StoneAge PROPOSITIONER PROP-DBP User Manual
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StoneAge PROPOSITIONER PROP-DBP User Manual

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P
P
RO
OSITIONER™
(PROP-DBP) ACCESSORY
USER MANUAL
PL 688 REV D
(08/2020)

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Summary of Contents for StoneAge PROPOSITIONER PROP-DBP

  • Page 1 OSITIONER™ (PROP-DBP) ACCESSORY USER MANUAL PL 688 REV D (08/2020)

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SUB-ASSEMBLY COLOR CODE DIAGRAM ........... . . MANUFACTURER’S INFORMATION .
  • Page 3 TABLE OF CONTENTS POSITIONER SET-UP INSIDE DOMED BUNDLE ..........INSTALL SPIDER PLATE ONTO TUBE FACE .

  • Page 4: Sub-Assembly Color Code Diagram

    SUB-ASSEMBLY COLOR CODE DIAGRAM REVIEW THIS BEFORE STARTING ASSEMBLY: THE FIVE COLOR CODED SUB-ASSEMBLIES NEED TO BE ASSEMBLED BEFORE CONNECTING EVERYTHING TO THE DOMED BUNDLE. THE COLORS ARE ASSOCIATED TO THEIR RESPECTIVE SECTIONS IN THIS MANUAL. THE HOSE CONNECTIONS WILL BE MADE IN A LATER SECTIONS OF THIS MANUAL SUB-ASSEMBLY 3 (RAIL MOUNT, SNOUT, AND TOOL)

  • Page 5: Manufacturer's Information

    MANUFACTURER’S INFORMATION StoneAge Inc. StoneAge NL 466 S. Skylane Drive Reedijk 7Q Durango, CO 81303, USA 3274 KE Heinenoord Phone: 970-259-2869 Netherlands Toll Free: 866-795-1586 (+31) (0) 85 902 73 70 www.stoneagetools.com sales-NL@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).

  • Page 6: Ec Declaration Of Conformity

    The Technical File for ProPositioner for Domed Bundle (PROP-DBP) and Control Box (CB-PROP-P) is maintained at: StoneAge Incorporated, 466 South Skylane Drive, Durango, CO 81303, USA and was compiled by the Engineering Manager. The Technical File is available through the Authorized Representative.
  • Page 7 NOTES PAGE LEFT BLANK INTENTIONALLY 866-795-1586 • WWW.STONEAGETOOLS.COM...

  • Page 8: Warning And Safety Instructions

    Aerosols • StoneAge WILL NOT accept responsibility for the results of misuse. Biological and microbiological (viral or bacterial) agents • IT IS THE RESPONSIBILITY OF THE INSTALLER/OPERATOR Combustible materials •...

  • Page 9: Pre-Run Safety Check

    • Check all hoses and accessories for damage prior to use. Do • Users of the ProPositioner PROP-DBP and accessories MUST • not use damaged items. Only high quality hoses intended for be trained and/or experienced in the use and application of waterblast applications should be used as high-pressure hoses.
  • Page 10 PROP-DBP-XXX-PKG CONTENTS PART ID PART ID CAM 102-V2 CB 488 MONITOR MONITOR MOUNT CAM 220 CAMERA HOUSING CAM 210 CIRCULAR CAM 200-AC-US CONNECTOR AC POWER PACK CAM 245 CAMERA CABLE PROP 430-001 CB 755-15-C SPIDER PLATE PRODRIVE SUPPLY ASSEMBLY HOSE WITH CAMERA &...

  • Page 11: Optional Equipment

    OPTIONAL EQUIPMENT PART ID PART ID ∆ ∆ PROP-300 CB-PROP-P PROPOSITIONER CONTROL BOX- PEDESTAL STYLE (SEE PROP-300 USER WITH UMBILICAL MANUAL FOR MORE HOSE CONNECTIONS INFORMATION) FPA-SKR ACDA 61020019-K FOOT PEDAL DUMP AIR ACTUATED DUMP WITH PRESSLOCK VALVE WITH FITTINGS FITTINGS AND 1/4”...

  • Page 12: Sub-Assembly 1 (Abx-Pro, Rollers, Collet Block, Guide Tube)

    SUB-ASSEMBLY 1 (ABX-PRO, ROLLERS, COLLET BLOCK, AND GUIDE TUBE) REMOVE ROLLERS IN ABX-PRO TRACTOR FIGURE 1 The standard roller size on the ABX-PRO Tractor is Ø.46 IN. PROP-DBP accessory comes with a set of replacement Ø.54 IN. Quick rollers to accommodate 8/4 hose. Release Pin (x2) The replacement rollers must be installed on the ABX-PRO...
  • Page 13 SUB-ASSEMBLY 1 (ABX-PRO, ROLLERS, COLLET BLOCK, AND GUIDE TUBE) INSTALL ROLLERS IN ABX-PRO TRACTOR Slide the PRO 174-54 Poly Rollers onto the Drive and Idler Hubs. Using a 1/4” Hex Key, fasten the Outer Hub Plates and Roller Washers onto the Rollers with two 5/16” socket head cap screws.

  • Page 14: Install Angled Guide Tube

    SUB-ASSEMBLY 1 (ABX-PRO, ROLLERS, COLLET BLOCK, AND GUIDE TUBE) INSTALL THE COLLET BLOCK ASSEMBLY Collet Block Remove the Slide Block with a 6mm hex key. Rotate it so that Slide Block the end with the most distance from the screws is pointing down.

  • Page 15: Sub-Assembly 2 (Linear Drive Handle)

    SUB-ASSEMBLY 1 (ABX-PRO, ROLLERS, COLLET BLOCK, AND GUIDE TUBE) INSTALL THE CAMERA MOUNT ANGLED GUIDE TUBE Loosen the adjustable handle on the Camera Mount and slide it up the guide tube. Orient the Camera as shown and tighten the adjustable handle when in place.

  • Page 16: Sub-Assembly 3 (Rail Mount, Snout, And High Pressure Hose)

    SUB-ASSEMBLY 3 (RAIL MOUNT, SNOUT, AND HIGH PRESSURE HOSE) LOAD THE HIGH-PRESSURE HOSE INTO THE SNOUT ON THE RAIL MOUNT Before installing High-Pressure hose, please be sure to review the “HIGH-PRESSURE HOSE” “WARNING AND SAFETY INSTRUCTIONS” section of this information in the manual.

  • Page 17: Sub-Assembly 4 (Control Box And Camera)

    SUB-ASSEMBLY 4 (CONTROL BOX AND CAMERA) CONNECT THE PNEUMATIC LINES TO THE CONTROL BOX Organize the supplied Air Line Umbilicals. (Figure15) Control Box to ABX-PRO and Camera 1/2” JIC and Camera Connections Umbilicals Control Box to Linear and Rotary Drives (Come contained 3/8”...

  • Page 18: Connect The Monitor Mount, Monitor, And Power Pack

    SUB-ASSEMBLY 4 (CONTROL BOX AND CAMERA) CONNECT THE MONITOR MOUNT, MONITOR AND POWER PACK TO THE CONTROL BOX Attach the Monitor to the Monitor Mount Assembly with the supplied screws, washers, and wing nuts as shown in (Figure 18). Tighten by hand.

  • Page 19: Sub-Assembly 5 (Optional Dump System Set-Up)

    SUB-ASSEMBLY 5 (OPTIONAL DUMP SYSTEM SET-UP) WARNING OPTIONAL PNEUMATIC DUMP CONTROL CONNECTIONS StoneAge recommends the use of some kind of dump valve for all Always use Hose Whip Restraints. Failure to do so can result waterblasting operations. We offer a variety of dump valve options.

  • Page 20: Install Spider Plate Onto Tube Face

    PROPOSITIONER ATTACHMENT TO DOMED BUNDLE POSITIONER STEP BY STEP SET-UP INSIDE THE DOMED BUNDLE TECH TIP: It is highly recommended to put five necessary tools in a tote for the installer to take inside the dome. • Tape Measure • 1/2”...
  • Page 21 PROPOSITIONER ATTACHMENT TO TUBE BUNDLE Locate the center of the tube face. If there is no center identifier, use a tape measure to locate and mark center. (Figure 27) Top Row Center 6” - 8”± (152mm - 203mm) Man Way FIGURE 27 Insert the Adjustable Expansion Plugs into the tube locations that will allow the Spider Plate to be positioned on the tube...

  • Page 22: Install Rotary Drive And Drive Rail Onto Spider Plate

    PROPOSITIONER ATTACHMENT TO TUBE BUNDLE INSTALL ROTARY DRIVE AND DRIVE RAIL ONTO SPIDER PLATE Hand the Rotary Drive and Drive Rail through the man way to the Unlocked person positioned inside the Domed Bundle. Unlock the Rail Clamp Handle on the Rotary Drive and slide the Drive rail into the Rail Clamp.

  • Page 23: Install Linear Drive And Rail Plug On Drive Rail

    PROPOSITIONER ATTACHMENT TO TUBE BUNDLE INSTALL LINEAR DRIVE AND RAIL PLUG ON DRIVE RAIL 12. Hand the Linear Drive through the man way to the person positioned inside the dome. 13. Rotate both Adjustable Handles on the Linear Drive up to retract the Drive Gear and allow the Linear Drive to slide along the Drive Rail.

  • Page 24: Install Sub-Assembly 1 On The Linear Drive

    PROPOSITIONER ATTACHMENT TO DOMED BUNDLE INSTALL SUB-ASSEMBLY 1 ON THE LINEAR DRIVE CAUTION The ABX-PRO, Guide Tube, Collet Block, sub-assembly is heavy. Use caution when handing it through the man way. 18. Hand Sub-Assembly 1 through the man way to the person positioned inside the Domed Bundle.

  • Page 25: Set The Drive Rail And Linear Drive In Place

    PROPOSITIONER ATTACHMENT TO DOMED BUNDLE SET THE DRIVE RAIL AND LINEAR DRIVE IN PLACE 23. Before locking the Positioner in place, be sure that the Guide Tube can swing in the direction shown below without hitting the walls and the Linear Drive has enough stroke to reach the Top Tube.
  • Page 26 SET-UP DIMENSIONS FOR 69 INCH (1753mm)TUBE FACE TOP AND CENTER INSTALLATION DIMENSIONS These four images are set-up dimensions to allow the Positioner system to clean the TOP, CENTER, LEFT, and RIGHT areas of the tube face without hitting the walls. These dimensional diagrams are for a 69in. (1753mm) tube face. Center Line FIGURE 40 Center Line...
  • Page 27 SET-UP DIMENSIONS FOR 69 INCH (1753mm) TUBE FACE LEFT AND RIGHT INSTALLATION DIMENSIONS Center Line in line with the man way LEFT Center Line FIGURE 42 This is an approximate measurement and can be anywhere between 6-8 inches Center Line in line with the man way Center Line...

  • Page 28: Control Box Connections To Positioner

    CONTROL BOX CONNECTIONS TO POSITIONER PNEUMATIC SUPPLY LINE CONNECTION FROM CONTROL BOX TO POSITIONER All the pneumatic supply lines should have been connected to the Control Box. If not please go back to the “Sub-Assembly 4 (Control Box and Camera)” section of this manual. Turn ON the main air supply line to the Control Box and blow out all lines to clear debris before connecting the ProPositioner.

  • Page 29: Rail Mount Installation

    ICM (TOP MOUNT) RAIL MOUNT INSTALLATION ICM (TOP MOUNT) AND DELTA T (SIDE MOUNT) RAIL MOUNTS AND SNOUT INSTALLATIONS The ICM (top mount) and Delta T (side mount) Rail Mounts are similar TOP VIEW except for the man way Trolley Clamp Assemblies. The ICM (top mount) Rail Mount is designed to mount at an angle.
  • Page 30 DELTA T (SIDE MOUNT) RAIL MOUNT INSTALLATION To Mount to the Delta T (side mount) man way: Fasten the Trolley at the six O’Clock position on the flange of the Man Way. Use two 3/4” x 4” Hex Bolts, four 3/4” flat washers and two 3/4”...

  • Page 31: High Pressure Hose And Snout Installation

    HIGH-PRESSURE HOSE AND SNOUT INSTALLATION LOAD THE HOSE INTO THE ABX-PRO TRACTOR AND GUIDE FIGURE 52 CAM Lever TUBE/COLLET BLOCK To load the hose, push up to release the Adjustable Handle and rotate the Cam Lever counterclockwise until the Indicator Pin is in the “Disengaged”...

  • Page 32: Operation

    OPERATION CONTROL BOX SETTINGS Using the Pressure Regulator on the FRL, adjust the operating pressure to 100 psi (0.7 MPa) for the application. (Figure 55) Adjust in-line oiler to feed 1 drop of oil every 30-60 seconds for high speed or continuous duty usage. (Figure 55) WARNING Maximum operating pressure is 100 psi (0.7 MPa).
  • Page 33 OPERATION DANGER Do NOT run the positioner until all operators are outside of the dome and the system is ready to run. TEST RUN PROCEDURE POWER BUTTON Perform the PRE-RUN SAFETY CHECK • Follow “THE WARNING AND SAFETY INSTRUCTIONS” section in this manual.

  • Page 34: Maintenance And Troubleshooting

    -Check that the proper Rollers are installed (see roller and collet reference plate) -Tighten CAM lever on ABX-PRO Tractor to retain clamp force on hose. Contact StoneAge for Safety Data Sheets for material usage, a complete list of spare part numbers, and service instructions for the ProPositioner (PROP-DBP), and CONTROL BOX (CB-PROP-P).
  • Page 35 Please see the User Manuals for the ABX-PRO Hose Tractor and the ProPositioner PROP-300 for more detailed information on those components. https://www.stoneagetools.com manuals Contact StoneAge for Safety Data Sheets for material usage, a complete list of spare part numbers, and service instructions for the Positioner and all accessories. 866-795-1586 • WWW.STONEAGETOOLS.COM...
  • Page 36 PART DIAGRAMS BOP 090-7-001 7’X 1.25” CORRUGATED SNOUT WITH CAMLOCK PART NUMBER QTY. BOP 090.4 NIPPLE 1.25 MNPT BOP 090.5 CAMLOCK. FEMALE SS, 1.25 BOP 090.6 1.25 CORRUGATED SNOUT CAM 102-V2 MONITOR ASSEMBLY PART NUMBER QTY. CAM 102.1 MONITOR CAM 199 CONEC M12 SCREW TERMINAL MALE 8POS 866-795-1586 •...

  • Page 37: Cam 220 Camera Housing Assembly

    PART DIAGRAMS CAM 200-AC AC POWER PACK (US PLUG) *Input power requirements 100-240V AC 1.8A CAM 220 CAM 210 CAMERA HOUSING ASSEMBLY CIRCULAR CONNECTOR 4POS SCREW MALE CAM 245 CAMERA CABLE 866-795-1586 • WWW.STONEAGETOOLS.COM...

  • Page 38: Cb-Prop-P Control Box Pedestal Assembly

    PART DIAGRAMS OSITIONER (CB-PROP-P) CONTROL BOX PEDESTAL ASSEMBLY PART NUMBER QTY. CB-PROP.1-P CONTROL BOX UPPER ASSY, PEDESTAL CB 471 BASE HC 025.1 NUT, NYLOK 10-24 SS CB 472 BASE SIDE PLATE GS 319-03 SHCS 10-24 X .75 SS CB 473 BASE BRACE GS 319-20 SHCS 10-24 X 5.00 SS CB 480-BK FTG ASSY, PL6 BLACK GSB 319-02 BHCS 10-24 X .50 SS...
  • Page 39 PART DIAGRAMS OSITIONER (CB-PROP.1-P) CONTROL BOX PEDESTAL SUB- ASSEMBLY PART NUMBER QTY. CB 763 RL ASSY, ABX PRO GP 011-BK ID WASHER, RUBBER, MED, BLACK BOP 070 HINGE CLAMP ASSEMBLY CB 765-FWD 90 DEG FLOW CONTROL BLOCK, GP 011-R ID WASHER, RUBBER, MED, RED FORWARD BR 167 DUST CAP, J8 GPTB 0500-PUR95A-BK MAIN TUBE, FRL, 9IN...

  • Page 40: Cb 470 Base Assembly

    PART DIAGRAMS CB 470 CB 480-XX BASE ASSEMBLY FTG ASSY, PL6 (BK OR RD) PART NUMBER -BK PL6/QTY. -RD PL6/QTY. PART NUMBER QTY. GP 013-BK ID WASHER, RUBBER, SMALL, BLACK CB 471 BASE CB 472 BASE SIDE PLATE GP 013-R ID WASHER, RUBBER, SMALL, RED CB 473 BASE BRACE CB 482 FTG, BULKHEAD ADAPTER P4F PL4 GSB 319-02-32 BHCS 10-32 X .50 SS...

  • Page 41: Cb 755-15-C Prodrive Supply Hose With Camera Cable

    PART DIAGRAMS CB 496 CB 497 SPOOL VALVE ASSEMBLY SPOOL VALVE ASSEMBLY PART NUMBER QTY. BR 154 MUFFLER P6 PART NUMBER QTY. BUD 141 FTG, ELBOW SWIVEL 90 P6M PL8 BR 154 MUFFLER P6 CB 329-OPEN PILOT SPOOL VALVE, OPEN CENTER CB 329-OPEN PILOT SPOOL VALVE, OPEN CENTER CB 494 FTG, STEM ELBOW 90 PL8M PL8F CB 375 FTG, ELBOW SWIVEL 90 P6M PL4...
  • Page 42 PART DIAGRAMS DBP 305 RAIL PLUG ASSEMBLY PART NUMBER QTY. DBP 182 RAIL BLOCK DBP 305.1 RAIL PLUG PROP 008-2.5-001 2.5” WEDGE BOLT ASSEMBLY TB 050 SHCS .25-20 X .75 SS DBP 320 ICM (TOP MOUNT) TROLLEY CLAMP ASSEMBLY PART NUMBER QTY.

  • Page 43: Dbp 330 Delta T (Side Mount) Trolley Clamp Assembly

    PART DIAGRAMS DBP 330 DELTA T (SIDE MOUNT) TROLLEY CLAMP ASSEMBLY PART NUMBER QTY. FF 164 SS COMPRESSION SPRING BR 051-2.0-0 AXLE-ZERK GB 575-16 BOLT, HEX .75-10 X 4.00 BR 055 ROLLER ASSY GN 350-LJ NYLOK NUT THIN SS BU 151 HANDLE GN 575-L NYLOK NUT DBP 310 BOX RAIL FLANGE MOUNT WELDMENT GSSH 0312-1000-SS SHOULDER SCREW...
  • Page 44 PART DIAGRAMS OSITIONER (PROP 187-XX-K) EXPANSION PLUG KITS Tube ID Range: Inches Kit Part Number Expansion Plug Washer Spacer Knob screw Knob Washer Bolt 0.901-0.982 22.88-24.95 PROP 187-22-K DBP-187-22 DBP 188-20 PROP 435-20 0.983-1.064 24.96-27.03 PROP 187-24-K DBP-187-24 DBP 188-22 PROP 435-22 1.065-1.146 27.04-29.11...

  • Page 45: Prop 330 Linear Drive Assembly

    PART DIAGRAMS OSITIONER (PRO 320) ROTARY DRIVE ASSEMBLY NOTE: 1. APPLY BLUE LOCTITE: PN: 242 OR EQUIVALENT 2. APPLY BLUE GOOP (A SWAGELOK BRAND) ANTI-SEIZE TO THREADS OF THE HANDLE. PART NUMBER QTY. PROP 323 PLATE, COVER GS 3M10-18-1.5 SHCS M10X1.5 X 18 SS PROP 325 PIN, QUICK RELEASE GSB 3M3-6-0.5 BHCS M3X0.5 X 6 SS PROP 334 TAB, CLAMP...

  • Page 46: Prop 337 Adjustable M8 Handle

    PART DIAGRAMS LINEAR DRIVE HANDLE REPLACEMENT PARTS PROP 339 PROP 337 FLAT OVERSIZED M8 WASHER ADJUSTABLE M8 HANDLE PROP 340 GUIDE TUBE COLLET BLOCK ASSEMBLY PART NUMBER QTY. BOP 033 QUICK PIN WITH LANYARD GS 3M8-45-1.25 SHCS GS 331-06 SHCS .31-18 x 1.50 SS GS 331-10 SHCS .31-18 x 2.50 SS FULL THD GSB 319-015 BHCS 10-24 x .38 SS PROP 341 GUIDE TUBE COLLET BLOCK BODY...

  • Page 47: Prop 425 Snout Carriage Assembly

    PART DIAGRAMS OSITIONER (PROP 420-XX) RAIL FLANGE MOUNT ASSEMBLY PART NUMBER -ICM/QTY. -DT/QTY. BOP 085 CAM LOCK 1.25 FEMALE X 1.25 FEMALE NPT BOP 090-7-001 SNOUT, CORRUGATED, 1.25 CAMLOCK, 7FT BR 002-4.67-001 2.5” BOX RAIL EXTENSION DBP 305 RAIL PLUG ASSY DBP 320 ICM TROLLEY CLAMP ASSY DBP 330 DELTA T TROLLEY CLAMP ASSY PROP 425 SNOUT CARRIAGE ASSEMBLY...
  • Page 48 PART DIAGRAMS OSITIONER (PROP 430-001) SPIDER PLATE ASSEMBLY PART NUMBER QTY. GB 350-05 BOLT, HEX .50-13 X 1.25 SS GSF 331-03-24 FHCS .31-24 X .75 SS GW 350-F WASHER, FLAT .50 SS PROP 431 SPIDER PLATE PROP 434 SPIDER PLATE WELDMENT PROP 436 NUT, T-SLOT .50-13 PROP 452 SHAFT, SPIDER MOUNTING OSITIONER (PROP 440-24)
  • Page 49 PART DIAGRAMS OSITIONER (PROP 460-24) GUIDE WELDMENT BN24 PART NUMBER PROP 460.1-BN24 GUIDE TUBE, 60 DEG FOR BN24 PROP 460.2 GUIDE TUBE BN24 PROP 460.3 GUIDE TUBE INSERT BN24 OSITIONER (PROP 580-1.33-001) 2.5” BOX RAIL EXTENSION KIT, SLOTTED, 1.33 FT PART NUMBER PROP 580-1.33-001/QTY.

  • Page 50: Fpa-Skr Foot Pedal Assembly

    PART DIAGRAMS ACDA 6120019-K 20K DUMP VALVE ASSEMBLY WITH AIR FITTINGS PART NUMBER QTY. ACDA 61020019 DUMP VALVE 20K, AIR FITTINGS GPTB 0250-PUR95A-GN 250 URETHANE TUBING GREEN FPA-SKR FOOT PEDAL ASSEMBLY PART NUMBER QTY. FPA-100 FOOT PEDAL ASSY FPA 102 HOSE ASSY 866-795-1586 •...
  • Page 51 NOTES PAGE LEFT BLANK INTENTIONALLY 866-795-1586 • WWW.STONEAGETOOLS.COM...
  • Page 52 NOTES PAGE LEFT BLANK INTENTIONALLY 866-795-1586 • WWW.STONEAGETOOLS.COM...
  • Page 53 NOTES PAGE LEFT BLANK INTENTIONALLY 866-795-1586 • WWW.STONEAGETOOLS.COM...
  • Page 54 Conditions of Sale (“Terms and Conditions”) shall operate as the acceptance of these Terms and Conditions at any time, shall not in any way affect, limit or by StoneAge, Inc. (“Seller”) of the order submitted by the purchaser (“Buyer”). waive Seller’s right thereafter to enforce and compel strict compliance with Such acceptance is made expressly conditional on assent by Buyer to these every term and condition hereof.
  • Page 55 Product EXTENT SUCH DAMAGES WOULD CONSTITUTE DIRECT DAMAGES), WITH at any time without notice to End-User, and StoneAge is not obligated to make RESPECT TO THE COVERED STONEAGE PRODUCT, OR OTHERWISE...
  • Page 56 1-866-795-1586 • www.STONEAGETOOLS.com © 2020 StoneAge, Inc. All Rights Reserved...

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