4″ Badger Tool Manual
Contents
1. 04 04 2014 StoneAge All Rights Reserved2. Badger 4 Self Rotary Swivel BA P6 BA BSPP6 BA TM12 Description 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 Flow Range Engraved on each head is R16 or R22 this number is the offset of the head that makes it rotate Press psi R22 R16 The flow range for each head is given in the table nozzle sizes must be selected to fit within this 10 000 13 21 20 30 flow range If the flow is less than the range shown the tool will not rotate if it is more than the 15 000 13 17 18 30 allowable the tool will rotate too fast and wear out the seals and bearings 22 000 1500 bar 12 18 15 25 Operation The first step is to determine the jet sizes Jet thrust is used to pu
3. Pins 2 i E 9 Apply grease to the Tatiane flat face of the Seat as SS a RJ 011 RJ 011 KC and RJ 012 TO S ee place in bore of Shaft on RJ 012 KTO BA 001 Qs a Op OF Seal as Naw H P Seal BA 001 BSPP6 lip with spring up BA 201 Shaft 10 Install Shaft Seals BA 007 and BA 006 in a 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 the pins BA 016 5 Place an Outer Disc 3 Outer Disc BA 016 SM 016 on top of this O Ring 3 fenna e Ba O15 there are three Inner Disc 4 Outer Discs and four Inner Discs on Shaft 7 push down on top disc and install the Retaining Ring BA 017 in the groove around Shaft lip with spring u Head BA 040 240 as shown 11 Place O Ring WG 008 over threads and into groove of Head are installed in the Head assembly into the Head 12 Check that the Pins BA 018 BA 002 Nut 13 Align the notches on the Outer Discs with the pins in the Head slide shaft g up BA 006 Shaft Seal N BJ 026 Port 5 u P i Q 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 Maintenance Section install the Port Screws BJ 026 BJ 026 g Port Screw Wear Ring AA STONEAGE ENGINEERING THE POWER OF WATER
4. Port Screws Port Screw BA 040 RXX Head 15kpsi or in Head BJ 026 Port Screw BA 240 RXX Head 22kpsi BA 018 Pin BA 006 Shaft Seal BA 017 Retaining Ring WG 008 O Ring Available Maintenance Kits ci ra BA 600 x Service Kit Includes items needed for maintenance BA 600 TM12 x Service Kit Includes items needed for maintenance OTR BA 602 Seal Kit Includes parts needed for one seal change BA 610 x Overhaul Kit Includes parts needed for tool rebuild BA 610 TM12 x Overhaul Kit Includes parts needed for tool rebuild BA 612 Tool Kit Includes tools to aid assembly BA 001 or RJ 012 TO H P Seal 15kpsi Shaft 1Skpsi or RJ 012 KTO BA 002 Inlet Nut BA 016 H P Seal 22kspi Disc Outer 3 BJ 026 RJ 011 SM 016 Port Screw Seat Brass 15K O Ring 3 BA 201 or BA 015 Shaft 22kpsi RJ 011 KC Disc Inner 4 Seat Carbide 22kpsi UH 009 BA 018 Bearing Pin BA 007 Shaft Seal BA 030 Wear Ring A STONEAGE ENGINEERING THE POWER OF WATER 04 04 2014 StoneAge All Rights Reserved Badger 4 Self Rotary Swivel BA P6 BA BSPP6 BA TM12 Disassembly 1 Unscrew the Nut BA 002 from the Head BA 040 240 2 Pull the Shaft BA 001 BA 001 BSPP6 BA 201 out of the Head BA 002 Nut BA 030 Wear Ring BA 001 BA 001 BSPP6 BA 201 Shaft 4 Remove the Retaining Ring BA 017 from the Shaft 5 P
5. ended 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 Maintenance The most important item in maintaining the Badger is keeping the tool full of viscous fluid which controls the rotation speed As the viscous fluid is lost or contaminated the rotation speed of the tool will increase which shortens the high pressure seal and bearing life To fill the Badger with viscous fluid 1 Remove the Port Screws BJ 026 in the Nut and Head BJ 026 Port Screw 2 Fill the Syringe BC 410 with viscous fluid by removing the end near the handle in Nut pulling out the plunger and pouring the viscous fluid in from the back end 3 Thread the syringe end into the port in the Head and squeeze fresh viscous fluid BC 410 in until clean viscous fluid comes out the port in the Nut Hold the tool so the port Syringe in the Nut is the highest point BJ 026 4 Remove the Syringe and install the
6. ll the tool through the pipe An estimate of the amount of pulling force required is useful and depends on the number of elbows and N any vertical climbs that must be made On a horizontal run with no elbows 1 pound of pull is N 1 1 2 times required for every ten feet When climbing vertically the pulling force must equal the weight of the pipe ID 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 100 degree ports which do help pull as well Nozzles selected should be matched pairs except the front jet When installing nozzles we recommend using Parker Thread Mate and Teflon tape Because of the short length of the Badger the tool turn can around in large pipes and come back at the operator at a high rate of speed If cleaning larger pipes a rigid pipe stinger should be used between the hose and the tool Itis recommended that the rigid length of the tool including hose end is one and a half times the inside diameter of the pipe being cleaned 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
7. 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 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 3 rate When the work is complete and the tool is disconnected from the hose blow out all water to IMPROPER USE Bad Rie iae n Badger will turn around in aager with rigid stinger prolong the life of the tool A small amount of oil can be blown into the tool as well large diameter pipe to prevent turnaround still VERY DANGEROUS able to pass thru elbows Troubleshooting High pressure seal 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 recomm
8. ull the Discs BA 015 BA 016 and O Rings SM 016 off of the Shaft BA 017 Se Retaining Ring BA 015 Disc Inner 4 A BA 016 Disc Outer 3 SM 016 O Ring 3 6 Press the Bearing UH 009 off of the Shaft 7 There is no need to remove the Pins BA 018 from the Shaft however if they fall out do not lose them BA 018 fA Pins 2 BA 001 BA 001 BSPP6 BA 201 Shaft UH 009 Bearing 10 Remove the Port Screw BJ 026 from the Head 11 Remove the Shaft Seal BA 006 and O Ring WG 008 if they are damaged 12 There is no need to remove the Pins BA 018 however if they fall out do not lose them the Nut BA 002 and BA 040 240 BA018 i Head 8 Remove the Shaft Seal Pin 2 BA 007 if it is damaged BA 006 haft 9 Remove the Port Screw NOS BJ 026 from the Nut 3 Remove the Seat BA 040 240 RJ 011 RJ 011 KC and H P Seal Head RJ 012 TO RJ 012 KTO from the bore of the Shaft BA 007 Shaft Seal BJ 026 RJ 011 RJ 011 KC Port Screw Seat RJ 012 TO RJ 012 KTO H P Seal BA 002 Nut BJ 026 Port Screw Assembly 1 Press Bearing UH 009 RJ 011 RJ 011 KC chamfered onto Shaft BA 001 BA 001 BSPP6 Seat face BA 201 8 Apply grease to and RJ 011 install the H P Seal 2 Check that Pins BA 018 BA 017 RJ012 TO MS RJ 011 KC ni RJ012 KTO RJ 012 TO RJ 012 KTO t are installed in Shaft Retaining Ring Se Ro a O moere oF hari Sea ED
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