AutoBox ABX-2L-V2 User Manual - StoneAge Waterblast Solutions
Contents
1. 24 HIGH PRESSURE HOSE AND HOSE 21 s csssiiiiisrniorirsiiii iihi vE n neii 29 STORAGE TRANSPORTATION AND HANDLING MAINTENANCE PARTS DIAGRAMS TERMS AND CONDITIONS 2 p vuU 866 795 1586 e 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 AUTOBOX ABX 2L V2 Hose Tractor Weight AUTOBOX ABX 2L V2 Hose Tractor Size Maximum Feed Rate Minimum Feed Rate Maximum Push Pull Force Minimum 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 AUTOBOX ABX 2L V2 System consists of the AUTOBOX ABX 2L V2 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 The2. STONEAGE ENGINEERING THE POWER OF WATER PL 602 V2 REV A 10 2015 TABLE CONTENTS MANUFACTURER S INFORMATION 3 DESCRIPTION OF EQUIPMENT AND INTENDED 3 DECLARATION OF kostet 4 WARNING AND SAFETY INSTRUCTIONS OPERATOR TIRING C 5 PERSONAL PROTECTIVE EQUIPMENT 1 1 6 PRE RUN SAFETY 6 SYSTEM ASSEMBLY OVERVIEW LIGHTWEIGHT POSITIONER OVERVIEW LIGHTWEIGHT POSITIONER CLAMP 9 LIGHTWEIGHT POSITIONER 5 riter ttn 10 GUIDE ASSEMBLY OVERVIEW GUIDE ASSEMBLY 13 GUIDE ASSEMBLY TO LIGHTWEIGHT POSITIONER SET 14 AUTOBOX ABX 2L V2 HOSE TRACTOR OVERVIEW AUTOBOX ABX 2L V2 HOSE TRACTOR DOORS AND PINS 16 AUTOBOX ABX 2L V2 HOSE TRACTOR DRIVE ROLLERS 17 AUTOBOX ABX 2L V2 HOSE TRACTOR GUIDE ASSEMBLY 18 CONTROL BOX OVERVIEW 20 CONTROL BOX SUPPLY FITTING 21 CONTROL BOX TO AUTOBOX ABX 2L V2 HOSE TRACTOR ASSEMBLY 22 OPERATION COLLET INSERTION HOSE AND HOSE STOP INSTALLATION 23 CONTROL BOX TEST RUN AND RUN
3. ABX 223 Shaft Link ABX 224 Link Bar ABX 225 Spacer Link ABX 227 Spacer Top Shaft ABX 226 Shaft Drive Roller 5 N Bo 1 4 4 1 1 21 1 1 4 41 4 ABX 228 Bearing 500 ID x 1 125 OD Sealed Permalube 35 ABX 249 Retaining Ring HD Ext SS ABX 229 Ball Plunger 36 ABX 250 Air Motor Globe ABX 231 Drive Aluminum Sprocket 32T x 5 ABX 232 Cap Air Motor Shaft 37 38 253 Step Key ABX 252 Plate Air Motor Bearing 39 ABX 255 Pad Bearing Plate RH ABX 233 Cylinder ABX 234 Rod End 40 41 256 Pad Bearing Plate LH ABX 257 Bearing 19mm x 37mm x 9mm ABX 235 Plate Bearing 42 ABX 258 Shim Washer ABX 236 Plate Air Cylinder Clevis ABX 237 Cylinder Pivot Plate 43 259 FTG x PL5F 45 Elbow 44 ABX 260 FTG PAM PL8mmF 90 Elbow ABX 238 Headless Clevis Pin 50 OD x 1 25 SS 239 Sleeve Bearing 500 oD 5 OD 45 46 ABX 261 FTG PL8mmF to PAM Straight Adpt Elbow PMO oO ABX 262 FTG PL8mmM to PL8mmF 90 ABX 240 Shaft Idler Nut ABX 242 Drive Belt ABX 243 001 Hose Guide Block 47 ABX 263 FTG PL8mmM to PL8mmF 90 Elbow 48 ABX 265 Manifold ABX 247 Flow Control Valve MASC200 08 49 ABX 266 Filter 25 NPT
4. 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 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 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 indemn
5. 297 in 8 mm 1 115 GUIDE TUBE 459 ID REQUIRES ABX 114 2 ABX 121 328 HOSE STOP COLLET 328 8 mm 1 ABX 116 XX GUIDE TUBE 546 ID 2 121 406 HOSE STOP COLLET 406 in 10 mm 1 4 m NUBE 7450 REQUIRES ABX 121 438 HOSE STOP COLLET 438 11 mm I ADAPTER REQUIRES 124 5 121 460 HOSE STOP COLLET 460 in 12 mm 1 121 484 HOSE STOP COLLET 484 in 12 mm 1 121 516 HOSE STOP COLLET 516 in 13 mm 1 121 547 HOSE STOP COLLET 547in 14 mm 1 CLANS 121 594 HOSE STOP COLLET 594 in 15 mm 1 ali ABX 121 625 HOSE STOP COLLET 625 in 16 mm 1 HS 121 27 34 HOSE STOP CLAMP ASSEMBLY 27 34 2 HS 121 34 42 HOSE STOP CLAMP ASSEMBLY 34 42 2 HS 121 42 50 HOSE STOP CLAMP ASSEMBLY 34 42 2 TABLE 4 GUIDE ASSEMBLY HS 121 50 56 HOSE STOP CLAMP ASSEMBLY 50 56 2 PART NUMBER DESCRIPTION QTY HS 121 56 61 HOSE STOP CLAMP ASSEMBLY 56 61 2 ABX 100 8 HOSE STOP CLAMP ASSEMBLY 27 34 1 866 795 1586 e WWW STONEAGETOOLS COM S rygwEAGE PARTS DIAGRAM AUTOBOX ABX 100 8 GUIDE ASSEMBLY MAIN ASSEMBLY PARTS GUIDE 4X BLUE LOCTITE 4X BLUE LOCTITE SECTION B B 23 SCALE 1 2 N _ NOTE 1 REAM OR DRILL BUSHING TO 375 376 AFTER INSTALLATION 2 KNOB INSTALLATION SCREW KNOB ONTO SHAFT UNTIL IT JUST BOTTOMS OUT ON PLASTIC WASHER THEN BACK OFF TO FIRST SPOT FOR PIN INSTALLATIO
6. Training Requirements Section 7 0 of WJTA IMCA s Recommended Practices For The Use Of High pressure Water jetting 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 hazards 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 Maximum operating air pressure is 100 psi 0 7 MPa Never exceed 140 psi 0 97 MPa supply pressure Exceeding 140 psi 0 97 MPa supply pressure may result in injury to the Operator and or damage to the equipment 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 AWARNING Operations with this equipment can be p
7. waterblast applications should be used as high pressure hoses Check all high pressure threaded connections for tightness Ensure that an 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 AUTOBOX ABX 2L V2 Hose Tractor are closed and securely latched Test the Control Box before operating the AUTOBOX ABX 2 2 Hose Tractor with high pressure water to verify the control valves move the hose in the intended direction and that the high pressure dump valve and hose clamp are working properly Ensure that Operators never connect disconnect or tighten hoses adapters or accessories with the high pressure water pump unit running Ensure no personnel are in the hydroblasting zone lt 866 795 1586 WWW STONEAGETOOLS COM SYSTEM ASSEMBLY OVERVIEW LIGHTWEIGHT POSITIONER GUIDE ASSEMBLY AUTOBOX ABX 2L V2 HOSE TRACTOR AND CONTROL BOX SYSTEM ASSEMBLY LIGHTWEIGHT POSITIONER SEE PAGES 8 9 10 11 n l y CONTROL BOX SEE PAGES 19 20 21 22 AUTOBOX 21 4 2 HOSE TRACTOR SEE PAGES 15 16 17 18 HOSES RUN TO HIGH PRESSURE WATER SUPPLY NOTE Heat exchanger tube bundle face shown for graphic representation only Not inc
8. 86 GSF 319 02 FHCS 19 24 X 50 Lg SS 8 55 270 1 Clamp Tube 025 00 69 08558 Fig Elbow P4PL4 1 87 GSF 319 025 FHCS 19 24 631055 4 56 ABX 272 Drive Roller 70A Small Hose 10 2 88 GSF325 02FHCS 19 24X 501gSS 8 ABX 280 Drive Aluminum Sprocket 26T 1 88 325 08 BOI Hex 29 20 X19 55 2 89 GSF 325 025 19 24 631055 28 x 50 72 GB 937 06 Bolt Hex 37 16 1 50 55 111 GSF3M6 16 1 00 FHCS 6 1 00 16 58 1 gg ABX 281 Idler Aluminum Sprocket 26T ee 91 GSF 3M6 20 1 00 FHCS 6 1 00 20 55 4 6 92 GSSH0312 0375 SS Shoulder Screw 4 59 ABX 283 Plate Spacer 1 75 GK 188 188 1250 SE SS Key 6 ABX 285 FTG Elbow 90 Elbow P4M x 76 GN 337 L Nylok Nut SS l 60 yass 1 a g4 HRS 563 Ftg P2 x 25 OD Nylon Push U 28 p STONEAGE 866 795 1586 e WWW STONEAGETOOLS COM PARTS DIAGRAM AUTOBOX ABX 2L V2 HOSE TRACTOR SUB ASSEMBLIES NOTE PART NUMBERS DESCRIPTIONS AND QUANTITIES ARE LOCATED ON THE PREVIOUS TWO PAGES 3X UPPER DRIVE ROLLER ASSEMBLY 271 DARK GRAY BLACK ROLLERS ARE INCLUDED IN THE AUTOBOX ABX 2L V2 EPP 001 EXTRA PARTS PACKAGE PQ ABX 273 BLUE ROLLERS ARE IN THE AUTOBOX ABX 2L V2 EPP 001 EXTRA PARTS PACKAGE 3X LOWER DRIVE ROLLER ASSEMBLY ae MANIFOLD ASSEMBLY SEE NOTE 866 795 1586 WWW STONEAGETOOLS COM
9. AUTOBOX ABX 2L V2 System was designed to accommodate two simultaneous flex lances ranging in size from 3 2 to 8 4 matched with the appropriate BN9 5 BN13 BN15 or BN18 size Banshees The AUTOBOX ABX 2L V2 Hose Tractor utilizes six synchronized drive rollers to control the rate at which the hose and Banshee tools are advanced or retracted within the exchanger tubes 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 AUTOBOX ABX 2L V2 system was designed with simplicity safety lightweight components durability and reliability in mind It can be easily carried to the job site and setup in minutes 866 795 1586 WWW STONEAGETOOLS COM 42 16 19 05 kg AUTOBOX ABX 2L V2 box only 7 2 in Wide x 8 3 in Tall x 16 7 in Long 183 mm Wide 211 mm Tall x 424 mm Long 3 0 ft sec 914 mm sec 0 2 ft sec 61 mm sec 60 Ibs 30 16 per lance 27 2 kg 13 6 kg per lance 10 Ibs 5 Ibs per lance 4 5 kg 2 25 kg per lance 18 in 457 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 16 mm 61 mm 43 lbs 19 5 kg Includes Control FRL and stand 140 psi 0 97 MPa 100 psi 0
10. Directive Has been designed and manufactured to the relevant parts of the following specifications EN ISO 12100 2010 oafety 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 7 Date 07 01 2015 Andrew Birt Independent Dealer Manager Signed StoneAge Inc Worcester UK The technical file for the AUTOBOX ABX 2L V2 User Manual is maintained at StoneAge Inc 466 South Skylane Drive Durango CO 81303 USA 4 p i STONEAGE 866 795 1586 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 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 conduct a job specific
11. 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 tighten the quick adjust 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 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 to the equipment and or injury FIGURE 8 866 795 1586 e WWW STONEAGETOOLS COM S rygwEAGE 1 GUIDE ASSEMBLY OVERVIEW GUIDE ASSEMBLY GUIDE TUBES MULTIPLE SIZES AVAILABLE HOUSING TUBE CLAMP GUIDE TUBE ADAPTER SCREWS COLLET REFERENCE GUIDE COLLET MULTIPLE SIZES AVAILABLE MOUNTING BRACKET PITCH ADJUST KNOB QUICK RELEASE PIN HOSE STOP CLAMPS MULTIPLE SIZES AVAILABLE 12 p STONEAGE 866 795 1586 WWW STONEAGETOOLS COM GUIDE ASSEMBLY SE
12. components showing excessive wear should be replaced TO REPLACE THE BELT SETTING TENSION Using a 9 16 Socket Adjust belt tension with the Drive Rollers in the 4 4 loosen the hex head MAX open position It may be necessary to x DUST install a hose or other material to hold the rollers open The level of acceptable deflection can be the wen ball measured the top of the countersink of the FORWARD REVERSE CAPS bolt and slide the idler sprocket to the right screw shown below 20 30 in 5 8 mm Install the new belt in the wrap pattern shown in the diagram 28 For Reference Contact StoneAge for Safety Data Sheets for material usage a complete list of spare part numbers and service instructions for the AUTOBOX ABX 2L V2 Hose Tractor and Control Box 26 STONEAGE 866 795 1586 WWW STONEAGETOOLS COM PARTS DIAGRAM AUTOBOX ABX 2L V2 HOSE TRACTOR ASSEMBLY ON SHEET 2 DESCRIPTION QTY ABX 203 CE Serial Plate ABX 205 Side Plate Inlet ABX 206 Side Plate Outlet ABX 207 Plate Top ABX 208 Guard Back Assy ABX 210 Plate Bottom ABX 211 Door Assy ABX 215 Pull Handle Rubber Grip Grey O O dk ABX 217 Hose Guide Plate Inner L 218 001 Wear Ring 220 Plate Outer 4 RO ABX 221 Plate Inner ABX 222 Plate Stiffener
13. 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 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 mar
14. 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 AUTOBOX ABX 2L V2 Hose Tractor OPEN DOOR POSITION CLOSED DOOR POSITION STONEAGE 866 795 1586 WWW STONEAGETOOLS COM ABX 2L HOSE TRACTOR DRIVE ROLLERS WARNING 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 ABX 271 DARK GRAY BLACK rollers should be used with 5 mm and 6 mm 1 0 hoses The O D range for the ABX 271 roller is 44 50 in 11 mm 13 mm ABX 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 7 mm 10 mm e ABX 273 BLUE rollers should be used with 8 mm I D hoses The O D range for the ABX 273 is 52 61 in 13 mm 16 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 3 Use a small
15. risk assessment prior to use Job specific risk assessment MUST be repeated for each 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 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 DEFINITIONS The AUTOBOX ABX 2L V2 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 866 795 1586 WWW STONEAGETOOLS COM WARNING AND SAFETY INSTRUCTIONS Operators MUST read understand and follow the Operational and
16. rollers in the 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 mm JIC hoses Verify the Control Box moves the horizontal carriage in the appropriate direction m CLAMP REVERSE FORWARD ll LEFT UP RIGHT DOWN Note The 4 Positioner control lines are not color coded Colors are shown in manual for clarity 22 p STONEAGE 366 795 1586 WWW STONEAGETOOLS COM OPERATION COLLET INSERTION HOSE AND HOSE STOP INSTALLATION Remove Quick Release Pin and pull out existing Collet Insert Banshee tool on hose through the AUTOBOX ABX 2L V2 Hose Tractor and hose guide assembly Be sure that the Banshee tool and hose end pass the location of the Collet N 3 Select the appropriate Collet for the hoses to be used See Recommended Collets For Common Hose Sizes plaque on the ABX 100 Hose Guide Install the Collet and quick release pin Pull on the hoses from the back of the AUTOBOX ABX 2L V2 Hose Tractor to ensure that the Collet does not allow the Banshee to back out of the Guide or Hose Tractor BL og 6 install hose stops push tool through until the tips are 1 2 25 51 mm past the end of the tube bundle Loosely install the stop then push toward the mounting bracket and tighten in place AWARNING Ap
17. 29 30 PARTS DIAGRAM NOTE ABX 290 REAR MOUNT ASSEMBLY 1 GREASE O RING ID AND OD DURING ASSEMBLY STONEAGE SEE NOTE 1 PART NUMBER DESCRIPTION QTY 1 ABX 216 001 HOSE GUIDE PLATE OUTER 1 2 230 SPIRAL INTERNAL RETAINING RING 625 BORE SS 4 3 ABX 292 001 REAR MOUNTING BRACKET INSIDE 1 4 293 SPACER ORING 12 5 ABX 294 ORING SHOCK ABSORBER 10 6 GSF 319 025 FHCS 19 24 X 63 Lg 55 2 866 795 1586 WWW STONEAGETOOLS COM PARTS DIAGRAM AUTOBOX ABX 100 XX GUIDE ASSEMBLY ACCESSORY PARTS GUIDE F 2 ae 4 REDUCERS ARE ONLY NEEDED WITH d GUIDE TUBES OF 5 8 OD 459 ID zu ZE ADAPTERS ARE ONLY NEEDED WITH GUIDE TUBES 7 8 OD 745 ID SECTION A A SCALE 1 2 ABX 100 8 GUIDE ASSEMBLY SEE TABLE 3 FOR AVAILABLE HOSE STOP CLAMP SIZES HOSE STOPS WILL BE INSTALLED ON THE HOSES BEHIND THE HOSE DRIVE UNIT 21 SEE TABLE 1 FOR AVAILABLE GUIDE TUBE SIZES THE DASH NUMBER WILL REPRESENT THE SEE TABLE 2 LENGTH OF TUBES DESIRED IN INCHES FOR AVAILABLE HOSE STOP COLLET SIZES TABLE 1 INCHES ADAPTERS TABLE 2 HOSE STOP COLLETS PARTNUMBER DESCRIPTION TY PART NUMBER DESCRIPTION QTY 114 REDUCER REQUIRES 115 2 121 297 HOSE STOP COLLET
18. 70 MPa 20 F to 140 F 29 C to 60 C KEY FEATURES Lightweight Positioner e Modular lightweight design e Quick install drive carriages Utilizes 2 5 in 6 mm box rail 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 e 17 4 SS hose stop oollets AUTOBOX ABX 2L V2 Hose Tractor e Six powered drive rollers ensure traction in all operating conditions Quick change drive rollers three 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 e Small lightweight ergonomic design that includes 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 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 Tractor Model name ABX 2L V2 Is in accordance with the following Directives 2006 42 EC Conforms to the Essential Health and Safety Requirements of the Machinery
19. ABX 248 Idler Nut N C Ns 866 795 1586 WWW STONEAGETOOLS COM 50 STONEAGE ABX 267 Retaining Ring SL External SS 27 PARTS DIAGRAM AUTOBOX ABX 2L V2 HOSE TRACTOR NOTE DRIVE ROLLERS MANIFOLD AND SHAFT ASSEMBLIES ARE DETAILED ON THE NEXT PAGE MANIFOLD ASSEMBLY FITTING ATTACHES TO SMC AIR CYL FITTINGS ATTACH GLOBE AIR MTR ROLLER SHAFT UPPER E ROLLER ASSY ASSEMBLIES 3X LOWER ROLLER SHAFT ASSEMBLIES 3X LOWER ROLLER ASSY 90 ABX 286 FTG Elbow 90 Elbow J8 SS 2 78 GP 011 Blue ID Band 79 GP 011 Black ID Band 61 DESCRIPTION QTY 62 ABX 290 Rear Mount Inside Assembly 1 80 GP 011 R Red ID Band 1 51 268 1 Black Tube 8mm Air Motor 1 63 ABX291 001 Mounting Bracket 2 81 GS 316 09 SHCS 16 32 X 2 25 SS 2 Fwd 64 ABX 298 Quick Pin 17 4 SS 38 x 3 0 4 82 GS 319 05 SHCS 19 24 X 1 25 SS 4 52 ABX 268 2 Black Tube 8mm Air Motor ABX 566 Spring Plunger Pull Ring GS 325 03 SHCS 25 20 X 75 SS TB Fwd 5 Locking 55 66 53 ABX 268 R 1 Red Tube 6mm Air Motor 1 66 BR 167 90 Dust 2 84 GS 325 035 SHCS 25 20 X 0 88 SS 4 ney 67 BR 168 90 Dust Cap 1 85 65325 09 SHCS 25 20 X 2 25 SS 6 68 BRLM 191 Spring Pin 125 x 75 3
20. IC DUMP CONTROL HOSE CLAMP HOSE CLAMP POSITIONER PRESSURE REGULATOR PRESSURE GAUGE CONTROLS CONTROL BOX CONTROL BOX FRONT VIEW REAR VIEW POLE MOUNT 1 4 6 mm PUSH CONNECT WITH THUMB SCREW PNEUMATIC DUMP VERTICAL CONTROL FITTING POSITIONER FITTINGS MAIN BOX Lu FRAME mene WITH DUST CAPS PRESSURE REGULATOR REGULATOR LUBRICATOR P j INLET AIR 27 FITTING NN TRIPOD 7777771 INLINE OILER ADJUSTMENT AIR SUPPLY COLOR CODED HORIZONTAL COLOR CODED FITTING JIC FITTINGS POSITIONER JIC FITTING WITH DUST CAP WITH DUST CAPS FITTIN WITH DUST CAP WITH DUST CAPS 866 795 1586 e WWW STONEAGETOOLS COM SragwEAGE 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 from 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 and tighten the short 1 2 in 13 I D hose between through one wall that the thumbscrew must engage the FRL and the Control Box 3 Slide the Filter Regulator Lubricator FRL assembly over the vertical tube down to the trip
21. IGURE 2 3 Insert the Lower Rail non slotted into the lower mounting Mh brackets It is not critical that this rail is aligned as precisely as the top rail but it should be close to parallel with the top rail for best performance Tighten the clamps securing the rail to the mounting brackets 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 tighten the quick adjust handle Figure 4 10 p STONEAGE 866 795 1586 WWW STONEAGETOOLS COM LIGHTWEIGHT POSITIONER SET UP 1111 Dee 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 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
22. L V2 Hose Tractor and Control Box MUST be supervised at all times and should never be left unattended Do not fully release the hose clamp decreasing pressure to zero during operation or the AUTOBOX ABX 2L V2 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 AUTOBOX ABX 2L V2 Hose Tractor lift with care to prevent bodily injury Do not operate the AUTOBOX ABX 2L V2 Hose Tractor while either side door is open PRE RUN SAFETY CHECK Refer to WJTA IMCAS 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
23. LOCK GUIDE TUBE 44 1 27 GSB 313 0075 BHCS 6 32 X 1 88 LG SS 4 11 ABX 111 KNOB MODIFIED 1 28 GSB 319 015 BHCS 19 24 X 38 LG SS 1 12 112 WASHER THRUST 1 29 GSF 316 015 FHCS 16 32 X 38 LG SS 6 13 ABX 113 001 COUPLING 2 30 GSF 325 025 FHCS 25 20 X 63 LG SS 2 14 ABX 114 REDUCER 459 ID GUIDE TUBE 2 31 GSF 337 03 FHCS 37 16 75 LG SS 4 15 118 CAP HOSE GUIDE 2 32 GW319 L LOCK WASHER SS 1 16 ABX 120 001 MOUNTING BRACKET INSIDE 1 STONEAGE 866 795 1586 WWW STONEAGETOOLS COM 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 perf
24. N TO ASSURE THE V BLOCKS ARE LOCATED PROPERLY THREAD THEM ON THE CENTER SCREW AND MAKE THEM BUTT UP AGAINST EACH OTHER ADJUST THEIR POSITION AS NECESSARY TO LOCATE THE MATING PLANE AT THE DIMENSION SHOWN RED LOCTITE 262 OR EQUIVALENT BLUE LOCTITE 242 oR EQUIVALENT BLUE GOOP IS A SWAGELOK BRAND ANTI SEIZE AN EQUIVALENT ALTERNATIVE IS ACCEPTABLE BLUE LOCTITE BLUE NOTE HIGHER SIDES V BLOCKS ARE OUTBOARD A SECTION C C 2 PLACES 32 7 ADAPTER ONLY USED WITH 5 8 16 mm OD GUIDE TUBES 8 ADAPTER ONLY USED WITH 7 8 22 mm OD GUIDE TUBES PART NUMBER DESCRIPTION QTY 17 ABX 124 ADAPTER 745 ID GUIDE TUBE 1 1 ABX 101 001 HOUSING 1 18 130 001 QUICK RELEASE PIN 1 2 102 INSERT THREAD CLAMP WITH HELICOIL 1 19 131 FLANGED BUSHING 2 3 103 MACHINED BOLT 50 13 MALE 1 20 132 BALL PLUNGER 2 4 104 BAR CLAMP 1 21 133 SCREW BHCS FLANGED 1 5 105 BLOCK DETENT 1 22 135 WASHER PLASTIC 1 6 ABX 106 SCREW CENTER 1 23 136 SPRING PIN 1 7 107 BARREL NUT 38 24 1 24 138 SCREW SHOULDER 1 8 ABX 108 BARREL NUT 44 24 LH 1 25 139 COLLET REFERENCE PLATE 1 9 ABX 109 V BLOCK GUIDE TUBE 38 1 26 GS 325 06 SHCS 25 20 X 1 50 SS 044 2 10 ABX 110 V B
25. T UP GUIDE ASSEMBLY 1 Select the appropriate Guide Tube size and length for the 2 the existing Guide Tubes loosen the Tube Clamp application The length of the Guide Tubes for an exchanger Bolt and the two 3 16 in Socket Head Cap Screws SHCS bundle with no channel head is 12 5 in 318 mm The guide located on top of the Guide Assembly After selecting the tube assembly has approximately 5 in 127 mm of adjustment appropriate Guide Tubes install the Guide Tubes into the Guide A deeper channel head will require extended Guide Tubes Assembly length will give the desired tube length Longer guide tubes AWARNING are available if required for use with channel heads Note The Banshee tool should not have excessive clearance if the correct Appropriate size Collet selection is CRITICAL to ensuring length Guide Tube size is used proper backout prevention of the tool NOTE 9 5 guide tubes 0 625 in 6 mm O D require StoneAge SA PART NUMBER an ABX 114 adapter BN18 guide tubes require an ABX 124 to be installed into the Guide Assembly SA PART NUMBER SA TOOL INSIDE DIAMETER LENGTH StoneAge SA PART NUMBER ABX 115 12 BN9 5 459 in 12 mm 12 5 in 318 mm COLLET REFERENCE CHART ABX 115 36 BN9 5 459 in 12 mm 36 in 914 mm SA PART NUMBER COLLET SIZE ABX 116 12 BN13 546
26. an result in severe injury and or death A WARNING Crush Hazard Keep hands hair and clothing clear of drive rollers and belts Contact with moving parts can result in severe injury re 4 1 a 1 Me STORAGE TRANSPORTATION AND HANDLING When moving the AUTOBOX ABX 2L V2 Hose Tractor lift with care to prevent bodily injury The AUTOBOX ABX 2L V2 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 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 866 795 1586 WWW STONEAGETOOLS COM lt 25 MAINTENANCE Maintenance Item Frequency Maintenance Required Forward reverse and clamp fittings Before each use Inspect threads on fittings for wear or damage Forward and reverse fittings After each use 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
27. anufacturer s instructions If another pneumatic Connection is preferred this fitting can be removed and any male 72 in 13 mm NPT fitting may be used PNEUMATIC DUMP CONTROL FITTING AND LINE A MOMENTARY PNEUMATIC DUMP CONTROL is located on the Control 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 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 NOT INCLUDED CONTROL BOX REAR VIEW 866 795 1586 e WWW STONEAGETOOLS COM A SrrgwEAGE 21 CONTROL BOX AUTOBOX ABX 2L V2 HOSE TRACTOR 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 Box with two 1 4 in 6 mm JIC hoses Verify the Control fittings of the Control Box and the AUTOBOX ABX 2L V2 Box moves the vertical carriage in the appropriate direction Hose Tractor 5 Test the Control Box before operating the AUTOBOX ABX 2 Connect the AUTOBOX ABX 2L V2 Hose Tractor to the 2L V2 Hose Tractor with high pressure water to verify the control valves move the hose in the intended direction and that the dump valve is working properly Control Box with two 1 2 in 13 mm JIC hoses and one 1 4 in 6 mm JIC hose Verify the Control Box rotates the
28. ble 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 D BE CONTAINS 4 2 A 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 securing the rail to the mounting brackets Ensure upper mounting brackets are securely clamped or bolted to the tube bundle flange Figure 2 F
29. 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 Install the Drive Rollers by sliding into place until the spring plungers snap out NOTE Drive Rollers should be installed with the keyway facing up to prevent losing keys 6 Once the correct Drive rollers are installed close and lock the doors The Hose Tractor can now be installed onto the Guide Assembly ABX 271 DARK GRAY BLACK ABX 273 BLUE ABX 272 ORANGE KEY WAY DRIVE Pd ROLLERS X6 SPRING PLUNGER ORIENTATION 866 795 1586 e WWW STONEAGETOOLS COM S rygwEAGE 17 ABX 2L HOSE TRACTOR TO GUIDE ASSEMBLY ATTACH AUTOBOX ABX 2L V2 HOSE TRACTOR TO GUIDE ASSEMBLY 1 Remove the lower quick release pin from the AUTOBOX ABX 2L V2 Hose Tractor 2 Slide the mounting bracket over the block on the Guide Assembly and lay the pin onto the top slot on the Guide Assembly block Install the lower pin through the mounting bracket on the Hose Tractor and the block on the Guide Assembly 72 294 TARRENI an The tractor is now securely mounted to the Guide Assembly 18 p STONEAGE 866 795 1586 WWW STONEAGETOOLS COM CONTROL BOX OVERVIEW CONTROL BOX TOP VIEW MOMENTARY PNEUMAT
30. e 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 STONEAGE 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
31. 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 with drawal protection Collet does not impact the pressure containing crimp Operate the left right and up down positioner functions to begin high pressure cleaning 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 When operating the AUTOBOX ABX 2L V2 an obstacle or restriction within a heat exchanger tube may be encountered When this oc curs the AUTOBOX ABX 2L V2 is designed to slow and stall the air drive motor stopping the advancement of the hose lance and Ban shee
32. he rail clamps and adjust position until the Guide Tubes are approximately 1 2 in 13 mm away from the tube sheet face Tighten the four rail clamp bolts 2 urn 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 ABX 114 ADAPTER FOR BN9 5 0 625 in 6 mm Guide Tubes oe ABX 124 ADAPTER FOR BN18 0 875 in 22 mm Guide Tubes NOTE Adjust position until the Guide Tubes are approximately 1 2 in 13 mm away from the tube sheet face 14 P STONEAGE 866 795 1586 WWW STONEAGETOOLS COM AUTOBOX ABX 2L V2 HOSE TRACTOR COLOR CODED JIC FITTINGS WITH DUST CAPS HANDLE DOOR PIN FORWARD AND REVERSE SPEELD CONTROLS MOUNTING BRACKET MOUNTING BRACKET QUICK RELEASE PIN DRIVE ROLLERS DOOR SERIAL MOUNTING FOR GUIDE PINS PNEUMATIC SUPPLY LINES 25 7620 16 ABX 2L HOSE TRACTOR DOORS AND PINS DOOR Always run the AUTOBOX ABX 2L V2 Hose Tractor with the doors closed and locked DOOR PIN The Door Pin is a spring plunger with a
33. ify 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 7117 777 77 TERMS AND CONDITIONS 34 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 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 tra
34. in 14 mm 12 5 in 318 mm ABX 121 297 297 in 8 mm ABX 116 36 BN13 546 in 14 mm 36 in 914 mm ABX 121 328 328 in 8 mm ABX 117 12 BN15 674 in 17 mm 12 5 in 318 mm ABX 121 406 406 in 10 mm ABX 117 36 BN15 674 in 17 mm 36 in 914 mm ABX 121 438 428 in 11 mm ABX 119 12 18 745 in 19 mm 12 5 in 318 mm ABX 121 460 460 in 12 mm ABX 119 36 18 45 in 19 mm 36 in 914 mm ABX 121 484 484 in 12 mm ABX 121 516 516 in 13 mm ABX 121 547 547 14 mm StoneAge SA PART NUMBER ABX 121 594 594 in 15 mm HOSE STOP CLAMP REFERENCE CHART ABX 121 625 55 in Iemm SA PART 4 HOSE DIAMETER HS 121 27 34 27 34 in 7 9 mm HS 121 34 42 34 42 in 9 11 mm HS 121 42 50 42 50 in 11 13 mm HS 121 50 56 50 56 in 13 14 mm HS 121 56 61 56 61 14 16 mm RECOMMENDED COLLETS FOR COMMON HOSE SIZES COLLET SIZE SPIR STAR PARKER 046 snae 208 o4 2900495 096 o 8 amp 4 o ogs It is the responsibility of the user to select proper sizing to assure the end sleeve of the hose will not pass through collet 866 795 1586 e WWW STONEAGETOOLS COM A S rgywEAGE 3 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 t
35. ks 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 866 795 1586 WWW STONEAGETOOLS COM NOTES This page is intentionally left blank 866 795 1586 WWW STONEAGETOOLS COM S ruwEAGE 35 STONEAGE ENGINEERING THE POWER WATER 1 866 795 1586 www STONEAGETOOLS com 2015 StoneAge Inc All Rights Reserved
36. luded in assembly GUIDE ASSEMBLY SEE PAGES 12 13 14 866 795 1586 WWW STONEAGETOOLS COM p STONEAGE LIGHTWEIGHT POSITIONER OVERVIEW RAIL STOP ASSEMBLIES U 4 an M RAIL EXTENSIONS 2 4 OR 6 FT LENGTHS 610 mm 1219 mm OR 1829 mm HORIZONTAL NN DRIVE ASSEMBLY e VERTICAL SLOTTED 18 RAIL POSITIONER CONTROL LINE ASSEMBLY HORIZONTAL SLOTTED RAIL 25 FT 7 7620 mm STANDARD LENGTH CLAMP TYPES LWP 625 KIT INCLUDES ALL KITS SHOWN HERE VERTICAL DRIVE ASSEMBLY 0000000000 NON SLOTTED RAIL SLOTTED QUICK CLAMP LWP 620 KIT 8l CONTAINS 4 aati 2 96 QUICK CLAMP H i LWP 621 KIT PLATE CLAMP CONTAINS 4 LWP 622 KIT B CONTAINS 2 _ T Np 00 _ pap F RAIL STOP BLANK HORIZONTAL ASSEMBLY ASSEMBLY lt 866 795 1586 WWW STONEAGETOOLS COM LIGHTWEIGHT POSITIONER CLAMP SELECTION CLAMP SELECTION 5 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 inaccessi
37. n 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 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
38. n 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 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 866 795 1586 WWW STONEAGETOOLS COM 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 bee
39. nsportation 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 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 dat
40. od 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 p B THUMBSCREW KNOB ALIGN WITH PRE DRILLED HOLE ON TUBE INSERT TUBE INSERT THUMBSCREW KNOB 20 p STONEAGE 366 795 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 air pressure is 100 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 psi Assembly Connect a compatible compressed air line not 0 97 MPa supply pressure may result in injury to the Operator included according to the Manufacturer s instructions If and or damage to the equipment another pneumatic connection is preferred this fitting can be removed and any male 1 2 in 13 mm NPT fitting may be used 2 Using the regulator adjust the operating air pressure to 100 psi 0 7 MPa for the application ADJUST INLINE OILER TO 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 FRL Connect a compatible compressed air line not included according to the M
41. ormance 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 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 occupatio
42. otentially 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 connections are tight and free of leaks Users of the AUTOBOX ABX 2L V2 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 Water jetting 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 tool entering the exchanger tubes The AUTOBOX ABX 2
43. propriate size Collet selection is CRITICAL to ensuring proper anti withdrawal prevention of the tool COLLET Pd HEMOVED BANSHEE TOOL WITH HOSE END MUST BE PAST THE COLLET SLOT BEFORE INSERTING THE COLLET COLLET 866 795 1586 WWW STONEAGETOOLSCOM S rywEAGE 23 OPERATION CONTROL BOX The HOSE FEED LEVER will move the hose 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 AUTOBOX ABX 2L V2 Hose Tractor Speed is independently adjustable for Forward Reverse Minimum speed is 2ft sec 61 mm sec Maximum speed is 3 0ft sec 914 mm sec To use the 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 o de energize the system release the HOSE FEED LEVER and the MOMENTARY PNEUMATIC DUMP CONTROL This will stop the Drive Rollers from moving and reroute the high pressure water away from the AUTOBOX ABX 2L V2 Hose Tractor TEST RUN PROCEDURE Perform the PRE RUN SAFETY CHECK SEE PAGE 6 Ensure appropriate Collet is installed and hose clamp pressure is set at 20 30psi 14 20 MPa Operate the high pressure hose and waterjet tool at full pressure to test the clamp force Proper clamp force will provide good con
44. se 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 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 Hollers Increase the pressure on the HOSE CLAMP PRESSURE REGULATOR to extend the clamp rollers and clamp the hose Close and lock the door before operating the AUTOBOX ABX 2L V2 Hose Tractor Test the Control Box before operating the AUTOBOX ABX 2L V2 Hose Tractor with high pressure water to verify the control valves move the hose in the intended direction and that the dump valve is working properly HOSE CLAMP 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 will keep the hose running through the Drive Rollers AWARNING e Do not fully release the hose clamp decreasing pressure to zero during operation or the AUTOBOX ABX 2L V2 Hose Tractor will release the hose and may create a dangerous runaway hose condition which c
45. 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 Drive Rollers After each use The Drive Rollers are very durable and should last several hundred hours Howewver it is recommended to inspect all Drive 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 Belt After each use Check and adjust belt tension with the Rollers in the MAX open position It may be necessary to install a hose or other material to hold the rollers open NOTE Do not use any materials with sharp edges as they will damage the rollers To inspect press down between the two idlers with 5 lbs of force on the belt The belt should deflect 25 in gt 05 in 6 mm x1mm If the belt deflects more than 30 in 8 mm it should be tightened See Diagram below NOTICE Do not use any materials with sharp edges to hold the Drive components the hoses pass After each use Most wear parts are made from 17 4 PH stainless steel and should have a through very long life However as wear occurs the rounded edges could become sharp and damage hoses Any
46. tool The operator should stop forward feed and reverse the lance feed direction backing the tool away from the obstruction Repeat the back and forth operation until the resistance or obstruction is cleared via the cleaning action of Banshee tool at the end of the hose The AUTOBOX ABX 2L V2 is not designed for Drive Roller slip If slippage occurs gradually increase the clamp force using the HOSE CLAMP PRESSURE REGULATOR on the Control Box 24 Pp STONEAGE 366 795 1586 e WWW STONEAGETOOLS COM OPERATION HIGH PRESSURE HOSE The AUTOBOX ABX 2L V2 Hose Tractor is designed to be used with Parker Pro Lance and 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 16 mm 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 e 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 through the Drive Rollers The AUTOBOX ABX 2L V2 Hose Tractor MUST be supervised at all times This device is not intended to push the hose and wa terjet tool Once the waterjet tool has pulled the ho
47. trol of the hose 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 produc tivity Operate the high pressure water at full pressure and use the MOMENTARY PNEUMATIC DUMP CONTROL io verify that the dump valve is working properly RUN PROCEDURE After assembling and verifying the AUTOBOX ABX 2L V2 Hose Tractor system is ready for operation Once all hose connections have been secured and verified it is recommended to flush the hoses and verify the dump valve is working prop erly before installing the Banshee tools After flushing the hoses install the Banshee tools and insert both tools into the back of the AUTOBOX ABX 2L V2 Hose Tractor It may be necessary to twist the hoses slightly as the tools and hose ends are manually pushed through the Drive Rollers Once the Banshees are inside the Guide Tubes install the Collet anti withdrawal protection The appropriate Collet must be verified installed secured tested and performance confirmed before operating at high pressure Adjust the clamp pressure to 20 30 psi 14 20 MPa Align the Guide Tubes with an open set of tubes in the heat exchanger bundle Feed forward and advance the hoses into the tube bundle at low pressure and wait
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