 into the tool. WARNING If the 2” BADGER is being used in pipes larger than 4 inch diameter, a rigid stinger should be installed between the tool inlet and the hose end; otherwise the tool can turn around and come back toward the operator, causing serious injury or death. Operations with this equipment can be potentially hazardous. Caution must be exercised prior to and during machine and water jet tool use. Please read and follow all of these instructions, in addition to the guidelines in the WJTA Recommended Practices handbook, available online at www.wjta.org. Deviating from safety instructions and recommended practices can lead to severe injury and/or death. 6 866-795-1586 • WWW. SEWERNOZZLES.COM 2” BADGER TROUBLESHOOTING HEAD WILL NOT ROTATE: • First, make sure the head (BA 044-LK) is still tightened into the shaft (BA 501-LK). A safety feature built into the shaft stops the tool from rotating if the head comes loose. • If the head isn’t loose, try spraying a light oil such as WD-40 into the tool and rotate head by hand until it turns freely again. • Make sure that the jets in the head are not plugged. • If the tool still does not rotate after trying the steps above, it may need to be disassembled and cleaned on the inside. To do this requires a spanner wrench (available in StoneAge Tool Kit BA-P4 612) inserted into the rear of the shaft to remove the head from the shaft. Begin by removing the O-ring (WV 008) and the Retaining Ring (WV 010). Pull the Inlet Nut (BA 002-P4,-BSPP4,BA 502-MP9L,BA 502-MP9R) out of the Body (BA 503). Using a spanner wrench, unscrew the Shaft (BA 501) from the Head (BA 044). Make sure the two small holes in the side of the shaft are cleaned out; debris plugging these holes is the most likely cause of the tool not rotating. If the outside of the shaft is badly worn, it needs to be replaced. • See the “2” Badger Tool Service Information”and the “2” Badger Assembly and Parts” pages in this manual for more detailed information about service. 866-795-1586 • WWW.SEWERNOZZLES.COM 7 2” BADGER TOOL SERVICE INFORMATION TOOL SERVICE ***Product training and proper tools are required to service this nozzle. If you are uncomfortable performing the service, bring the nozzle to your authorized dealer.* The use of a bench vice is highly helpful. Take care throughout the entire procedure to keep the internals clean and free from grit, lint, and contamination. Failure to do so could result in premature failure after service. BA 182 Head removal tool LIST OF TOOLS: • Bench Vice (recommended) • 7/8”socket • 3/8” drive torque wrench • BA 612-LK Tool Kit (For 2” Badger Includes) BA 182 Head Removal Tool WV 181 Spanner Wrench LIST OF MATERIALS: • Clean lint free rags or blue shop towels • BA 185 Red Loctite® 262 WV 181 Spanner wrench NOZZLES The nozzle head has forward jets at 15º, 30º, 45º, two side jets at 90º, and two back jets at 132º.StoneAge recommends replacing the entire head assembly with the nozzles installed at the factory. ASSEMBLY If assembling tool, apply 2-4 drops of Loctite #262 Red (StoneAge p/n BA 185) around the circumference of the threads on the Head prior to screwing it into the Shaft. Care must be taken NOT to allow into the internal shaft bore below the female threads or onto the tapered external surface of the shaft. Torque to 100 in-lbs using 7/8” socket on the spanner wrench (available from StoneAge as p/n WV 181). Also replace Retaining Ring (WV 010) with a new one during each reassembly. If you do not have the required tools or you are not confident in performing these procedures please send the tools back to StoneAge for maintenance and repairs. WD-40® is a registered trademark of the WD-40 Corporation. Parker Threadmate™ is a registered trademark of Parker Hannifin Corporation. 8 866-795-1586 • WWW. SEWERNOZZLES.COM 2” BADGER ASSEMBLY AND PARTS Part Diagram Nozzle Locations 15º 30º OD3M XXX Nozzle (7) 45º DO NOT REMOVE SET SCREW 90º 90º BA 546-LK Head Assy BA 503 Body BA 501-LK Shaft BA 002-P4 (15k) or BA 002-BSPP4 (15K) or BA 502-MP6R (22K) or BA 502-MP6L (22K) or BA 502-MP9R (22K) Inlet Nut 2 x 132º 7 Ports: 1 @ 15º 1 @ 30º 1 @ 45º 2 @ 90º 2 @ 132º Accessories GP 200-BSPP4 Copper Seal Ring .250 REQUIRED FOR BSPP INLETS ONLY *Optional BA 530 Fairing WV 010 Retaining Ring WV 008 O-Ring 866-795-1586 • WWW.SEWERNOZZLES.COM 9 4” BADGER TOOL DESCRIPTION AND INTENDED USE 4” BADGER MODELS DESCRIPTION AND INTENDED USE The Badger™ Rotary Waterblast Nozzle was designed for waterblast cleaning of pipes as small as 4 inch with elbows. The BA-P6 has a 3/8 NPT female inlet connection and a maximum operating pressure of 15,000 psi (1035 bar). The BA-BSPP6 has a 3/8 BSPP female inlet connection and a maximum operating pressure of 15,000 psi (1035 bar). The BA-TM12 has a 3/4 type M male inlet connection and a maximum operating pressure of 22,000 psi (1500 bar). Two rotation speed ranges are available for each tool; a thick fluid is used for rotation speeds of 20 to 100 rpm, and a thinner fluid is used for rotation speeds of 75 to 250 rpm. The fluid in the swivel can be changed to provide either fast or slow rotation. The Badger™ heads have 1/8 NPT ports; one at 15 degrees, two at 100 degrees, and two at 135 degrees. Engraved on each head is R16 or R22; this number is the offset of the head that makes it rotate. The flow range for each head is given in the table; nozzle sizes must be selected to fit within this flow range. If the flow is less than the range shown, the tool will not rotate; if it is more than the allowable the tool will rotate too fast and wear out the seals and bearings. 4” BADGER FLOW RANGE PER HEAD OFFSET CHART PRESSURE 10 R22 R16 10,000 PSI (690 bar) 13-21 GPM (50-80 l/min) 20-30 GPM (76-114 l/min) 15,000 PSI (1035 bar) 13-17 GPM (50-65 l/min) 18-30 GPM (68-114 l/min) 22,000 PSI (1500 bar) 12-18 GPM (45-68 l/min) 15-25 GPM (57-95 l/min) 866-795-1586 • WWW. SEWERNOZZLES.COM 4” BADGER WARNING AND SAFETY INSTRUCTIONS WARNING Because of the short length of the Badger, the tool can turn around in large pipes and come back at the operator at a high rate of speed. If cleaning larger pipes, a rigid “stinger” should be used between the hose and the tool. It is recommended that the rigid length of the tool including hose end is 1-1/2 times the inside diameter of the pipe being cleaned (see below). Make sure there is an operator controlled dump in the system, operated by the person closest to the cleaning job. Flush out the high pressure hoses before connecting the Badger. It is recommended that the hose be marked a few feet from the end with a piece of tape so the operator knows when to stop when retracting the tool. Position the tool in the pipe opening. Close the dump and slowly bring up to pressure the first time to make sure no nozzles are plugged and the jet thrust is correct. The Badger should begin to slowly rotate. Once operating pressure is reached, feed the tool into the pipe to begin the cleaning job. Allow the jets time to do their work by feeding the hose out at a controlled rate. The StoneAge ABX-500 Hose Control Device can be used to achieve consistent feed rates for pipe cleaning. When the work is complete and the tool is connected from the hose, blow out all water to prolong the life of the tool. A small amount of oil can be blown into the tool as well as an added measure to maximize tool life. Operations with this equipment can be potentially hazardous. Caution must be exercised prior to and during machine and water jet tool use. Please read and follow all of these instructions, in addition to the guidelines in the WJTA Recommended Practices handbook, available online at www.wjta.org. Deviating from safety instructions and recommended practices can lead to severe injury and/or death. IMPROPER USE: Badger will turn around in large diameter pipe VERY DANGEROUS! 866-795-1586 • WWW.SEWERNOZZLES.COM PROPER USE: Badger with rigid “stinger” to prevent turnaround, still able to pass through elbows. 11 4” BADGER OPERATION OPERATION: • Make sure the operator has a controlled dump in the system and it is operated by the person closest to the job. Test the dump prior to beginning the job. • Flush out the high pressure hoses before connecting the Badger™ to eliminate debris. NOTICE The two most important items in maintaining the Badger tools; - Keep debris from entering the tool and preventing it from rotating by flushing high pressure hoses before use. - Keep the 4” and 6” models full of viscous fluid to maintain control and rotation speed. When the viscous fluid is lost or contaminated, the rotation speed of the tool will increase, which reduce the life of the high pressure seal and bearing. • Attach tool to the end of the hose. • It is recommended that the hose be marked a few feet from the end with a piece of tape so the operator knows when to stop on the way back out. • Position the tool in the pipe opening. • Close the dump and slowly bring the pump up to pressure the first time to make sure no nozzles are plugged and the jet thrust is correct. The Badger should begin to slowly rotate. • Once operating pressure is reached, feed the tool into the pipe to begin the cleaning job. • Allow the jets time to do their work by feeding the hose out at a controlled rate. • When the work is complete and the tool is disconnected from the hose, blow out all water to prolong the life of the tool. • 4” & 6” BADGERS ONLY- A small amount of 3-IN-ONE or equivalent lubricant can be blown into the tool as well. 12 866-795-1586 • WWW. SEWERNOZZLES.COM 4” BADGER TROUBLESHOOTING HIGH-PRESSURE WATER SEALS LEAK: • The high pressure seal may leak initially at lower pressures, but should pop closed as pressure is increased. A continuous leak at operating pressure from the weep holes indicates the need to replace the HP Seal and Seat. HP Seals wearing out too quickly can be an indication that the shaft bore is worn, the HP Seat is installed upside-down, or the tool is over spinning. Over spinning is caused by low or contaminated viscous fluid, water in the fluid chamber (replace shaft seals), or too much jet torque. Refilling the viscous fluid every 30-40 hours of operation is important for proper speed control. Only use StoneAge recommended viscous fluid. TOOL WILL NOT ROTATE: • Check the nozzles for plugging or wear (nozzles have to be removed to check for obstructions), Check that the nozzle sizes are correct for the desired flow and that the desired flow matches the head flow range. Check that the nozzle sizes are installed in a balanced configuration. If the tool feels rough when manually rotating the head, this indicates internal damage. Replace bearings, shaft seals, viscous fluid, and check the Inner and Outer Discs for flatness. These discs can be deformed if tool is reassembled when discs are not properly aligned with BA 018 Pins. TOOL SPINS TOO FAST: • A significant increase in rotation speed means that the speed control mechanism in the tool has lost functionality. This can be a result of viscous fluid loss or fluid contamination. Operation of the tool in this state can cause damage to other components and accelerated wear of the high pressure seal. If this occurs, the first step is to flush the tool with new viscous fluid as shown in Figure 12. LOCK-UP TROUBLESHOOTING TIP: • Rotate in reverse 1 1/4 to 1 1/2 turns to unlock braking mechanism. If tool rotates smoothly then redress may not be required. • If the head rotates freely by hand, check the jet sizes and calculate pressure loss through the coil tubing and check with your distributor or StoneAge® to make certain there is enough jet torque to provide rotation. • Verify jetting at http://jetting.stoneagetools.com/#/, contact your factory authorized Warthog® dealer or contact StoneAge®, Inc. WEEP HOLES Figure 12 866-795-1586 • WWW.SEWERNOZZLES.COM 13 4” BADGER TOOL SERVICE INFORMATION TOOL SERVICE ***Product training and proper tools are required to service this nozzle. If you are uncomfortable performing the service, bring the nozzle to your authorized dealer.* The use of a bench vice and an arbor press is highly helpful. Take care throughout the entire procedure to keep the internals clean and free from grit, lint, and contamination. Failure to do so could result in premature failure after service. LIST OF TOOLS: • • • • • • • Bench Vice (recommended) Arbor Press (recommended) 18” Adjustable Wrench (such as Crescent® C718 Automatic Adjustable Pipe Wrench) Medium size flat-head screw driver Pick Bearing Splitter 3/8 Drive Ratchet with 3” Extension • BA 612 Tool Kit (For 4” Badger Includes) BA 100 Retaining Ring Pliers BA 105 Seal Press Tool LIST OF MATERIALS: • • • • • Clean lint free rags or blue shop towels Anti-Seize - StoneAge PN (GP 043 Blue Goop) Lithium Soap Grease – StoneAge PN (GP 048 Grease) Blue Loctite® 242 Isopropyl Alcohol or Denatured Alcohol WD-40® is a registered trademark of the WD-40 Corporation. Parker Threadmate™ is a registered trademark of Parker Hannifin Corporation. 14 866-795-1586 • WWW. SEWERNOZZLES.COM 4” BADGER FLUID REPLACEMENT VISCOUS FLUID FLUSH INSTRUCTIONS (4” BADGER) 1. Remove the Port Plugs (BJ 026) in the Nut (BA 002) and Head (BA 040-RXX) (see Figure 1). 2. Fill the Syringe (BC 410) with viscous fluid by removing the end near the handle, pulling out the plunger, and pouring the Viscous Fluid (BJ 048-F) in to fill the Syringe Body. With plunger re-installed, purge air out of Syringe hose. 3. Thread the syringe end into the port in the Head, and squeeze fresh Viscous Fluid in until clean Viscous Fluid comes out the port in the Nut. Hold the tool so the port in the Nut is the highest point. If air bubbles come out of the port on the nut, keep flushing new fluid until air bubbles stop. 4. Install Port Plug into Nut first. Remove the Syringe and install the Port Plug in the Head. BJ 026 Port Plug (In Nut) BA 002 Nut (1) BJ 026 Port Plug (In Head) BC 410 Syringe BA 040-RXX Head (15kpsi) or BA 240-RXX Head (22kpsi) Figure 1: Viscous Fluid Flush 866-795-1586 • WWW.SEWERNOZZLES.COM 15 4” BADGER DISASSEMBLY DISASSEMBLY 1. Unscrew the Nut (BA 002) from the Head (BA 040/240) 4. Remove Retaining Ring (BA 017) from the shaft. 5. Pull the Discs (BA 015, BA 016) and O-Rings (SM 016) off of the Shaft. 2. Pull the Shaft (BA 001/ BA 001BSPP6/ BA 201) out of the head. BA 002 Nut BA 017 Retaining Ring BA 015 Inner Disc (4) BA 030 Wear Ring BA 016 Outer Disc (3) BA 001/ BA 001-BSPP6/ BA 201 Shaft SM 016 O-Ring (3) BA 040-RXX Head (15kpsi) or BA 240-RXX Head (22kpsi) Figure 3: For Steps 1-2 3. Remove the Seat (RJ 011/RJ 011-KC) and H.P. Seal (RJ 012-TO/RJ 012-KTO) from the bore of the Shaft. RJ 011/ RJ 011-KC Seat RJ 012-TO/ RJ 012-KTO H.P. Seal Figure 4: For Step 3 16 Figure 5: For Step 4-5 866-795-1586 • WWW. SEWERNOZZLES.COM 4” BADGER DISASSEMBLY 6. Press the Bearing (UH 009) off of the Shaft. 10. Remove the Port Plug (BJ 026) from the Head. 7. There is no need to remove the Pins (BA 018) from the Shaft; however, if they fall out do not lose them. 11. Remove the Shaft Seal (BA 006) and O-Ring (WG 008) if they are damaged. BA 018 Pins (2) 12. There is no need to remove the Pins (BA 018); however, if they fall out, do not lose them. WG 008 O-Ring BA 001/ BA 001-BSPP6/ BA 201 Shaft BA 006 Shaft Seal BA 018 Pins (2) BA 040-RXX Head (15kpsi) or BA 240-RXX Head (22kpsi) UH 009 Bearing Figure 6: For Steps 6-7 BJ 062 Port Plug 8. Remove the Shaft Seal (BA 007) if it is damaged. Figure 8: For Steps 10-12 9. Remove the Port Plug (BJ 026) from the Nut. BA 007 Shaft Seal BA 002 Nut BJ 062 Port Plug Figure 7: For Steps 8-9 866-795-1586 • WWW.SEWERNOZZLES.COM 17 4” BADGER ASSEMBLY ASSEMBLY 1. Press Bearing (UH 009) onto Shaft (BA 001 / BA 001-BSPP6) BA 017 Retaining Ring 2. Check that Pins (BA 018) are installed in Shaft. BA 018 Pins (2) BA 001/ BA 001-BSPP6/ BA 201 Shaft UH 009 Bearing BA 016 Outer Disc (3) Figure 9: For Steps 1-2 Insert Pins just far enough to clear groove for retaining ring SM 016 O-Ring (3) BA 015 Inner Disc (4) .380 3. Place an Inner Disc (BA 015) on Shaft, aligning with pins. 4. Place an O-Ring (SM 016) on top of this Disc, stretched around Pins. 5. Place an Outer Disc (BA 016) on top of this. 6. Repeat these steps until there are three Outer Discs and four Inner Discs on the Shaft. 7. Push down on top disc and install the Retaining Ring (BA 017) in the groove around the Shaft. Figure 10: For Step 3-7 18 866-795-1586 • WWW. SEWERNOZZLES.COM 4” BADGER ASSEMBLY 8. Apply grease to and install the H.P. Seal (RJ 012-TO/RJ 012-KTO) in the bore BA 007 Shaft Seal (1) of the Shaft. BA 002 Nut (1) 9. Apply grease to the face of the Seat (RJ 011/RJ 011-KC) and place in bore of Shaft, on top of Seal, as shown. 10. Install Shaft Seals (BA 007 and BA 006) in the Nut (BA 002) and Head (BA 040/240) as shown. 11. Place O-Ring (WG 008) over threads and into groove of Head. Figure 12: For Step 10 WG 008 O-Ring 12. Check that the Pins (BA 018) are installed in the Head. BA 006 Shaft Seal Chamfered Face BA 018 Pins (2) Flat Face RJ 011/ RJ 011-KC Seat BA 040/240 Head RJ 012-TO/ RJ 012-KTO H.P. Seal Figure 13: For Steps 10-12 Figure 11: For Steps 8-9 13. Align the notches on the Outer Discs with the pins in the Head; slide shaft assembly into the Head. 14. Apply anti-seize to threads on Head; install Wear Ring (BA 030) onto the Nut (BA 002); thread the Nut onto the Head. Tighten to 50 ft-lb. 15. Use syringe to fill the tool with viscous fluid as shown in the “Fluid Replacement” Section: install Port Plugs (BJ 026). 866-795-1586 • WWW.SEWERNOZZLES.COM BJ 026 Port Plug BA 330 Wear Ring BJ 026 Port Plug Figure 14: For Steps 13-15 19 4” BADGER PART NAMES/NUMBERS RJ 011/ RJ 011-KC Seat RJ 012-TO/ RJ 012-KTO H.P. Seal BA 040/240 Head BA 017 Retaining Ring BA 016 Outer Disc (3) BA 015 Inner Disc (4) BA 018 Pins (2) SM 016 O-Ring (3) BA 006 Shaft Seal WG 008 O-Ring UH 009 Bearing BA 006 Shaft Seal BA 030 Wear Ring BA 018 Pins (2) BA 201 Shaft BA 001/ BA 001-BSPP6/ Shaft BA 002 Nut BJ 026 Port Plug 20 866-795-1586 • WWW. SEWERNOZZLES.COM 4” BADGER SERVICE KITS 4” BADGER MODELS KITS AND KIT CONTENTS BA 600-F SERVICE KIT (FAST) 1 1 1 1 1 1 BJ 048-F Visc Fluid, Fast, 6oz BJ 062-S Anti-seize, 2g RJ 011 Brass Seat RJ 012-TO H.P. Seal and O-Ring BC 410 Syringe Assembly GP 025-P2SS Hex Socket Plug, 1/8 NPT Male, SS 1 PL 663 BA Manual BA-P6 / BA-BSPP6 (15K) BA 600-S SERVICE KIT (SLOW) 1 1 1 1 1 1 BJ 048-S Visc Fluid, Slow, 6oz BJ 062-S Anti-seize, 2g RJ 011 Brass Seat RJ 012-TO H.P. Seal and O-Ring BC 410 Syringe Assembly GP 025-P2SS Hex Socket Plug, 1/8 NPT Male, SS 1 PL 663 BA Manual BA 610-F OVERHAUL KIT (FAST) 1 1 1 1 1 1 1 1 1 1 1 BA 006 Seal BA 007 Seal BA 017 Retaining Ring, External .688 BJ 026 Port Plug BJ 048-F Visc Fluid, Fast, 6oz PL 663 BA Manual RJ 011 Brass Seat RJ 012-TO H.P. Seal and O-Ring SM 016 Seal, O-Ring UH 009 Bearing, Ball WG 008 O-Ring BA 610-S OVERHAUL KIT (SLOW) 1 1 1 1 1 1 1 1 1 1 1 BA 600-TM12-F SERVICE KIT (FAST) 1 1 1 1 1 1 BJ 048-F Visc Fluid, Fast, 6oz BJ 062-S Anti-seize, 2g RJ 011-KC Brass Seat RJ 012-KTO H.P. Seal and O-Ring BC 410 Syringe Assembly GP 025-P2SS Hex Socket Plug, 1/8 NPT Male, SS 1 PL 663 BA Manual BA-TM12 (20K) BA 600-TM12-S SERVICE KIT (SLOW) 1 1 1 1 1 1 BJ 048-S Visc Fluid, Slow, 6oz BJ 062-S Anti-seize, 2g RJ 011-KC Brass Seat RJ 012-KTO H.P. Seal and O-Ring BC 410 Syringe Assembly GP 025-P2SS Hex Socket Plug, 1/8 NPT Male, SS 1 PL 663 BA Manual BA 610-TM12-F OVERHAUL KIT (FAST) 1 1 1 1 1 1 1 1 1 1 1 BA 006 Seal BA 007 Seal BA 017 Retaining Ring, External .688 BJ 026 Port Plug BJ 048-F Visc Fluid, Fast, 6oz PL 663 BA Manual RJ 011-KC Brass Seat RJ 012-KTO H.P. Seal and O-Ring SM 016 Seal, O-Ring UH 009 Bearing, Ball WG 008 O-Ring BA 006 Seal BA 007 Seal BA 017 Retaining Ring, External .688 BJ 026 Port Plug BJ 048-S Visc Fluid, Slow, 6oz PL 663 BA Manual RJ 011-KC Brass Seat RJ 012-KTO H.P. Seal and O-Ring SM 016 Seal, O-Ring UH 009 Bearing, Ball WG 008 O-Ring BA 610-TM12-S OVERHAUL KIT (SLOW) 1 1 1 1 1 1 1 1 1 1 1 BA 006 Seal BA 007 Seal BA 017 Retaining Ring, External .688 BJ 026 Port Plug BJ 048-S Visc Fluid, Slow, 6oz PL 663 BA Manual RJ 011-KC Brass Seat RJ 012-KTO H.P. Seal and O-Ring SM 016 Seal, O-Ring UH 009 Bearing, Ball WG 008 O-Ring 866-795-1586 • WWW.SEWERNOZZLES.COM BA 602 H.P. SEAL KIT 1 RJ 011 Brass Seat 1 RJ 012-TO H.P. Seal and O-Ring BA 612 TOOL KIT 1 BA 100 Retaining Ring Pliers 1 BA 105 Tool BA 602-TM12 H.P. SEAL KIT 1 RJ 011-KC Brass Seat 1 RJ 012-KTO H.P. Seal and O-Ring BA 612 TOOL KIT 1 BA 100 Retaining Ring Pliers 1 BA 105 Tool 21 6” BADGER DESCRIPTION AND INTENDED USE 6” BADGER MODELS DESCRIPTION AND INTENDED USE The Badger™ P8, MP9 and M24 Rotary Waterblast Nozzles were designed to waterblast clean pipes as small as 6 inches with elbows. The BA-P8 has a 1/2 NPT female inlet connection and a maximum working pressure of 15,000 psi (1035 bar). The BA-MP9 has a 9/16 medium pressure female inlet connection and a maximum working pressure of 22,000 psi (1500 bar). The BA-M24 has a metric M24x1.5 female face seal inlet connection and a maximum working pressure of 22,000 psi (1500 bar). The Badger™ has an adjustable speed mechanism that allows rotation speed to be changed. For the fastest speed setting, the Shaft Adjust Sleeve (BA 303) is backed out all the way against the shoulder of the shaft. The slowest speed setting is about 1-1/4 turn inward. Do not force the adjustment in this direction. To adjust the speed, hold the wrench flats on the shaft while turning the Shaft Adjust Sleeve with wrench (BA 300). This Badger uses fast viscous fluid for speed control and bearing lubrication. The Badger™ heads have 1/4 NPT ports; one at 15 degrees, two at 100 degrees, and two at 135 degrees. Engraved on each head is R21, R31 or R40; this number is the offset of the head that makes it rotate. The flow range for each head is given in the table; nozzle sizes must be selected to fit within this flow range. If the flow is less than the range shown, the tool will not rotate; it is okay to use more than the allowable, but the tool MUST be slowed down using the adjustable speed mechanism to prevent over-speeding and damaging the tool. 6” BADGER FLOW RANGE PER HEAD OFFSET CHART PRESSURE 22 R40 R31 R21 10,000 (690 bar) 15-24 GPM (57-91 l/min) 21-31 GPM (80-117 l/min) 31-55 GPM (117-208 l/min) 15,000 (1035 bar) 15-24 GPM (57-91 l/min) 23-33 GPM (87-125 l/min) 33-55 GPM (125-208 l/min) 22,000 (1500 bar) 14-21 GPM (53-80 l/min) 21-30 GPM (80-114 l/min) 30-43 GPM (114-163 l/min) 866-795-1586 • WWW. SEWERNOZZLES.COM 6” BADGER WARNING AND SAFETY INSTRUCTIONS WARNING Because of the short length of the Badger, the tool can turn around in large pipes and come back at the operator at a high rate of speed. If cleaning larger pipes, a rigid “stinger” should be used between the hose and the tool. It is recommended that the rigid length of the tool including hose end is 1-1/2 times the inside diameter of the pipe being cleaned (see Figure 1). Make sure there is an operator controlled dump in the system, operated by the person closest to the cleaning job. Flush out the high pressure hoses before connecting the Badger. It is recommended that the hose be marked a few feet from the end with a piece of tape so the operator knows when to stop when retracting the tool. Position the tool in the pipe opening. Close the dump and slowly bring up to pressure the first time to make sure no nozzles are plugged and the jet thrust is correct. The Badger should begin to slowly rotate. Once operating pressure is reached, feed the tool into the pipe to begin the cleaning job. Allow the jets time to do their work by feeding the hose out at a controlled rate. The StoneAge ABX-500 Hose Control Device can be used to achieve consistent feed rates for pipe cleaning. When the work is complete and the tool is connected from the hose, blow out all water to prolong the life of the tool. A small amount of oil can be blown into the tool as well as an added measure to maximize tool life. Operations with this equipment can be potentially hazardous. Caution must be exercised prior to and during machine and water jet tool use. Please read and follow all of these instructions, in addition to the guidelines in the WJTA Recommended Practices handbook, available online at www.wjta.org. Deviating from safety instructions and recommended practices can lead to severe injury and/or death. IMPROPER USE: Badger will turn around in large diameter pipe VERY DANGEROUS! 866-795-1586 • WWW.SEWERNOZZLES.COM PROPER USE: Badger with rigid “stinger” to prevent turnaround, still able to pass through elbows. 23 6” BADGER OPERATION OPERATION: • Make sure the operator has a controlled dump in the system and it is operated by the person closest to the job. Test the dump prior to beginning the job. • Flush out the high pressure hoses before connecting the Badger™ to eliminate debris. NOTICE The two most important items in maintaining the Badger tools; - Keep debris from entering the tool and preventing it from rotating by flushing high pressure hoses before use. - Keep the 4” and 6” models full of viscous fluid to maintain control and rotation speed. When the viscous fluid is lost or contaminated, the rotation speed of the tool will increase, which reduce the life of the high pressure seal and bearing. • Attach tool to the end of the hose. • It is recommended that the hose be marked a few feet from the end with a piece of tape so the operator knows when to stop on the way back out. • Position the tool in the pipe opening. • Close the dump and slowly bring the pump up to pressure the first time to make sure no nozzles are plugged and the jet thrust is correct. The Badger should begin to slowly rotate. • Once operating pressure is reached, feed the tool into the pipe to begin the cleaning job. • Allow the jets time to do their work by feeding the hose out at a controlled rate. • When the work is complete and the tool is disconnected from the hose, blow out all water to prolong the life of the tool. • 4” & 6” BADGERS ONLY- A small amount of 3-IN-ONE or equivalent lubricant can be blown into the tool as well. 24 866-795-1586 • WWW. SEWERNOZZLES.COM 6” BADGER TROUBLESHOOTING HIGH-PRESSURE WATER SEALS LEAK: • The high pressure seal may leak initially at lower pressures, but should pop closed as pressure is increased. A continuous leak at operating pressure from the weep holes indicates the need to replace the HP Seal and Seat. HP Seals wearing out too quickly can be an indication that the shaft bore is worn, the HP Seat is installed upside-down, or the tool is over spinning. Over spinning is caused by low or contaminated viscous fluid, water in the fluid chamber (replace shaft seals), or too much jet torque. Refilling the viscous fluid every 30-40 hours of operation is important for proper speed control. Only use StoneAge recommended viscous fluid. TOOL WILL NOT ROTATE: • Check the nozzles for plugging or wear (nozzles have to be removed to check for obstructions), Check that the nozzle sizes are correct for the desired flow and that the desired flow matches the head flow range. Check that the nozzle sizes are installed in a balanced configuration. If the tool feels rough when manually rotating the head, this indicates internal damage. Replace bearings, shaft seals, viscous fluid, and check the Inner and Outer Discs for flatness. These discs can be deformed if tool is reassembled when discs are not properly aligned with BA 018 Pins. TOOL SPINS TOO FAST: • A significant increase in rotation speed means that the speed control mechanism in the tool has lost functionality. This can be a result of viscous fluid loss or fluid contamination. Operation of the tool in this state can cause damage to other components and accelerated wear of the high pressure seal. If this occurs, the first step is to flush the tool with new viscous fluid as shown in Figure 12. LOCK-UP TROUBLESHOOTING TIP: • Rotate in reverse 1 1/4 to 1 1/2 turns to unlock braking mechanism. If tool rotates smoothly then redress may not be required. • If the head rotates freely by hand, check the jet sizes and calculate pressure loss through the coil tubing and check with your distributor or StoneAge® to make certain there is enough jet torque to provide rotation. • Verify jetting at http://jetting.stoneagetools.com/#/, contact your factory authorized Warthog® dealer or contact StoneAge®, Inc. WEEP HOLES Figure 12 866-795-1586 • WWW.SEWERNOZZLES.COM 25 6” TOOL SERVICE INFORMATION TOOL SERVICE ***Product training and proper tools are required to service this nozzle. If you are uncomfortable performing the service, bring the nozzle to your authorized dealer.* The use of a bench vice and an arbor press is highly helpful. Take care throughout the entire procedure to keep the internals clean and free from grit, lint, and contamination. Failure to do so could result in premature failure after service. LIST OF TOOLS: • • • • • • • Bench Vice (recommended) Arbor Press (recommended) 18” Adjustable Wrench (such as Crescent® C718 Automatic Adjustable Pipe Wrench) Medium size flat-head screw driver Pick Bearing Splitter 3/8 Drive Ratchet with 3” Extension • BA 612-P8/M9 Tool Kit (For 6” Badger Includes) BA 100 Retaining Ring Pliers BA 105 Seal Press Tool LIST OF MATERIALS: • • • • • 26 Clean lint free rags or blue shop towels Anti-Seize - StoneAge PN (GP 043 Blue Goop) Lithium Soap Grease – StoneAge PN (GP 048 Grease) Blue Loctite® 242 Isopropyl Alcohol or Denatured Alcohol 866-795-1586 • WWW. SEWERNOZZLES.COM 6” BADGER FLUID REPLACEMENT VISCOUS FLUID FLUSH INSTRUCTIONS (6” BADGER) 1. Remove the Port Plugs (BJ 026) in the Nut (BA 302) and Head (BA 340-RXX) (see Figure 2). 2. Fill the Syringe (BC 410) with viscous fluid by removing the end near the handle, pulling out the plunger, and pouring the Viscous Fluid (BJ 048-F) in to fill the Syringe Body. With plunger re-installed, purge air out of Syringe hose. 3. Thread the syringe end into the port in the Head, and squeeze fresh Viscous Fluid in until clean Viscous Fluid comes out the port in the Nut. Hold the tool so the port in the Nut is the highest point. If air bubbles come out of the port on the nut, keep flushing new fluid until air bubbles stop. 4. Install Port Plug into Nut first. Remove the Syringe and install the Port Plug in the Head. BJ 026 Port Plug (In Nut) BA 302 Nut (1) BJ 026 Port Plug (In Nut) BA 340-RXX Head (1) BC 410 Syringe Figure 1: Viscous Fluid Flush 866-795-1586 • WWW.SEWERNOZZLES.COM 27 6” BADGER DISASSEMBLY DISASSEMBLY 1. Unscrew the Nut (BA 002) from the Head (BA 040/240) 4. Remove Retaining Ring (BA 017) from the shaft. 5. Pull the Discs (BA 015, BA 016) and O-Rings (SM 016) off of the Shaft. 2. Pull the Shaft (BA 001/ BA 001BSPP6/ BA 201) out of the head. BA 302 Nut BA 311 Retaining Ring CST 141 Retaining Ring BA 330 Wear Ring BA 315 Inner Disc (4) BA 316 Outer Disc (3) BA 301-P8 or BA 301-M9 or BA 301-M24x1.5 Shaft SM 116 O-Ring (3) BA 340-RXX Head Figure 3: For Steps 1-2 3. Remove the Seat (BJ 011-C) and H.P. Seal (BJ 012-TRO) from the bore of the Shaft. BJ 011-C Seat BJ 012-TRO H.P. Seal BA 313 Wave Spring Figure 4: For Step 3 28 Figure 5: For Step 4-5 866-795-1586 • WWW. SEWERNOZZLES.COM 6” BADGER DISASSEMBLY 6. Press the Bearing (UH 009) off of the Shaft. 10. Remove the Port Plug (BJ 026) from the Head. 7. There is no need to remove the Pins (BA 018) from the Shaft; however, if they fall out do not lose them. 11. Remove the Shaft Seal (BA 006) and O-Ring (WG 008) if they are damaged. BA 303 Shaft Adjust Sleeve 12. There is no need to remove the Pins (BA 018); however, if they fall out, do not lose them. BA318 Pins (2) BA 309 Bearing BA 307 Shaft Seal BA 312 O-Ring BA 310 O-Ring (2) BA 318 Pins (2) BJ 062 Port Plug BA 301-P8 or BA 301-M9 or BA 301-M24x1.5 Shaft BA 340-RXX Head Figure 8: For Steps 10-12 Figure 6: For Steps 6-7 8. Remove the Shaft Seal (BA 007) if it is damaged. 9. Remove the Port Plug (BJ 026) from the Nut. BA 307 Shaft Seal BA 302 Nut BJ 062 Port Plug Figure 7: For Steps 8-9 866-795-1586 • WWW.SEWERNOZZLES.COM 29 6” BADGER ASSEMBLY ASSEMBLY 1. Press Bearing (BA 309) onto Shaft (BA 303) BA 311 Bearing 2. Check that Pins (BA 318) are installed in Shaft. CST 141 Retaining Ring BA 318 Pins (2) BA 303 Shaft Adjust Sleeve BA 309 Bearing BA 316 Outer Disc (4) Figure 9: For Steps 1-2 Pins should be just far enough to clear groove for retaining ring SM 116 O-Ring (4) .380 BJ 008 O-Ring (3) 3. Place an Inner Disc (BA 315) on Shaft, aligning with pins. 4. Place an O-Ring (SM 116) on top of this Disc, stretched around the pins. BA 315 Inner Disc (5) 5. Place an Outer Disc (BA 316) around the outside of this O-Ring 6. Place another Inner Disc, and also place an O-Ring (BJ 008) around the outer edge of this Disc. 7. Repeat steps 4 through 6, until there are four Outer Discs and five Inner Discs on Shaft. Note that there is no outer O-Ring on the Inner Discs at each end of the stack. 8. Push down on top disc and install the Retaining Ring (CST 141) in the groove around Shaft. Install Bearing (BA 311) on shaft. 30 Figure 10: For Step 3-8 866-795-1586 • WWW. SEWERNOZZLES.COM 6” BADGER ASSEMBLY 9. Insert Wave Spring (BA 313) into bore of Shaft. Apply grease to and install the H.P. Seal (BJ 012-TRO) in bore of Shaft. 10. Apply grease to the flat face of the Seat (BJ 011-C) and place in bore of Shaft, on top of Seal, as shown. Chamfered Face 12. Install Shaft Seals (BA 307) in the Head (BA 340) as shown. 13. Place O-Ring (BA 312) over threads and into groove of Head. 14. Check that the Pins (BA 318) are installed in the Head. BA 307 Shaft Seal Lip with spring side UP Flat Face BA 318 Pins (2) BA 312 O-Ring BJ 011-C Seat BJ 012-TRO H.P. Seal BA 313 Wave Spring BA 340-RXX Head Figure 13: For Step 11-14 15. Align the notches on the Outer Discs with the pins in the Head; slide shaft assembly into the Head, taking care that the outer O-Rings remain captured between the Discs. Figure 11: For Steps 9-10 11. Install Shaft Seals (BA 308) in the Nut (BA 302) as shown. BA 308 Shaft Seal (1) BA 302 Nut (1) 16. Apply anti-seize to threads on Head; install Wear Ring (BA 330) onto the Nut (BA 302); thread the Nut onto the Head. Tighten to 50 ft-lb. 17. Use syringe to fill the tool with viscous fluid as shown in the Maintenance Section; install the Port Screws (BJ 026). BA 330 Wear Ring BJ 026 Port Plug BJ 026 Port Plug Figure 12: For Step 11 Figure 14: For Steps 15-17 866-795-1586 • WWW.SEWERNOZZLES.COM 31 6” BADGER PART NAMES/NUMBERS CST 141 Retaining Ring BA 340-RXX Head BA 309 Bearing BJ 026 Port Plug BA 312 O-Ring BA 310 O-Ring (2) BA 318 Pins (2) BA 318 Pins (2) BA 301-P8 or BA 301-M9 or BA 301-M24x1.5 Shaft BA 330 Wear Ring (1) BA 307 Shaft Seal BA 316 Outer Disc (4) BA 311 Bearing SM 116 O-Ring (4) BJ 011-C Seat BJ 008 O-Ring (3) BJ 012-TRO H.P. Seal BA 308 Shaft Seal (1) BA 313 Wave Spring BA 302 Nut (1) BA 315 Inner Disc (5) BJ 026 Port Plug 32 866-795-1586 • WWW. SEWERNOZZLES.COM 6” BADGER SERVICE KITS 6” BADGER KITS AND KIT CONTENTS BA 600-P8/MP9 SERVICE KIT (FAST) 1 1 1 1 1 1 1 BA-P8/ MP9 BA 313 Wave Spring BC 410 Syringe Assembly BJ 011-C Carbide Seat BJ 012-TRO H.P. Seal and O-Ring BJ 026 Port Plug BJ 048-F Visc Fluid, Fast, 6oz PL 663 BA Manual BA 610-P8/MP9 OVERHAUL KIT (FAST) 1 1 1 2 1 1 1 3 1 1 2 1 1 4 1 BA 307 Seal BA 308 Seal BA 309 Bearing, Ball, JEM BA 310 O-Ring BA 311 Bearing, Ball, Open BA 312 O-Ring BA 313 Wave Spring BJ 008 O-Ring BJ 011-C Carbide Seat BJ 012-TRO H.P. Seal & O-Ring BJ 026 Port Plug BJ 048-F Viscous Fluid, Fast - 6oz. CST 141Retaining Ring, HD External .875 SM 116 O-Ring, Sealing PL 663 Consumable, BA Manual 866-795-1586 • WWW.SEWERNOZZLES.COM BA 602-P8/MP9 H.P. SEAL KIT 1 BJ 011-C Carbide Seat 1 BJ 012-TRO H.P. Seal and O-Ring BA 612 P8/MP9 TOOL KIT 1 BA 100 Retaining Ring Pliers 1 BA 305 Tool (6” Badger Elbow) 33 TERMS AND CONDITIONS AND WARRANTY INFORMATION 1. Acceptance of Terms and Conditions. Receipt 3. Warranty. SELLER MAKES NO WARRANTIES OR of these Terms and Conditions of Sale (“Terms and REPRESENTATIONS AS TO THE PERFORMANCE Conditions”) shall operate as the acceptance by OF ANY PRODUCT EXCEPT AS SET FORTH IN THE StoneAge, Inc. (“Seller”) of the order submitted by STONEAGE LIMITED WARRANTY PROVIDED WITH THE the purchaser (“Buyer”). Such acceptance is made PRODUCT. expressly conditional on assent by Buyer to these Terms and Conditions. Such assent shall be deemed to have 4. Delivery. Seller is not obligated to make delivery by been given unless written notice of objection to any of a specified date, but will always use its best efforts to these Terms and Conditions (including inconsistencies make delivery within the time requested. The proposed between Buyer’s purchase order and this acceptance) is shipment date is an estimate. Seller will notify Buyer given by Buyer to Seller promptly on receipt hereof. promptly of any material delay and will specify the revised delivery date as soon as practicable. UNDER Seller desires to provide Buyer with prompt and efficient NO CIRCUMSTANCES SHALL SELLER HAVE ANY service. However, to individually negotiate the terms LIABILITY WHATSOEVER FOR LOSS OF USE OR of each sales contract would substantially impair FOR ANY DIRECT OR CONSEQUENTIAL DAMAGES Seller’s ability to provide such service. Accordingly, the RESULTING FROM DELAY REGARDLESS OF THE product(s) furnished by Seller are sold only according REASON(S). to the terms and conditions stated herein and with the terms and conditions stated in any effective StoneAge All product(s) will be shipped F.O.B. point of origin, Dealer Agreement or StoneAge Reseller Agreement, if unless specifically agreed otherwise, and Buyer shall applicable. Notwithstanding any terms and conditions pay all shipping costs and insurance costs from that on Buyer’s order, Seller’s performance of any contract point. Seller, in its sole discretion, will determine and is expressly made conditional on Buyer’s agreement arrange the means and manner of transportation of the to these Terms and Conditions unless otherwise product(s). Buyer shall bear all risk of loss commencing specifically agreed to in writing by Seller. In the absence with the shipment or distribution of the product(s) from of such agreement, commencement of performance, Seller’s warehouse. Order shortages or errors must be shipment and/or delivery shall be for Buyer’s reported within fifteen (15) business days from receipt of convenience only and shall not be deemed or construed shipment to secure adjustment. No product(s) may be to be an acceptance of Buyer’s terms and conditions. returned without securing written approval from Seller. 2. Payment/Prices. Unless other arrangements have 5. Modification. These Terms and Conditions are been made in writing between Seller and Buyer, payment intended by Seller and Buyer to constitute a final, for the product(s) shall be made upon receipt of invoice. complete and exclusive expression of agreement The prices shown on the face hereof are those currently relating to the subject matter hereof and cannot be in effect. Prices invoiced shall be per pricelist in effect supplemented or amended without Seller’s prior written at the time of shipment. Prices are subject to increase approval. for inclusion of any and all taxes which are applicable and which arise from the sale, delivery or use of the 6. Omission. Seller’s waiver of any breach or Seller’s product(s), and the collection of which Seller is or may failure to enforce any of these Terms and Conditions be responsible to provide to any governmental authority, at any time, shall not in any way affect, limit or waive unless acceptable exemption certificates are provided Seller’s right thereafter to enforce and compel strict by Buyer in accordance with applicable law. Buyer compliance with every term and condition hereof. shall pay all charges for transportation and delivery and all excise, order, occupation, use or similar taxes, 7. Severability. If any provision of these Terms and duties, levies, charges or surcharges applicable to the Conditions is held to be invalid or unenforceable, such product(s) being purchased, whether now in effect invalidity or unenforceability shall not affect the validity or hereafter imposed by any governmental authority, or enforceability of the other portions hereof. foreign or domestic. 34 866-795-1586 • WWW. SEWERNOZZLES.COM TERMS AND CONDITIONS AND WARRANTY INFORMATION 8. Disputes. Seller and Buyer shall attempt in good 10. Jurisdiction and Venue. Seller and Buyer agree faith to promptly resolve any dispute arising under that the state or federal courts located within the City these Terms and Conditions by negotiations between and County of Denver, Colorado shall have sole and representatives who have authority to settle the exclusive jurisdiction over any litigation concerning any controversy. If unsuccessful, Seller and Buyer shall dispute arising under these Terms and Conditions not further attempt in good faith to settle the dispute otherwise resolved pursuant to Section 9 as well as any by nonbinding third-party mediation, with fees and alleged defects of any Products or damages sustained expenses of such mediation apportioned equally to as a result of such alleged defects. Seller and Buyer each side. Any dispute not so resolved by negotiation further agree that should any litigation be commenced or mediation may then be submitted to a court of in connection with such a dispute, it shall only be competent jurisdiction in accordance with the terms commenced in such courts. Seller and Buyer agree to hereof. These procedures are the exclusive procedures the exclusive jurisdiction of such courts and neither will for the resolution of all such disputes between the Seller raise any objection to the jurisdiction and venue of such and Buyer. courts, including as a result of inconvenience. 9. Governing Law. All sales, agreements for sale, offers 11. Attorney’s Fees. If any litigation is commenced to sell, proposals, acknowledgments and contracts between Seller and Buyer, or their personal of sale, including, but not limited to, purchase orders representatives, concerning any provision hereof, accepted by Seller, shall be considered a contract under the party prevailing in the litigation shall be entitled, the laws of the State of Colorado and the rights and in addition to such other relief that is granted, to a duties of all persons, and the construction and effect of reasonable sum as and for their attorneys’ fees and all provisions hereof shall be governed by and construed costs in such litigation or mediation. according to the laws of such state. STONEAGE TRADEMARK LIST View the list of StoneAge’s trademarks and service marks and learn how the trademarks should be used. Use of StoneAge trademarks may be prohibited, unless expressly authorized. http://www.StoneAgetools.com/trademark-list/ STONEAGE PATENT DATA View the list of StoneAge’s current U.S. patent numbers and descriptions. http://www.sapatents.com STONEAGE TERMS AND WARRANTY View StoneAge’s Terms and Warranty Conditions online. http://www.stoneagetools.com/terms http://www.stoneagetools.com/warranty 866-795-1586 • WWW.SEWERNOZZLES.COM 35 TERMS AND CONDITIONS AND WARRANTY INFORMATION WARRANTY: Warranties set forth herein extend only to End-Users, modification of the Product or use of parts not approved meaning customers acquiring, or that have previously by StoneAge will void this Limited Warranty. StoneAge acquired, a product manufactured by StoneAge reserves the right to change or improve the material and (“Product”) for their own use and not for resale, either design of the Product at any time without notice to End- directly from StoneAge Inc. (“StoneAge”) or from a User, and StoneAge is not obligated to make the same StoneAge Authorized Dealer or Reseller (“Dealer”). No improvements during warranty service to any Product warranty of any kind or nature is made by StoneAge previously manufactured. beyond those expressly stated herein. 4. WARRANTY EXCLUSIONS. This Limited Warranty 1. LIMITED WARRANTY PERIOD. Subject to does not cover, and StoneAge shall not be responsible the limitations and conditions hereinafter set forth, for the following, or damage caused by the following: StoneAge warrants its Product to be free from defects (1) any Product that has been altered or modified in any in workmanship and material for a period of one (1) year way not approved by StoneAge in advance in writing; from the date of purchase by the End-User, provided that (2) any Product that has been operated under more the end of the limited warranty period shall not be later severe conditions or beyond the rated capacity specified than eighteen (18) months from the date of shipment of for that Product; (3) depreciation or damage caused the Product to the Dealer or the End-User by StoneAge by normal wear and tear, failure to follow operation or (“Limited Warranty Period”). All replacement parts which installation instructions, misuse, negligence or lack are furnished under this Limited Warranty and properly of proper protection during storage; (4) exposure to installed shall be warranted to the same extent as the fire, moisture, water intrusion, electrical stress, insects, original Product under this Limited Warranty if, and only explosions, extraordinary weather and/or environmental if, the original parts were found to be defective within the conditions including, but not limited to lightning, natural original Limited Warranty Period covering the original disasters, storms, windstorms, hail, earthquakes, acts Product. Replacement parts are warranted for the of God or any other force majeure event; (5) damage to remainder of the original Limited Warranty Period. This any Product caused by any attempt to repair, replace, Limited Warranty does not cover any component part of or service the Product by persons other than StoneAge any Product not manufactured by StoneAge. Any such authorized service representatives; (6) costs of normal component part is subject exclusively to the component maintenance parts and services; (7) damage sustained manufacturer’s warranty terms and conditions. during unloading, shipment or transit of the Product; 2. LIMITED WARRANTY COVERAGE. StoneAge’s sole obligation under this Limited Warranty shall be, at StoneAge’s option and upon StoneAge’s inspection, to or (8) failure to perform the recommended periodic maintenance procedures listed in the Operator’s Manual accompanying the Product. repair, replace or issue a credit for any Product which is 5. REQUIRED WARRANTY PROCEDURES. To be determined by StoneAge to be defective in material or eligible for warranty service, the End-User must: (1) workmanship. StoneAge reserves the right to examine report the Product defect to the entity where the Product the alleged defective Product to determine whether this was purchased (i.e. StoneAge or the Dealer) within Limited Warranty is applicable, and final determination the Limited Warranty Period specified in this Limited of limited warranty coverage lies solely with StoneAge. Warranty; (2) submit the original invoice to establish No statement or recommendation made by a StoneAge ownership and date of purchase; and (3) make the representative, Dealer or agent to End-User shall Product available to a StoneAge authorized service constitute a warranty by StoneAge or a waiver or representative for inspection to determine eligibility modification to any of the provisions hereof or create any for coverage under this Limited Warranty. This Limited liability for StoneAge. Warranty shall not extend to any person or entity who fails to provide proof of original purchase from StoneAge 3. WARRANTY SERVICE PROVIDERS. Service and repair of the Product is to be performed only by StoneAge authorized service representatives, including Dealers who are authorized repair centers, with or a Dealer. No Product may be returned for credit or adjustment without prior written permission from StoneAge. StoneAge approved parts. Information about StoneAge authorized service representatives can be obtained through the StoneAge website at www.stoneagetools. com/service. Unauthorized service, repair or 36 866-795-1586 • WWW. SEWERNOZZLES.COM TERMS AND CONDITIONS AND WARRANTY INFORMATION 6. DISCLAIMER OF IMPLIED WARRANTIES AND OTHER REMEDIES. EXCEPT AS EXPRESSLY STATED HEREIN (AND TO THE FULLEST EXTENT ALLOWED UNDER APPLICABLE LAW), STONEAGE HEREBY DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, AND ANY AND ALL WARRANTIES, REPRESENTATIONS OR PROMISES AS TO THE QUALITY, PERFORMANCE OR FREEDOM FROM DEFECT OF THE PRODUCT COVERED BY THIS LIMITED WARRANTY. STONEAGE FURTHER DISCLAIMS ALL IMPLIED INDEMNITIES. 7. LIMITATION OF LIABILITY. End-User specifically acknowledges that the Product may be operated at high speeds and/or pressures, and that as such it may be inherently dangerous if not used correctly. EndUser shall familiarize itself with all operation materials provided by StoneAge and shall at all times use and require its agents, employees and contractors to use ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. IT IS UNDERSTOOD THAT STONEAGE’S LIABILITY, WHETHER IN CONTRACT, IN TORT, UNDER ANY WARRANTY, IN NEGLIGENCE, OR OTHERWISE SHALL NOT EXCEED THE AMOUNT OF THE PURCHASE PRICE PAID BY THE END-USER FOR THE PRODUCT. STONEAGE’S MAXIMUM LIABILITY SHALL NOT EXCEED, AND END-USER’S REMEDY IS LIMITED TO EITHER (1) REPAIR OR REPLACEMENT OF THE DEFECTIVE WORKMANSHIP OR MATERIAL OR, AT STONEAGE’S OPTION, (2) REFUND OF THE PURCHASE PRICE, OR (3) ISSUANCE OF A CREDIT FOR THE PURCHASE PRICE, AND SUCH REMEDIES SHALL BE END-USER’S ENTIRE AND EXCLUSIVE REMEDY. YOU, THE END-USER, UNDERSTAND AND EXPRESSLY AGREE THAT THE FOREGOING LIMITATIONS ON LIABILITY ARE PART OF THE CONSIDERATION IN THE PRICE OF THE STONEAGE PRODUCT YOU PURCHASED. all necessary and appropriate safety devices, guards Some jurisdictions do not allow the limitation or and proper safe operating procedures. In no event shall exclusion of liability for certain damages, so the above StoneAge be responsible for any injuries to persons or limitations and exclusions may not apply to you. This property caused directly or indirectly by the operation Limited Warranty gives you specific legal rights, and you of the Product if End-User or any agent, employee, or may also have other rights which vary from jurisdiction contractor of End-User: (1) fails to use all necessary to jurisdiction. If any provisions of this Limited Warranty and appropriate safety devices, guards and proper is held to be invalid or unenforceable, such invalidity safe operating procedures; (2) fails to maintain in good or unenforceability shall not affect the validity or working order such safety devices and guards; (3) alters enforceability of the other portions hereof. or modifies the Product in any way not approved by StoneAge in advance in writing; (4) allows the Product to be operated under more severe conditions or beyond the rated capacity specified for the Product; or (5) otherwise negligently operates the Product. End-User shall indemnify and hold StoneAge harmless from any and all liability or obligation incurred by or against StoneAge, including costs and attorneys’ fees, to or by any person so injured. TO THE FULL EXTENT ALLOWED BY APPLICABLE LAW, STONEAGE SHALL NOT BE LIABLE FOR ANY INDIRECT, SPECIAL, INCIDENTAL, CONSEQUENTIAL, OR PUNITIVE DAMAGES (INCLUDING WITHOUT LIMITATION, LOSS OF PROFITS, LOSS OF GOODWILL, DIMINUTION OF VALUE, WORK STOPPAGE, INTERRUPTION OF BUSINESS, RENTAL OF SUBSTITUTE PRODUCT, OR OTHER COMMERCIAL LOSS EVEN TO THE EXTENT SUCH DAMAGES WOULD CONSTITUTE DIRECT DAMAGES), WITH RESPECT TO THE COVERED STONEAGE PRODUCT, OR OTHERWISE IN CONNECTION WITH THIS LIMITED WARRANTY, REGARDLESS OF WHETHER STONEAGE HAS BEEN 866-795-1586 • WWW.SEWERNOZZLES.COM 37 NOTES THIS PAGE LEFT INTENTIONALLY BLANK 38 866-795-1586 • WWW. SEWERNOZZLES.COM NOTES THIS PAGE LEFT INTENTIONALLY BLANK 866-795-1586 • WWW.SEWERNOZZLES.COM 39 1-866-795-1586 • www.STONEAGETOOLS.com © 2017 StoneAge, Inc. All Rights Reserved
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