AUTOBOX™ (ABX-2L)
Contents
1. STONEAGE ENGINEERING THE POWER OF WATER PL602 REV B 03 2015 TABLE OF CONTENTS MANUFACTURER S INFORMATION 5 3 DESCRIPTION OF EQUIPMENT AND INTENDED 42 4 44 3 TE 3 DECLARATION OF CONFORMITY u uuu keen 4 WARNING AND SAFETY INSTRUCTIONS PEER TENNE 5 PERSONAL PROTECTIVE EQUIPMENT REQUIREMENT S 5 PRE RUN SAFETY CHECK 09 7 6 SAFETY LABEL DEFINITIONS ce rasende 6 SYSTEM ASSEMBLY OVERVIEW LIGHTWEIGHT POSITIONER OVERVIEW LIGHTWEIGHT POSITIONER CLAMP 9 LIGHTWEIGHT TOSILIONER SE turc th atia NE 10 GUIDE ASSEMBLY OVERVIEW GUIDE ASSEMBLY SET UP 13 GUIDE ASSEMBLY TO LIGHTWEIGHT POSITIONER 14 ABX 2L HOSE TRACTOR OVERVIEW ABX 2L HOSE TRACTOR DOORS amp 16 ABX 2L HOSE TRACTOR DRIVE 17 ABX 2L HOSE TRACTOR TO GUIDE ASSEMBLY 18 CONTROL BOX OVERVIEW WONTOL BOX 20 CONTOL BOX AIR SUPPLY FITTING 21 CONTROL TO SYSTEM ASSEMBLY uuu uu a ettet toto EEn Pee rhet 22 OPERATION COLLET INSERTION HOSE AND HOSE STOP INSTALLATION 232. 1 3 cm away from the tube sheet face 14 P v7 866 795 1586 WWW STONEAGETOOLS COM ABX 2L HOSE TRACTOR COLOR CODED JIC FITTINGS WITH DUST CAPS HANDLE DOOR PIN N FORWARD AND REVERSE SPEED CONTROLS Q MOUNTING BRACKET DRIVE ROLLERS DOOR MOUNTING BRACKET FOR GUIDE ASSEMBLY PNEUMATIC SUPPLY LINES 25FT 7 6m 5 TO Li 7 GE ABX 2L HOSE TRACTOR DOORS amp PIN DOOR Always run the ABX 2L Hose Tractor with the doors closed and locked DOOR PIN The Door Pin is a spring plunger with a pull ring To unlock the door pull and twist the pull ring then release it so that it is no longer in the groove Close the door by raising it into position To lock the door pull and twist the pull ring then release it into the groove of the pin NOTE Make sure to lock both doors on each side of the Hose Tractor before operating ABX 2L Hose Tractor OPEN DOOR POSITION CLOSED DOOR POSITION STONEAGE 805 795 1586 WWW STONEAGETOOLS COM ABX 2L HOSE TRACTOR DRIVE ROLLERS AWARNING Always de energize the system before servicing or replacing any parts Failure to do so can result in severe injury and or death Keep hands hair and clothing clear of rotating parts TO REPLACE THE DRIVE ROLLERS 1 Select the correct roller size for the particular hose being used e ABX 271 DK GRAY B
3. HS 121 27 34 27 34 in 6 8 8 6 mm HS 121 34 42 34 42 in 8 6 10 7 mm HS 121 42 50 42 50 in 10 7 12 7 mm It is the responsibility of the user to select proper sizing to 866 795 1586 WWW STONEAGETOOLSCOM S7onEAGE 13 GUIDE ASSEMBLY TO LIGHTWEIGHT POSITIONER SET UP ATTACH GUIDE ASSEMBLY TO LIGHTWEIGHT POSITIONER 1 Using a 9 16 in wrench loosen all four rail clamp bolts located on the vertical carriage Install the Guide Assembly into the rail clamps and adjust position until the Guide Tubes are approximately 1 2 in 1 3 cm away from the tube sheet face Tighten the four rail clamp bolts 2 Turn the pitch adjustment knob until the guide tubes are at the same pitch as the tubes in the bundle Adjust the Tube Clamp Bolt until the Guide Tubes are resting in the bottom of the V blocks Make any fine adjustment to the Guide Tube pitch if required and tighten the Tube Clamp Bolt NOTE Over tightening the Tube Clamp may damage thin wall guide tubes Wy 1 F Pita ATI TIN UTT 1 TT Hii MITT mA SPI AES i AID i hin T 114 ADAPTER FOR BN9 5 0 625 OD Guide Tubes NOTE Adjust position until n the Guide Tubes are ME approximately 1 2 in s
4. U 2 Connect the ABX 2L Hose Tractor to the Control Box with 9 2 2 before slats two 1 2 in 1 3 cm JIC hoses and one 1 4 in 6 35 mm id E 9 2 s ne s h S JIC hose Verify the Control Box rotates the rollers in the ieee s appropriate direction and that the clamp functions correctly 3 Connect the horizontal positioner drive air motor to the Control Box with two 1 4 in 6 35 mm JIC hoses Verify the Control Box moves the horizontal carriage in the appropriate direction CLAMP REVERSE FORWARD LEFT UP RIGHT DOWN Note The 4 Positioner control lines are not color coded Colors are shown in manual for clarity S a oF 1 22 P STONEAGE 866 795 1586 WWW STONEAGETOOLS COM OPERATION COLLET INSERTION HOSE AND HOSE STOP INSTALLATION 1 Remove Quick Release Pin and pull out existing Collet 2 Insert Banshee tool on hose through the ABX 2L Hose Tractor and hose guide assembly Be sure that the Banshee tool and hose end pass the location of the Collet Select the appropriate Collet for the hoses to be used Install the Collet and quick release pin Pull on the hoses from the back of the ABX 2L Hose Tractor to ensure that the Collet does not allow the Banshee to back out of the Guide or Hose Tractor 6 To install hose stops push tool through
5. 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 26 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 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 additi
6. To inspect press down between the two idlers with 10 lbs of force on the belt The belt should deflect 25 in 6 35 mm If the belt deflects more than 30 in 76 2 mm it should be tightened See Diagram below After cach use All components the hoses pass through After each 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 TO REPLACE THE BELT Using a 1 2 wrench loosen the hex head bolt and slid the idler sprocket to the right Remove the worn belt Install the new belt in the wrap pattern shown in the diagram SETTING TENSION The level of acceptable i deflection can be measured off the top of the countersink of the screw shown below CAPS DUST m REVERSE FORWARD Contact StoneAge for Safety Data Sheets for material usage a complete list of part numbers and service instructions for the ABX 2L Hose Tractor and Control Box 866 795 1586 WWW STONEAGETOOLS COM p i STONEAGE 25 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
7. and lay the pin onto the top slot on the Guide Assembly block 3 Install the lower pin through the mounting bracket on the Hose Tractor and the block on the Guide Assembly 969949 61 CNN eg PANG VAN gt The tractor is now securely mounted to the Guide Assembly 18 Pp STONEAGE 866 795 1586 WWW STONEAGETOOLS COM CONTROL BOX OVERVIEW CONTROL BOX TOP VIEW MOMENTARY PNEUMATIC DUMP CONTROL HOSE FEED LEVER a DUM CLAN FRESSURE GEN EEE EG HOSE FEED Sm HOSE CLAMP HOSE CLAMP POSITIONER PRESSURE REGULATOR PRESSURE GAUGE CONTROLS CONTROL BOX CONTROL BOX FRONT VIEW REAR VIEW POLE MOUNT 1 4 6 35 mm PUSH CONNEC WITH THUMB SCREW PNEUMATIC DUMP VERTICAL CONTROL FITTING POSITIONER P FITTINGS MAIN BOX FRAME WITH DUST CAPS PRESSURE REGULATOR REGULATOR LUBRICATOR INLET AIR FITTING TRIPOD 4 INLINE OILER LEGS FEED ADJUSTMENT AIR SUPPLY COLOR CODED HORIZONTAL CODED FITTING JIC FITTINGS POSITIONER JIC FITTING WITH DUST CAP WITH DUST CAPS FITTIN WITH DUST CAP WITH DUST CAPS 866 795 1586 WWW STONEAGETOOLS COM 79 CONTROL BOX SET UP ASSEMBLE CONTROL BOX FRL AND TRIPOD BASE 1 Setup the tripod base in a location with good visibility to the 4 Slide the Control Box over the vertical tube The Control Box bundle face but at a safe distance away f
8. 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 StoneAgetools com trademark list STONEAGE PATENT DATA View the list of StoneAge s current U S patent numbers and descriptions http www sapatents com AA STONEAGE 27 STONEAGE ENGINEERING THE POWER OF WATER 1 866 795 1586 www STONEAGETOOLS com 2015 StoneAge Inc All Rights Reserved
9. of tubes in the heat exchanger bundle Feed forward and advance the hoses into the tube bundle at low pressure and wait for the tools to exit the far side of the heat exchanger Set the forward hose stops in the desired position to ensure the entire tube is cleaned but that the hose crimp does not fully exit the tube Retract the hoses into the Guide Tubes Close the dump and gradually increase the pump to the desired operating pressure Feed forward and advance the hoses into the tube bundle Dump and make any desired changes to forward and or reverse operating speeds If the Drive Rollers are slipping excessively increase the clamp pressure It is recommended to operate the clamp pressure as low as possible without excessive slippage Optimal clamp pressure is achieved when the Drive Rollers slip 2 to 1 full rotation after hitting the hose stops forward or the Collet engages the hose crimp reverse It is recommended to use hose supplied with the secondary crimp so the anti withdrawl protection Collet does not impact the pressure containing crimp Operate the left right and up down positioner functions to begin high pressure clean ing at the preferred location on the tube bundle Always align the Guide Tubes as closely as possible with the heat exchanger tubes before advancing the hoses The ABX 2L System is now ready to operate HIGH PRESSURE HOSE The ABX 2L Hose Tractor is designed to be used with Parker Pro Lance a
10. 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 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
11. 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 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 STONEAGET
12. CONTROL BOX TEST RUN AND RUN cee 24 HIGH PRESSURE HOSE AND HOSE CLAMP ar tat tan 24 STORAGE TRANSPORTATION AND HANDLING MAINTENANCE TERMS AND CONDITIONS 2 P CTI Pra 866 795 1586 WWW STONEAGETOOLS COM MANUFACTURER S INFORMATION otoneAge Inc 466 S Skylane Drive Durango CO 81303 USA Phone 970 259 2869 Toll Free 866 795 1586 www stoneagetools com Andrew Birt Consulting Ltd UK 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 SPECIFICATIONS ABX 2L Hose Tractor Weight ABX 2L Hose Tractor Size Maximum Feed Rate Minimum Feed Rate Maximum Push Pull Force Mininimum Push Pull Force Manway Access Lightweight Positioner Weight Guide Assembly Weight Pitch Adjustment Range Control Box Weight Maximum Air Supply Pressure system Operating Pressure Recommended Operational Temperature Range DESCRIPTION OF EQUIPMENT AND INTENDED USE The ABX 2L System consists of the ABX 2L Hose Tractor Control Box Guide Assembly and Lightweight Positioner This system was developed for Hands Free heat exchanger tube cleaning applications It is recommended to be used with StoneAge s Banshee line of self rotary waterblast tools The ABX 2L System was designed to a
13. E CLAMP FIGURE 1 FIGURE 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 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 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 Insert the Lower Rail non slotted into the lower mounting brackets It is not critical that this rail is aligned as precisely as ET HILL the top rail but it should be close to parallel with the top rail for MM LLLA best performance Tighten the clamps securing the rail to the v M mounting brackets and ensure lower mounting brackets a 99 47 securely clamped or bolted to the tube bundle flange Figure binde 3 4 Loosen the Quick Adjust Handle and pull
14. Figure 7 Ce TIT TT ET 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 WAW STONEAGETOOLSCOM S rygNEAGE 1 GUIDE ASSEMBLY OVERVIEW GUIDE TUBES MULTIPLE SIZES HOUSING TUBE CLAMP GUIDE TUBE ADAPTER SCREWS COLLET REFERENCE GUIDE COLLET MULTIPLE SIZES MOUNTING ee a PITCH ADJUST KNOB QUICK RELEASE PIN HOSE STOP CLAMPS MULTIPLE SIZES 12 Jh SruwtAGE 9667951586 WWW STONEAGETOOLS COM GUIDE ASSEMBLY SET UP GUIDE ASSEMBLY 1 Select the appropriate Guide Tube size and length for the application The length of the Guide Tubes for an exchanger bundle with no channel head is 12 5 in 32 cm The guide tube assembly has approximately 5 in 13 cm of adjustment appropriate guide tubes install the Guide Tubes into the Guide A deeper channel head will require extended Guide Tubes The Assembly depth of the channel head added to the 12 5 in 32 cm length 3 Secure t
15. GETOOLS COM STONEAGE LIGHTWEIGHT POSITIONER OVERVIEW LIGHTWEIGHT POSITIONER RAIL STOP ASSEMBLIES r LELEL LELLI RAIL EXTENTIONS 2 4 OR 6 FT LENGTHS 61 m 1 2 m OR 1 8 m 5 Ia HORIZONTAL E DRIVE Trey ER ASSEMBLY E VERTICAL E EN E SLOTTED E i RAIL 3 i 4 POSITIONER E CONTROL LINE 21 HORIZONTAL 3 ASSEMBLY pos nu Luc a SLOTTED RAIL Wm oe ae FI SO STANDARD LENGTH CLAMP TYPES VERTICAL DRIVE ASSEMBLY NON SLOTTED RAIL wm 7 SLOTTED QUICK CLAMP TITT FER RAIL STOP a BLANK HORIZONTAL ASSEMBLY ASSEMBLY P vU 866 795 1586 WWW STONEAGETOOLS COM LIGHTWEIGHT POSITIONER CLAMP SELECTION CLAMP SELECTION Is dependent upon the heat exchanger geometry bolt holes hole spacing 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 e s SLOTTED QUICK CLAMP T QUICK CLAMP 3 PLAT
16. Hose Tractor lift with care to prevent bodily injury Do not operate the ABX 2L Hose Tractor while either side door Is open Pp STONEAGE WARNING AND SAFETY INSTRUCTIONS 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 objects 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 Ensure the doors of the ABX 2L Hose Tractor are closed and securely latched Test the Control Box before operating the ABX 2L Hose Tractor with high pressure water to verify the con
17. LACK rollers should be used with 5 mm and 6 mm I D hoses The O D range for the ABX 271 roller is 44 50 in 11 17 mm 12 7 mm 272 ORANGE rollers should be used with 3 mm and 4 mm I D hoses The O D range for the ABX 272 is 27 41 in 6 85 mm 10 41 mm 2 Slowly run the Drive Rollers in order to orient the key ways of the Drive Rollers upward and the spring plungers downward NOTE Rollers should be removed with the keyway facing up to prevent losing keys Use a small common screwdriver or similar tool to depress the ball spring plunger and pull the rollers straight out from the shafts Prior to reinstalling the Drive Rollers onto the shafts apply a liberal coat of Anti seize to the shaft OD and keys We recommend Mariners Choice Never Seez 5 Reinstall the rollers by sliding into place until the spring plungers snap out NOTE Rollers should be installed with the keyway facing up to prevent losing keys 6 Once the correct rollers are installed close and lock the doors The Hose Tractor can now be installed onto the Guide Assembly KEY WAY SPRING PLUNGER ORIENTATION DRIVE ROLLERS 6 272 ORANGE 866 795 1586 WWW STONEAGETOOLS COM STONEAGE 17 ABX 2L HOSE TRACTOR TO GUIDE ASSEMBLY ATTACH ABX 2L HOSE TRACTOR TO GUIDE ASSEMBLY 1 Remove the lower quick release pin from the ABX 2L Hose Tractor 2 Slide the mounting bracket over the block on the Guide Assembly
18. OOLS 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 laws 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
19. c connection is preferred this fitting can be removed and any male 1 2 in 1 3 cm NPT fitting may be used 2 Using the regulator adjust the operating pressure to 100 psi 0 7 MPa for the application N TADJUST INLINE OILER 1O FEED 1 DROP OF OIL EVERY 30 60 SECONDS FOR HIGH SPEED OR CONTINUOUS DUTY USAGE AIR SUPPLY FITTING A universal AIR SUPPLY FITTING Chicago style is located on the back of the Control Box Connect a compatible compressed air line not included according to the manufacturer s instructions If another pneumatic connection is preferred this fitting can be removed and any male 1 in NPT fitting may be used PNEUMATIC DUMP CONTROL FITTING AND LINE A MOMENTARY PNEUMATIC DUMP CONTROL is located on the Contol Box panel and can be set up to control an air actuated dump valve To utilize the toggle the end user will need to install 1 4 in 6 35 mm O D nylon tubing not included between the PNEUMATIC DUMP CONTROL FITTING and the pneumatic dump valve PNEUMATIC DUMP CONTROL FITTING IN OD TUBING CONTROL BOX REAR VIEW 866 795 1586 e WWW STONEAGETOOLS COM Pp STONEAGE CONTROL BOX TO SYSTEM ASSEMBLY PNEUMATIC SUPPLY LINE CONNECTIONS 4 Connect the vertical positioner drive air motor to the Control 1 Remove the dust caps from the Joint Industry Council JIC with 4 mm 2 ee n fittings of the Control Box and the ABX 2L Hose Tractor
20. ccommodate two simultaneous flex lances ranging in size from 3 2 to 6 4 matched with the appropriate BN9 5 BN13 or BN15 size Banshees The ABX 2L Hose Tractor utilizes six synchronized drive rollers to control the rate at which the hose and Banshee tools are advanced or retracted inside the tube The Guide Assembly provides anti withdrawal protection and precise tube pitch adjustment The Lightweight Positioner can be mounted to a variety of heat exchanger tube bundles and has pneumatic powered horizontal and vertical drives The Control Box is small and lightweight with an emphasis on ergonomics The ABX 2L system was designed with simplicity safety lightweight components durability and reliability in mind It can be easily carried to the jobsite and setup in minutes 866 795 1586 WWW STONEAGETOOLS COM 42 lbs 19 05 kg ABX 2L box only 7 2 in wide x 8 3 in Tall x 16 7 in Long 182 9 mm wide x 210 8 mm Tall x 424 2 mm Long 3 0 ft sec 91 44 cm sec 0 2 ft sec 6 cm sec 60 Ibs 80 Ibs per lance 27 2 kg 13 6 kg per lance 10 Ibs 5 Ibs per lance 4 5 kg 18 in 457 2 mm 120 Ibs 54 4 kg Includes 6ft rails horiz vert and idler carriage and 4 clamps 10 Ibs 4 5 kg 5 8 2 4 in 15 9 mm 60 9 mm 43 lbs 19 5 kg Includes Control FRL and stand 140 psi 0 97 MPa 100 psi 0 70 MPa 20 F to 140 F 29 C to 60 C KEY FEATURES Lightweight Positioner Modular lightweight
21. ch different set up material and location The risk assessment MUST conform to the Health and Safety at Work Act 1974 and other relevant Health and Safety legislation 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 IMCAS 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 866 795 1586 WWW STONEAGETOOLS COM WARNING AND SAFETY INSTRUCTIONS 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 equivalent Operators MUST read understand and follow the Warnings Safety Information Assembly Installation Connection Operation Transport Handling Storage and Maintenance Instructions detailed in this manual The risk assessment MUST consider potential material or substance ha
22. connections are tight and free of leaks Users of the ABX 2L Hose Tractor MUST be trained and or experienced 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 ABX 2L Hose Tractor and Control Box MUST be supervised at all times and should never be left unattended Test the Control Box before operating the ABX 2L Hose Tractor 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 Do not fully release the hose clamp decreasing pressure to zero during operation or the ABX 2L Hose Tractor will release the hose and may create a dangerous runaway hose condition which can result in severe injury and or death Always de energize the system before opening the door to service or replace any parts Failure to do so can result in severe injury and or death When moving the ABX 2L
23. 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 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
24. design e Quick install drive carriages Utilizes 2 5 in 6 35 cm box rail e Stainless Steel air motors e Variety of clamp and bolt on attachment options are available Guide Assembly Compact and lightweight design Turn knob control provides precise pitch adjustment Quick change guide tubes are common material 17 4 SS hose stop oollets ABX 2L Hose Tractor Six powered drive rollers ensure traction in all operating conditions Quick change drive rollers two sizes Lightweight and compact design Can be used in dual or single lance applications Quick pin attachment to guide assembly Hinged side doors for easy access to rollers and drive components Independent forward reverse speed controls Control Box Small lightweight ergonomic design that includes a portable stand and filter regulator lubricator assembly Tractor controls forward reverse hose feed and clamp pressure Positioner controls left right and up down Pneumatic dump control switch p 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 AutoBox Hose Control Device Model name ABX 2L 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
25. door before operating the ABX 2L Hose Tractor Test the Control Box before operating the ABX 2L Hose Tractor with high pressure water to verify the control valves move the hose in the intend ed direction and that the dump valve is working properly HOSE CLAMP e The Drive Rollers are controlled by turning the HOSE CLAMP PRESSURE REGULATOR Use the HOSE CLAMP PRESSURE GAUGE to record desired pressure for future use Clamp force will not damage hoses Proper clamp force will provide good control of the hose in forward and reverse directions and keep the hose running through the drive rollers AWARNING Do not fully release the hose clamp decreasing pressure to zero during operation or the ABX 2L Hose Tractor will release the hose and may create a dangerous runaway hose condition which can result in severe injury and or death AWARNING Crush Hazard Keep hands hair and clothing clear of drive rollers and belts Contact with moving parts can result in severe injury well CLAMP FORCE STORAGE TRANSPORTATION AND HANDLING When moving the ABX 2L Hose Tractor lift with care to prevent bodily injury The ABX 2L Hose Tractor is shipped in a custom wooden crate and should be stored upright in the same crate between jobs When storing the unit use compressed air to blow out the air lines to remove debris and moisture Use mild soapy water to clean the machine in order to remove corrosive materials Apply a small amount of ai
26. 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 03 03 2015 Andrew Birt Independent Dealer Manager Signed otoneAge Inc Worcester UK The technical file for the AutoBox ABX 2L User Manual is maintained at StoneAge Inc 466 South Skylane Drive Durango CO 81303 USA 4 Pp STONEAGE 966 795 1586 e WWW STONEAGETOOLS COM OPERATOR TRAINING Managers Supervisors and Operators MUST be trained in Health 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 equipment 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 15 THE RESPONSIBILTY OF THE INSTALLER OPERATOR to conduct a job specific risk assessment prior to use Job specific risk assessment MUST be repeated for ea
27. he Guide Tubes by tightening the two 3 16 in SHCS will give the desired tube Longer guide tubes are available if required for use with channel heads Note The Banshee tool should not have excessive clearance if the correct length Guide Tube size is used 2 To remove the existing Guide Tubes loosen the Tube Clamp Bolt and the two 3 16 in Socket Head Cap Screws SHCS located on top of the Guide Assembly After selecting the Appropriate size Collet selection is critical to ensuring proper backout prevention of the tool StoneAge PART NUMBER NOTE GUIDE TUBE REFERENCE CHART 9 5 guide tubes 0 625 OD require an ABX 114 adapter SA PART NUMBER SA TOOL DIAMETER LENGTH to install into the Guide Assembly ABX 115 12 BN9 5 459 I D 12 5 in 315 7 mm StoneAge PART NUMBER ABX 115 36 BN9 5 459 1 0 36 in 914 4 mm COLLET REFERENCE CHART ABX 116 12 BN13 1546 I D 12 5 in 315 7 mm SA PART NUMBER COLLET SIZE ABX 116 36 5461D 36in 9144mm ABX 121 297 297 in 7 54 mm ABX 117 12 BN15 674 1 D 12 5 in 315 7 mm ABX 121 328 328 in 8 33 mm ABX 117 36 BN15 674 1 0 36 in 914 4 mm ABX 121 406 406 in 10 31 mm ABX 121 438 438 in 11 13 mm ABX 121 450 450 in 11 43 mm ABX 121 484 484 in 12 3 mm ABX 121 516 516 in 13 1 mm StoneAge PART NUMBER HOSE STOP CLAMP REFERENCE CHART SA PART NUMBER HOSE DIAMETER
28. is set at 20 30psi 14 20 MPa e Operate the high pressure hose and waterjet too at full pressure to test the clamp force Proper clamp force will provide good control of the hose in forward and reverse directions Adjust the hose feed speed controls Proper forward and reverse speeds will vary depending on the type of material being removed and the tube size Adjustment of the hose feed speed controls may be necessary during operation in order to optimize cleaning and overall productivity e Operate the high pressure water at full pressure and use the MOMENTARY PNEU MATIC DUMP CONTROL to verify that the dump valve is working properly RUN PROCEDURE e After completing the setup the ABX 2L Hose Tractor system is ready for operation e Once all hose connections have been made it is recommended to flush the hoses and verify the dump valve is working properly before installing the Banshee tools After flushing the hoses install the Banshee tools and insert both tools into the back of the ABX 2L Hose Tractor It may be necessary to twist the hoses slightly as the tools and hose ends are manually pushed through the machine Once the Banshees are inside the Guide Tubes install the Collet anti withdrawl protection The appropriate Collet must be verified installed secured tested and performance confirmed before operating at high pressure e Adjust the clamp pressure to 20 30 psi 14 20 MPa Align the Guide Tubes with an open set
29. nd or Spir Star Blast Pro hose ends Standard hose ends may not fit into Hose Tractor and or Guide Tubes Note MAXIMUM hose end diameter must NOT exceed 62 in 15 75 mm p STONEAGE e Only high quality hoses intended for waterblast applications should be used as high pressure hoses Pressure rating of high pressure hoses MUST NEVER be exceeded Verify that the high pressure hose is properly installed in the back out preventer Operate the high pressure hose and waterjet tool at full pressure to test the clamp force Proper clamp force will provide good control of the hose in forward and reverse directions and keep the hose running running through the drive rollers e The ABX 2L Hose Tractor MUST be supervised at all times This device is not intended to push the hose and waterjet tool Once the waterjet tool has pulled the hose to its capacity slack will form in the hose between the device and the back out preventer NOTICE Do not use a shrouded hose or hose with a steel protective cover This will cause severe damage to the Drive Rollers e Open the door to install the high pressure hose The HOSE CLAMP PRESSURE REGULATOR on the Control Box MUST be turned to zero pressure to open the Drive Rollers for easy hose installation Insert the hose equipped with the waterjet tool between the Drive Rollers Increase the pressure on the HOSE CLAMP PRESSURE REGULATOR 10 extend the clamp rollers and clamp the hose Close and lock the
30. on 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 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 necessa
31. r tool oil directly into the forward and reverse 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 three fittings to keep moisture and dirt out 866 795 1586 WWW STONEAGETOOLS COM MAINTENANCE Maintenance Item Frequency Maintenance Required Forward reverse and clamp fittings Before each use Inspect threads for wear or damage Drive Rollers may continue to function normally after some wear Forward and reverse fittings Apply a small amount of air tool oil directly into the forward and reverse 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 three fittings to keep moisture and dirt out NOTICE Do not add oil to the clamp fitting as oil may accumulate in the air cylinders and prevent them from fully retracting After cach use Drive rollers The rollers are very durable and should last several hundred hours However it is recommended to inspect all rollers for wear and or cracks at the completion of each job Replacement is required when wear begins to affect the hose feed in forward or reverse or when it affects the hose alignment It is recommended to replace all six drive rollers at the same time to maintain optimal performance After cach use Belt
32. rom waterblast zone has a stop that keeps it located at the top of the vertical tube 2 Slide the vertical tube into the tripod base Secure with the secure with the supplied thumbscrew knob supplied thumbscrew knob Note The vertical tube has a hole 5 Install the short 1 2 in 1 3 D hose between the FRL and through one wall that the thumbscrew must engage the Control Box 3 Slide the Filter Regulator Lubricator FRL assembly over the vertical tube down to the tripod base Secure with the supplied thumbscrew knob Note The vertical tube has a hole through one wall that the thumbscrew must engage FILTER REGULATOR THUMBSCREW LUBRICATOR ASSEMBLY KNOB FRL ALIGN WITH PRE DRILLED HOLE ON TUBE INSERT si ew THUMBSCREW KNOB ALIGN WITH PRE DRILLED HOLE ON TUBE INSERT THUMBSCREW KNOB TUBE INSERT 20 Pp STONEAGE 866 795 1586 WWW STONEAGETOOLS COM CONTROL BOX AIR SUPPLY FITTING AIR SUPPLY AND LUBRICATOR SETTING AWARNING 1 The Control Box is supplied with a twist claw style inlet Maximum operating pressure is100 psi 0 7 MPa Never coupling Chicago style located on the side of the FRL exceed 140 psi 0 97 MPa supply pressure Exceeding 140 Assembly Connect a compatible compressed air line not psi supply pressure may result in injury to the Operator and or included according to the Manufacturer s instructions If damage to the equipment another pneumati
33. ry 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 TERMS AND CONDITIONS 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 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 wi
34. 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 Pp 570 866 795 1586 WWW STONEAGETOOLS COM LIGHTWEIGHT POSITIONER SET UP 5 Slide the Idler Carriage onto the Lower Non Slotted Rail Figure 5 MILLL 6 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 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
35. thout 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 Buyer s 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 Shortages 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
36. trol valves move the hose in the intended direction and that the dump valve and hose clamp are working properly Ensure that Operators never connect disconnect or tighten hoses adaptors or accessories with the high pressure water pump unit running Ensure no personnel are in the hydroblasting zone SAFETY LABEL DEFINITION The ABX 2L Hose Tractor has the potential to cause serious injury if fingers hair or clothing become caught between the hose rollers or drive belts DO NOT OPERATE WITH THE DOORS OPEN ENSURE THAT ALL FOUR DOOR PINS ARE SECURED PRIOR TO OPERATION Do not operate with door open Maximum operating pressure is100 psi 0 7 MPa Never exceed 140 psi 0 97 MPa supply pressure Exceeding 140 psi supply pressure may result in injury to the Operator and or damage to the equipment 866 795 1586 WWW STONEAGETOOLS COM SYSTEM ASSEMBLY OVERVIEW LIGHTWEIGHT POSITIONER GUIDE ASSEMBLY ABX 2L HOSE TRACTOR AND CONTROL BOX SYSTEM ASSEMBLY LIGHTWEIGHT POSITIONER SEE PAGES 8 9 10 11 FABX 2L HOSE TRACTOR H SEE PAGES 15 16 17 18 H CONTROL BOX SEE PAGES 19 20 21 22 HOSES RUN TO HIGH PRESSURE SUPPLY CFYFYFTTTTTTTTTTEmO GUIDE ASSEMBLY SEE PAGES 12 13 14 NOTE Heat exchanger tube bundle face shown for graphic representation only Not included in assembly 866 795 1586 WWW STONEA
37. until the tips are 1 2 2 5 5 cm past the end of the tube bundle Loosely install the stop then push toward the mounting bracket and tighten in place AWARNING Appropriate size Collet seclection is critical to ensuring proper anti withdrawl prevention of the tool COLLET REMOVED BANSHEE TOOL WITH HOSE END MUST BE PAST THE COLLET SCOT BEFORE INSERTING THE COLLET COLLET 866 795 1586 WWW STONEAGETOOLS COM T T 23 OPERATION 24 CONTROL BOX e The HOSE FEED LEVER will move the hose in the forward feeding and reverse retracting directions The OFF position is at the spring centered middle position and will stop the Drive Rollers from turning The speed controls are located on the ABX 2L Hose Tractor Speed is independantly adjustable for Forward Reverse Mini mum speed is 2ft sec 6 cm sec Maximum speed is 3 0ft sec 91 44 cm sec To use MOMENTARY PNEUMATIC DUMP CONTROL hold it in the High Pressure On position to route the high pressure water to the tool Release the knob to divert the high pressure water away from the tool e To de energize the system release the HOSE FEED LEVER and the MOMEN TARY PNEUMATIC DUMP CONTROL This will stop the Drive Rollers from moving and reroute the high pressure water away from the ABX 2L Hose Tractor TEST RUN PROCEDURE e Perform the PRE RUN SAFETY CHECK SEE PAGE 6 e Ensure Collet is installed and hose clamp pressure
38. zards including Aerosols Biological and microbiological viral or bacterial agents Combustible materials Dusts Explosion Fibers Flammable substances Fluids Fumes Gases Mists Oxidizing Agents 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 AA STONEAGE AWARNING 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 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
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