Lightweight Positioner (LWP-500) User Manual
Contents
1. 2 0000000000000000000000000000000000000000000000000000000000000000000000 1000000000000000000000000000000000000000 LWP 500 1 LIGHTWEIGHT POSITIONER PARTS BU 152 LWP 502 VERTICAL RAIL STOP STO DRIVE ASSY HORIZONTAL DRIVE 5 z LWP 502 VERTICAL DRIVE 5 5 SRT 115 POSITIONER CONTROL LINE 5 SRT 560 BLANK 5 HORIZONTAL ASSY gt eaS AATF 0 5 0 BU 152 RAIL STOP PART NUMBER QTY 1 BR 002 XX 2 5 BOX RAIL EXTRUSION 1 2 BU 002 2 5 BOX RAIL EXTRUSION SLOTTED 2 3 LWP 500 1 LIGHTWEIGHT POSITIONER PARTS 1 866 795 1586 e WWW STONEAGETOOLS COM lt 13 PARTS DIAGRAM LIGHTWEIGHT POSITIONER LWP 501 HORIZONTAL POSITIONER gt ees _ 1 5 5 5 MEE 0 art gt BLUE LOCTITE 1 BLUE LOCTITE PN 243 OR EQUIVALENT 2 BLUE GOOP IS A SWAGELOK BRAND ANTI SEIZE AN EQUIVALENT ALTERNATIVE IS ACCEPTABLE 65331205 65 31 18 50085 SRT 548 HORIZONTAL MOUNTING PLATE QTY 2 2 2 5 GSSH 0375 0500 SS SHOULDER SCREW SRT 556 ADJUSTABLE 38 16 X 1 56 55 LP 652 1 38 AXLE ZERK SRT 557 ADJUSTABLE HANDLE 25 20 X 1 19 SS 7 SRT 506 HORIZONTAL CARRIAGE PLATE LWP 503 MOTOVARI0 DRIVE ASSY 1 SRT 546 HANDLE MOUNT BLOCK 4 STONEAGE 66 795 1586 WWWSTONEAGETOOLS COM2. O 5 LWP 516 WASHER OVERSIZED 2 2 15 16 17 18 19 21 29 24 25 26 27 28 29 866 95 1586 WWW STONEAGETOOLS COM PARTS DIAGRAM LIGHTWEIGHT POSITIONER SRT 560 BLANK HORIZONTAL ASSEMBLY PART NUMBER QTY 4 SRT 561 BLANK HORIZONTAL CARRIAGE PLATE 1 1 BR 052 2 0 AXLE ZERK 2 5 SRT 562 BLANK ROLLER SPACER 1 2 BR 055 SS ROLLER ASSY 6 6 GS 337 03 5 5 37 16 X 75 SS 2 3 LP 652 1 38 AXLE ZERK 4 LIGHTWEIGHT POSITIONER BU 152 RAIL STOP ASSEMBLY PART NUMBER QTY 1 BU 149 PLATE RAIL STOP 1 2 BR 060 RAIL CLAMP 1 3 GB 537 05 BOLT HEX 37 16 X 1 25 1 4 BU 151 HANDLE 1 PARTS DIAGRAM LIGHTWEIGHT POSITIONER LWP 518 SLOTTED QUICK CLAMP ASSEMBLY TIGHTEN NUT JUST REMOVE FREELY NOTON 9 3 8 THREADS lt lt lt ee YY Z j 2 UNDER BUSHING 7 A 024 AL S T SECTION A A NOTE 2 2 23 OCTITE 11 INSTALL PLUNGER SO BOTTOM FACE IS FLUSH WITH WALL OF PLATE l BLUE 1 BLUE LOCTITE SECTION B B 1 BLUE GOOP IS A SWAGELOK BRAND ANTI SEIZE AN EQUIVALENT ALTERNATIVE IS ACCEPTABLE 2 BLUE LOCTITE PN 242 OR EQUIVALENT 3 RED
3. TERMS AND CONDITIONS 1 Acceptance of Terms and Conditions These Terms and Conditions shall operate as Seller s acceptance of Buyer s purchase order and such acceptance is made expressly conditional on assent by Buyer to the Terms and Conditions Such assent shall be deemed to have been given unless written notice of objection to any of such Terms and Conditions including inconsistencies between Buyer s purchase order and this acceptance is given by Buyer to Seller promptly on receipt hereof Seller desires to provide its Buyer with prompt and efficient service However to negotiate individually the terms of each sales contract would substantially impair Seller s ability to provide such service Accordingly products furnished and services rendered by Seller are sold only on the Terms and Conditions stated herein Notwithstanding any Terms or Conditions on Buyer s order Seller s performance of any contract is expressly made conditional on Buyer s agreement to Seller s Terms and Conditions of sale unless otherwise specifically agreed to in writing by Seller In the absence of such agreement commencement of performance shipment and or delivery shall be for Buyer s convenience only and shall not be deemed or construed to be an acceptance of Buyer s Terms and Conditions PRODUCTS SOLD BY SELLER ARE DESIGNED AND INTENDED TO BE USED AT HIGH PRESSURES AND SPEEDS AND MAY BE DANGEROUS IF OPERATED IMPROPERLY OR WITHOUT THE USE
4. 0 4 11 PTY 2 5 SLOTTED RAIL CLAMP 3 OPTIONS FOR DIFFERENT FLANGE TYPES ARE AVAILABLE VERTICAL DRIVE ASSEMBLY 2 5 NON SLOTTED RAIL HORIZONTAL ASSEMBLY RAIL STOP 866 795 1586 WWW STONEAGETOOLS COM STONEAGE LIGHTWEIGHT POSITIONER OVERVIEW RAIL STOP ASSEMBLIES RAIL EXTENSIONS 2 4 OR 6 FT LENGTHS 61 m 1 2m OR 1 8 m E HORIZONTAL DRIVE TT ASSEMBLY VERTICAL SLOTTED 1 RAIL DE POSITIONER CONTROL LINE ASSEMBLY HORIZONTAL SLOTTED RAIL 4 3 3 25 7 6 STANDARD LENGTH CLAMP TYPES LWP 625 KIT INCLUDES ALL KITS SHOWN HERE VERTICAL DRIVE ASSEMBLY ere NON SLOTTED RAIL APEP SLOTTED QUICK CLAMP LWP 620 KIT CONTAINS 4 QUICK kaum 18 LWP 621 KIT PLATE CLAMP CONTAINS 4 LWP 622 KIT CONTAINS 2 lt 1 VEE E 0 0 pap F RAIL STOP BLANK HORIZONTAL ASSEMBLY ASSEMBLY P lt 866 795 1586 WWW STONEAGETOOLS COM LIGHTWEIGHT POSITIONER CLAMP SELECTION CLAMP SELECTION Is dependent upon the heat exchanger geometry holes hole spacing
5. PARTS DIAGRAM LIGHTWEIGHT POSITIONER LWP 502 BLUE GOOP NOTE 1 BLUE LOCTITE PN 243 OR EQUIVALENT 8 BLUE LOCTITE BLUE LOCTITE 2 BLUE G00P 15 A SWAGELOK BRAND ANTI SEIZE AN EQUIVALENT ALTERNATIVE 15 ACCEPTABLE _ 866 795 1586 WWW STONEAGETOOLS COM SRT 579 CLEVIS PIN SS WITH E RING SRT 582 VERTICAL BOTTOM PIPE CLAMP SRT 583 VERTICAL TOP PIPE CLAMP SRT 585 CLAMP SPACER STONEAGE PARTS DIAGRAM LIGHTWEIGHT POSITIONER LWP 503 MOTOVARIO DRIVE ASSEMBLY BLUELOCTITE 2 SEENOIES 2 LOOP LANYARDS TIGHTLY AROUND THEIR FITTING 5 BASES AND CRIMP IN PLACE s 220 RED LOCTITE 27 IN EXHAUST PORT DOWN RED LOCTITE 24 BLUE coor COMPONENTS ORIENT MOTOR AND FITTINGS APPROAIMATELY AS SHOWN 16 BLUE LOCTITE 15 BLUE LOCTITE NOTE 1 RED LOCTITE PN 262 0R EQUIVALENT 2 BLUE LOCTITE PN 242 0R EQUIVALENT 3 BLUE G00P IS A SWAGELOK BRAND ANTI SEIZE AN EQUIVALENT ALTERNATIVE 15 ACCEPTABLE 4 REMOVE MOUNTING FLANGE THAT COMES WITH GEARBOX KEEP INPUT SHAFT FACING UP PREVENT OIL LEAKAGE 5 ASSURE LANYARD EYELET CAN ROTATE 0909026006 7 90 4 _ 5 mesener STONEAGE LWP 520 1 AIR MOTOR o soos
6. AA STONEAGE ENGINEERING THE POWER OF WATER LIGHTWEIGHT POSITIONER LWP 500 Wa key A A aL aE RET AE ART ee ae ae aa E ae ea PL 610 REV A 10 2015 TABLE OF CONTENTS MANUFACTURER S INFORMATION 3 DESCRIPTION OF EQUIPMENT AND INTENDED 3 L DEOLAPATION OF 4 WARNING AND INSTRUCTIONS OPERATOR 5 PERSONAL PROTECTIVE EQUIPMENT 1 1 6 PRE RUN SAFETY 26 6 SYSTEM ASSEMBLY OVERVIEW LIGHTWEIGHT POSITIONER OVERVIEW LIGHTWEIGHT POSITIONER CLAMP 9 LIGHTWEIGHT POSITIONER 0 daya 10 STORAGE TRANSPORTATION AND HANDLING MAINTENANCE PARTS DIAGRAMS TERMS AND CONDITIONS 2 P STONEAGE 866 795 1586 e WWW STONEAGETOOLS COM MANUFACTURER S INFORMATION StoneAge Inc Andrew Birt Consulting Ltd 466 S Skylane Drive UK Durango CO 81303 USA Phone 970 259 2869 Toll Free 866 795 1586 www stoneagetools com 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 S
7. agreement and cannot be supplemented or amended without Seller s prior written approval Seller s waiver of any breach or failure to enforce any of the Terms and Conditions at any time shall not in any way affect 866 795 1586 WWW STONEAGETOOLS COM limit or waive Seller s right thereafter to enforce and compel strict compliance with every Term and Condition thereof If any provisions of these Terms and Conditions are held to be invalid or unenforceable such invalidity or unenforceability shall not affect the validity or enforceability of the other portions hereof 8 Disputes Buyer and Seller shall attempt in good faith promptly to resolve any dispute arising under these Terms and Conditions by negotiations between representatives who have authority to settle the controversy If unsuccessful Buyer and Seller shall further attempt in good faith to settle the dispute by nonbinding third party mediation with fees and expenses of such mediation apportioned equally to each side Any dispute not so resolved by negotiation or mediation may then be submitted to a court of competent jurisdiction in accordance with the terms hereof These procedures are the exclusive procedures for the resolution of all such disputes between the parties All sales agreements for sale offers to sell proposals acknowledgments and contracts of sale including but not limited to purchase orders accepted by Seller shall be considered a contract under the l
8. LOCTITE PN 262 OR EQUIVALENT 4 IF SHAFT DOES NOT SLIDE THROUGH BUSHING EASILY REAM BUSHING ID TO SHAFT OD 005 001 sma Ta os 25 0 CREW SHO STANLESS 2 74 1 _ usan o YC 18 STONEAGE ia umama 096 e wesa mn soea TT R KRK a 4 _ ESEZ TT mus 866 795 1586 WWW STONEAGETOOLS COM x PARTS DIAGRAM LIGHTWEIGHT POSITIONER LWP 519 6 BLUE LOCTITE SEE NOTE 3 j 6 i gt i BLUE LOCTITE I N 00 77 08 1 BEFORE INSTALLING KNOB INSTALL MIDDLE SPRING PIN 8 ADJACENT FLAT WASHER APPLY A THIN LAYER OF GENERAL PURPOSE GREASE TO UNTHREADED SECTION OF SHAFT THEN INSTALL SHAFT UP THROUGH SLIDE CLAMP THREAD KNOB ON SHAFT AS FAR AS POSSIBLE WHILE STILL ALLOWING SHAFT TO FREELY ROTATE THEN BACK OFF TO FIRST SPOT FOR SPRING PIN INSTALLATION 2 APPLY A THIN LAYER OF GENERAL PURPOSE GREASE TO ALL SURFACES OF PLATE THAT CLAMP WILL SLIDE ON 3 THREAD PLUNGER IN SO BALL ENGAGES DETENTS IN SHAFT DO NOT ALLOW BODY OF PLUNGER TO TOUCH SHAFT 4 BLUE GOOP IS A SWAGELOK BR
9. OF APPROPRIATE SAFETY DEVICES AND GUARDS BUYER IS CAUTIONED TO CAREFULLY READ AND UNDERSTAND THESE TERMS AND CONDITIONS AS THEY HAVE IMPORTANT LEGAL CONSEQUENCES 2 Payment Prices Unless other arrangements have been made in writing between Seller and Buyer payment for product delivered shall be made upon receipt of invoice The prices shown on the face hereof are those currently in effect Prices invoiced shall be per price list in effect at the time of shipment Prices are subject to increase for inclusion of any and all taxes which are applicable and which arise from the sale delivery or use of Seller s products or services and for the collection of which Seller is or may be responsible to any governmental authority unless acceptable exemption certificates are provided by Buyer in accordance with law Buyer shall pay all charges for transportation and delivery and all excise order occupation use or similar taxes duties levies charges or surcharges applicable to the equipment or services being purchased whether now in effect or hereafter imposed by any governmental authority foreign or domestic 3 Warranty Subject to the limitations and conditions hereinafter set forth Seller warrants to the original Buyer that its products are free from defects in workmanship and material for a period of one 1 year from shipment date Seller s obligation under this warranty shall be limited to repairing replacing or issuing a credit for
10. and flange accessibility QUICK CLAMPS Use if heat exchanger flange provides a robust clamping surface or if flange holes are inaccessible Align clamps on the surface of the flange to maximize flange engagement to clamps Figure 2 SLOTTED QUICK AND PLATE CLAMPS Use if heat exchanger flange has bolt holes that are easily accessible Use quick clamps or plate clamps depending on the spacing of the hole pattern Figures 1 amp 3 FIGURE 1 FIGURE 2 CLAMP TYPES LWP 625 KIT INCLUDES ALL KITS SHOWN HERE SLOTTED QUICK CLAMP LWP 620 KIT 2 CONTAINS 4 2 QUICK CLAMP LWP 621 KIT PLATE CLAMP CONTAINS 4 LWP 622 KIT CONTAINS 2 FIGURE 3 866 795 1586 WWW STONEAGETOOLS COM STONEAGE LIGHTWEIGHT POSITIONER SET UP LIGHTWEIGHT POSITIONER STEP BY STEP SET UP 1 Mount the appropriate frame Positioner Clamps to the tube bundle as shown on the previous page Shown in Figure 1 with Slotted Quick Clamps Positioner Clamps should be aligned horizontally with the direction of the tube rows Figure 1 NOTE Heat exchanger tube bundle face shown for graphic representation only Not included in assembly FIGURE 1 2 Insert the Top Rail slots facing out into the upper mounting brackets If the rail is not closely aligned with the tube rows loosen one of the upper mounting brackets and adjust until the top rail is parallel with the horizontal tube rows Tighten the clamps
11. at Seller s option any products or services it finds to be defective in material or workmanship In no event shall Seller be liable for any incidental consequential or indirect damages of any kind THIS WARRANTY SHALL BE IN LIEU OF ANY OTHER WARRANTY EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY FOR MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE No statement or recommendation made by Seller or its representative to Buyer or User shall constitute a warranty by Seller or a waiver or modification to any of the provisions hereof or create any liability for Seller All warranty claims are subject to the exclusions and limitations set forth below 22 P STONEAGE a The warranty shall not apply if the product or service 1 has been subject to misuse negligence or accident 2 has not been installed or operated in accordance with Seller s recommendations 3 has been operated under more severe conditions than those specified for the particular product or service 4 has been operated beyond the rated capacity of the product or 5 has been repaired or altered outside Seller s facilities or in any way so as in Seller s judgment to affect its stability or reliability b Products that Seller furnishes but does not manufacture carry only the warranty of the Manufacturer of such products Where other Manufacturers or Suppliers products used in Seller s products or services prove defective Seller s liability shall exist
12. securing the rail to the mounting brackets and ensure upper mounting brackets are securely clamped or bolted to the tube bundle flange Figure 2 FIGURE 2 3 Insert the Lower Rail non slotted into the lower mounting e 2240 brackets is not critical that this rail is aligned as precisely the top rail but it should be close to parallel with the top rail for best performance Tighten the clamps securing the to the mounting brackets and ensure lower mounting brackets are securely clamped or bolted to the tube bundle flange Figure 3 4 Loosen the Quick Adjust Handle and pull the gearbox away from the carriage plate This will allow the Horizontal Drive Carriage to slide onto the rail without pneumatic power to rotate the drive Center the carriage on the top rail and push the gearbox back toward the carriage plate This will engage the gear into the rail slots Verify the gear is engaging the slots correctly and retighten the adjustable handle Figure 4 10 STONEAGE 866 795 1586 e WWW STONEAGETOOLS COM LIGHTWEIGHT POSITIONER SET UP eee 5 Slide the Idler Carriage onto the Lower Non Slotted Rail Figure 5 FIGURE 5 6 Loosen the Large Adjustable Handle for the Vertical Rail Clamp Align the Idler Carriage with the vertical rail clamp on the horizontal carriage Install the Vertical Rail with slots facing out down through the horizontal carriage clamp and
13. AND ANTI SEIZE AN EQUIVALENT ALTERNATIVE IS ACCEPTABLE 5 BLUE LOCTITE PN 242 OR EQUIVALENT 68957 05800 HEX HED STANLESS 4 ow sr Lock sames a e 7 owe sso sac nose srama unen PARTS DIAGRAM LIGHTWEIGHT POSITIONER LWP 552 SLOTTED QUICK CLAMP ASSEMBLY BLUE GOOP A NOT 3 8 THREADS TIGHTEN NUT JUST ENOUGH TO REMOVE SLOP BUT STILL ALLOW SHAFT TO ROTATE FREELY lt SECTION A A INSTALL PLUNGER SO BOTTOM FACE IS FLUSH WITH WALL OF PLATE NOTE 1 BLUE G00P IS A SWAGELOK BRAND ANTI SEIZE AN EQUIVALENT ALTERNATIVE IS ACCEPTABLE 2 BLUE LOCTITE PN 242 0R EQUIVALENT 3 RED LOCTITE PN 262 0R EQUIVALENT 0 2 6559 0312 0750 55 SHOULDER SCREW 5 ws aL NOSE Ear masr rr 1 2 3 5 7 20 866 795 1586 WWW STONEAGETOOLS COM 5 DIAGRAM LIGHTWEIGHT POSITIONER SRT 115 POSITIONER CONTROL LINE ASSEMBLY PART NUMBER QTY 1 SRT 121 POSITIONER AIR LINE COVER 26FT 0AL 1 2 SRT 118 CONTROL LINE RED 2 3 SRT 119 FEMALE J4 SWIVEL 250 1 0 HOSE BARB 4 866 795 1586 e WWW STONEAGETOOLS COM A
14. PECIFICATIONS Lightweight Positioner Weight 120 108 54 4 kg Includes rails horiz vert and idler carriage and 4 clamps DESCRIPTION OF EQUIPMENT AND INTENDED USE The Lightweight Positioner can be mounted to a variety of heat exchanger tube bundles and has pneumatic powered horizontal and vertical drives It is intended to be used with AUTOBOX ABX 2L HOSE TRACTOR and the AUTOBOX ABX 500 V2 KEY FEATURES Modular lightweight design e Quick install drive carriages e Utilizes 2 5 in 6 35 cm box e Stainless Steel air motors e Variety of clamp and bolt on attachment options are available 866 795 1586 WWW STONEAGETOOLS COM STONEAGE CE DECLARATION OF CONFORMITY In accordance with BS EN ISO IEC 17050 1 2010 We StoneAge Inc 466 South Skylane Drive Durango CO 81303 USA Declare that Equipment Lightweight Positioner Model name LWP 500 Is in accordance with the following Directives 2006 42 EC Conforms to the Essential Health and Safety Requirements of the Machinery Directive Has been designed and manufactured to the relevant parts of the following specifications EN ISO 12100 2010 Safety of machinery General principles for design Risk assessment and risk reduction hereby declare that the equipment named above has been tested and found to comply with the relevant sections of the above referenced specifications and directives a Date 08 23 2015 Andrew Birt In
15. Seller s quotations are recommended for purchase Seller may provide necessary safety devices and guards not offered in this quotation at an extra price in accordance with the specifications of Buyer Buyer shall at all times use and require its contractors to use all necessary and appropriate safety devices guards and proper safe operating procedures Buyer shall ensure that proper Operator training is provided Buyer shall not remove or modify any such devices guards or warning signs and shall insist on safe operating practices on the part of its personnel In no event shall Seller be responsible for any injuries to persons or property caused by defects in any equipment including by way of illustration and not limitation any pumps compressors fittings connections components piping or hoses up to the point that same are connected to the product Buyer agrees to indemnify and to save Seller harmless from any and all liability or obligation incurred by or against Seller including costs and attorneys fees to or by any persons injured directly or indirectly in the operation of the equipment furnished under the following conditions 866 795 1586 WWW STONEAGETOOLS COM a if Buyer fails to purchase and use necessary and appropriate safety devices and guards as determined and or recommended by Seller b if Buyer fails to maintain in good working order such safety devices and guards as are purchased from Seller c if Buyer adds
16. aws of the State of Colorado and the rights and duties of all persons and the construction and effect of all provisions hereof shall be governed by and construed according to the laws of such state A state or federal court located within the State of Colorado shall have sole and exclusive jurisdiction over any litigation concerning any such matters as well as any alleged defects of any products or equipment covered thereby or damages sustained as a result of such alleged defects If any litigation is commenced between Seller and Buyer or their personal representatives concerning any provision hereof the party prevailing in the litigation shall be entitled in addition to such other relief that is granted to a reasonable sum as and for their attorneys fees and costs in such litigation or arbitration 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 sStoneAgetools 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 CONDITIONS 23 6 ENGINEERING THE POWER OF WATER 1 866 795 1586 www STONEAGETOOLS com 2015 StoneAge Inc All Rights Reserved
17. between the rollers on the idler carriage Adjust the position of the vertical rail as required and secure the clamp on the horizontal carriage by tightening the large adjustable handle Figure 6 FIGURE 6 7 Loosen the Quick Adjust Handle and pull the gearbox away from the carriage plate This will allow the Vertical Drive Carriage to slide onto the rail without pneumatic power to rotate the drive Center the carriage on the vertical rail and push the gearbox back toward the carriage plate This will engage the gear into the rail slots Verify the gear is engaging the slots correctly and retighten the adjustable handle Figure 7 8 Install the four Rail Stops at both ends of the top slotted horizontal rail and both ends of the vertical slotted rail Figure 8 NOTE Verify the mounting brackets and rail clamps are securely tightened and that the drive carriages are securely engaged and the adjustable handles are tightened Never loosen the vertical gearbox once the guide assembly and tractor are installed as it may result in the carriage falling vertically down This may cause damage and or injury FIGURE 8 866 795 1586 e WWW STONEAGETOOLS COM A S79NEAGE 1 MAINTENANCE Maintenance Item Frequency Maintenance Required Forward reverse clamp fittings Before each use Inspect threads for wear or damage Carriage rollers Every 100 Hours of use Lubricate Zerks on all Carriage Rollers using any multipurpos
18. cts e g loose parts hoses tools Ensure all Operators are using the correct Personal Protective Equipment PPE Check that the air hoses are properly connected and tight Check all hoses and accessories for damage prior to use Do not use damaged items Only high quality hoses intended for waterblast applications should be used as high pressure hoses Check all high pressure threaded connections for tightness Ensure that a anti withdrawal device back out preventer whip checks hose whips and all other applicable safety devices are installed and set up properly e Ensure the doors of the Lightweight Positioner LVVP 500 are closed and securely latched e Test the Control Box before operating the Lightweight Positioner LWP 500 with high pressure water to verify the control valves move the hose in the intended direction and that the dump valve and hose clamp are working properly e Ensure that Operators never connect disconnect or tighten hoses adapters or accessories with the high pressure water pump unit running e Ensure no personnel in the hydroblasting zone P lt 866 795 1586 WWW STONEAGETOOLS COM SYSTEM ASSEMBLY OVERVIEW LIGHTWEIGHT POSITIONER LWP 500 ASSEMBLY RAIL STOP HORIZONTAL DRIVE ASSEMBLY RAIL STOP Sisia I i ERENE 4
19. dependent Dealer Manager Signed StoneAge Inc Worcester UK The technical file for the Lightweight Positioner LWP 500 User Manual is maintained at StoneAge Inc 466 South Skylane Drive Durango CO 81303 USA 4 STONEAGE 866 795 1586 WWW STONEAGETOOLS COM WARNING AND SAFETY INSTRUCTIONS OPERATOR TRAINING Managers Supervisors and Operators MUST be trained in Health Operators MUST read understand and follow the Operational and Training Requirements Section 7 0 of WJTA IMCA s Recommended Practices For The Use Of High pressure Waterjetting Equipment or and Safety Awareness of High pressure Water Jetting and hold a copy the Water Jetting Association WJA Code of Practice or equivalent see www waterjetting org uk Operators MUST be trained to identify and understand all applicable standards for the equioment supplied Operators should be trained in manual handling techniques to prevent bodily injury StoneAge has designed and manufactured this equipment considering all hazards associated with its operation StoneAge assessed these risks and incorporated safety features in the design StoneAge WILL NOT accept responsibility for the results of misuse IT IS THE RESPONSIBILTY OF THE INSTALLER OPERATOR to equivalent Operators MUST read understand and follow the Warnings Safety Information Assembly Installation Connection Operation Transport Handling Storage and Maintenance Instructi
20. e NLGI 2 grease Vertical and Horizontal Rails As Needed Inspect for wear that would allow Carriage Rollers to slip off Replace Rail as needed All components the hoses pass through After cach use Most wear parts are made from 17 4 PH stainless steel and should have a very long life However as wear occurs the rounded edges could become sharp and damage hoses Any components showing excessive wear should be replaced STORAGE TRANSPORTATION AND HANDLING Use mild soapy water to clean the machine in order to remove corrosive materials Before storing the unit use compressed air to blow off debris and moisture Apply a small amount of air tool oil directly into the Horizontal and Vertical Drive fittings Then briefly operate the controls at slow speed for a short duration in each direction to coat the interior parts of the motor Install the dust caps onto all fittings to keep moisture and dirt out The Lightweight POSITIONER LWP 500 can be broken down into smaller components that should be stored in a clean and dry area Contact StoneAge for Safety Data Sheets for material usage a complete list of part numbers and service instructions for the Lightweight Positioner 12 STONEAGE 866 795 1586 WWW STONEAGETOOLS COM PARTS DIAGRAM LIGHTWEIGHT POSITIONER LWP 500 BU 152 RAIL STOP LWP 501 HORIZONTAL DRIVE ASSY BU 152 RAIL STOP 152 STOP
21. e rollers 866 795 1586 WWW STONEAGETOOLS COM PPE may include Eye protection Full face visor Foot protection Keviar brand or steel toe capped waterproof non slip safety boots Hand protection Waterproof gloves Ear protection Ear protection for a minimum of 85 dBA Head protection Hard hat that accepts a full face visor and ear protection Body protection Multi layer waterproof clothing approved for waterjetting Hose protection Hose shroud Respiratory protection May be required refer to job specific risk assessment STONEAGE WARNING AND SAFETY INSTRUCTIONS 6 AWARNING Operations with this equipment 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 wijta org Deviating from safety instructions and recommended practices can lead to severe injury and or death Do not exceed the maximum operating pressure specified for any component in a system The immediate work area MUST be marked off to keep out untrained persons Inspect the equipment for visible signs of deterioration damage and improper assembly Do not operate if damaged until repaired Make sure all threaded connections are tight and free of leaks Users of the Lightweight Positioner LWP 500 MUST be trained and or experi
22. enced in the use and application of high pressure technology and cleaning as well as all associated safety measures according to the WJTA Recommended Practices for the use of High pressure Waterjetting Equipment An anti withdrawal device back out preventer MUST be used at all times The back out prevention device is the Hose Stop Collet located within the Hose Guide Assembly StoneAge offers several different size Hose Stop Collets The Collet Size Reference guide is located on the Hose Guide Assembly The Control Box should be located in a safe location where the Operator has good visibility of the pipe and hose The Lightweight Positioner LWP 500 and Control Box MUST be supervised at all times and should never be left unattended Always de energize the system before servicing or replacing any parts Failure to do so can result in severe injury and or death When moving the Lightweight Positioner LWP 500 lift with care to prevent bodily injury PRE RUN SAFETY CHECK Refer 5 Recommended Practices For The Use Of High pressure Waterjetting Equipment and or The Water Jetting Association s WJA Code of Practice for additional safety information Complete a job specific risk assessment and act on the resulting actions Adhere to all site specific safety procedures Ensure the waterblasting zone is properly barricaded and that warning signs are posted Ensure the work place is free of unnecessary obje
23. hortages or errors must be reported within fifteen 15 business days from receipt of shipment to secure adjustment No merchandise may be returned without securing written approval from Seller Seller will notify Buyer promptly of any material delay and will specify the revised delivery date as soon as practicable Seller shall not be liable for any delay in delivery or performance or for any failure to manufacture deliver or perform due to a any cause beyond its reasonable control b any act of God act of Buyer act of civil or military authority governmental priority strike or other labor disturbance flood epidemic war riot delay in transportation or car shortage or c inability on account of any cause beyond the reasonable control of Seller to obtain necessary materials components services or facilities In the event of any such delay the date of delivery or of performance shall be extended for a period equal to the time lost by reason of the delay 6 Technical Advice All technical advice recommendations and services of Seller are intended for use by persons having adequate skill at their own risk and Seller assumes no responsibility and Buyer hereby waives all claims against Seller for results obtained or damages incurred from the use of Seller s advice recommendations and services 7 Modification These Terms and Conditions are intended by Seller and Buyer to constitute a final complete and exclusive expression of
24. omits repairs modifies replaces or substitutes any components on the equipment without permission from Seller d if Buyer exceeds at any time the maximum safe loads pressures or speeds recommended by Seller for the equipment furnished hereunder without the specific written consent of Seller or e if Buyer otherwise fails to operate the product or equipment in accordance with Seller s printed instructions or otherwise negligently operates the equipment 5 Delivery Seller is not obligated to make delivery by a specified date but will always use its best efforts to make delivery within the time requested All deliveries are based on F O B Seller s factory unless specifically agreed otherwise and Buyer shall pay all shipping costs and insurance from that point Seller in its sole discretion will determine and arrange the means and manner of transportation of the products Responsibility of Seller shall cease and Buyer assumes all risk of loss or damages upon Seller s delivery to and receipt by a common carrier Carriers shall be responsible for goods lost or damaged in transit and Buyer shall immediately notify the carrier in writing of such loss or damage At request Seller will offer its assistance THE PROPOSED SHIPMENT DATE IS AN ESTIMATE UNDER NO CIRCUMSTANCES SHALL SELLER HAVE ANY LIABILITY WHATSOEVER FOR LOSS OF USE OR FOR ANY DIRECT OR CONSEQUENTIAL DAMAGES RESULTING FROM DELAY REGARDLESS OF THE REASON S S
25. only to the extent that Seller is able to recover from such Manufacturers or Suppliers for such defects c Any warranty granted by Seller to the Buyer shall be deemed void if any goods covered by such warranty are used for any purpose not recommended or permitted In addition the Buyer shall indemnify Seller and hold Seller harmless from and against any and all claims damages losses costs expenses and other liability of whatever nature that Seller suffers or incurs by reason of any such unintended use d Notice of defective product or service must be given in writing to Seller by Buyer or User within fifteen 15 business days following receipt of goods Buyer or User shall keep such products or services in an unaltered condition for examination by Seller s representative No goods may be returned for credit or adjustment without prior written permission from Seller 4 Product Liability Buyer specifically acknowledges that the products being purchased may be operated at high speeds and or pressures and that as such they may be inherently dangerous if not used correctly Buyer shall be solely responsible for the safe operation of the products at all times and for determining the safety devices and guards that may be required for the safe operation of the products Buyer shall undertake to specify and order all safety devices and guards necessary for the safe operation of the equipment covered All safety devices and guards offered in
26. ons detailed in this manual The risk assessment MUST consider potential material or substance hazards including Aerosols Biological and microbiological viral or bacterial agents Combustible materials conduct a job specific risk assessment prior to use Job specific risk e Dusts assessment MUST be repeated for each different set up material Explosion and location Fibers The risk assessment MUST conform to the Health and Safety at substances Work Act 1974 and other relevant Health and Safety legislation e Gases e Mists e Oxidizing Agents PERSONAL PROTECTIVE EQUIPMENT REQUIREMENTS Use of Personal Protective Equipment PPE is dependent on the working pressure of water and the cleaning application Managers Supervisors and Operators MUST carry out a job specific risk assessment to define the exact requirements for PPE See Protective Equipment for Personnel Section 6 of WJTA IMCA s Recommended Practices For The Use Of High pressure Waterjetting Equipment for additional information Hygiene Operators are advised to wash thoroughly after all waterjetting operations to remove any waterblast residue which may contain traces of harmful substances First aid provision users MUST be provided with suitable first aid facilities at the operation site SAFETY LABEL DEFINITION The Lightweight Positioner LWP 500 has the potential to Cause serious injury if fingers hair or clothing become caught between th
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