StoneAge Sentinel AUTOBOX ABXS-3L User manual

PL 689 REV H
(06/2023)
AUTOBOX®(ABXS-3L)
HOSE TRACTOR
WITH SENTINEL TECHNOLOGY
USER MANUAL
广州凌杰流体科技有限公司

2866-795-1586 • WWW.STONEAGETOOLS.COM
MANUFACTURER’S INFORMATION .......................................... 4
DESCRIPTION OF EQUIPMENT AND INTENDED USE ................................... 4
NEW FEATURES.......................................................................................... 4
SPECIFICATIONS ........................................................................................ 5
EC AND UKCA DECLARATIONS OF CONFORMITY....................................... 6 - 7
WARNING AND SAFETY INSTRUCTIONS .................................... 8
OPERATOR TRAINING................................................................................. 8
PERSONAL PROTECTIVE EQUIPMENT REQUIREMENTS.............................. 8
SAFETY LABEL DEFINITIONS....................................................................... 8
PRE-RUN SAFETY CHECK .......................................................................... 9
FULL SYSTEM ASSEMBLY - OVERVIEW ..................................... 10
ABXS-3L SYSTEM ASSEMBLY OVERVIEW ................................................... 11
HOSE GUIDE ASSEMBLY (ABXS-100) - OVERVIEW ......................... 12
HOSE GUIDE ASSEMBLY SET-UP ................................................................ 13
HOSE GUIDE INSTALL ONTO LIGHTWEIGHT POSITIONER........................... 14
HOSE TRACTOR (ABXS-3L) - OVERVIEW .................................... 15
HOSE TRACTOR CONNECTIONS TO POWER HUB...................................... 16
DOORS AND PINS....................................................................................... 17
HIGH PRESSURE HOSE LENGTH ................................................................ 18
COLLET INSERTION.................................................................................... 19
HOSE AND HOSE STOP INSTALLATION....................................................... 19
MAINTENANCE AND STORAGE, TRANSPORTATION, AND HANDLING ..... 20
ABXS 183-00X FACE PLATE MAINTENANCE ................................. 21
DRIVE BELT REPLACEMENT INSTRUCTIONS ............................... 22
PARTS DIAGRAMS ............................................................ 23
TERMS AND CONDITIONS.................................................... 34
WARRANTY INFORMATION................................................... 35
TABLE OF CONTENTS
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NEW FEATURES:
HOSE TRACTOR (ABXS-3L) WITH HOSE GUIDE (ABXS 160)
• Stop Sensors
-Proprietary design
-Reliably senses footballs and all hose crimps
-Wear indicating rings
-Replaceable 17-4 SS wear plate and anti-withdrawal collets
-Contactless design
-Easily removable sensor unit for maintenance and replacement
• Hub Bar
-Integrated into ABXS frame Durable bayonet style external
connectors Sealed and factory pressurized
• Lance Speed and Position Sensor
-Independent suspension allows each lance to be detected
separately
-Flat knurled rollers for traction and accuracy
-Pneumatic idlers pressurized from clamp circuit
-Contactless magnetic sensor
-Easily removable sensor unit for maintenance and replacement
• Belt Speed and Position Sensor
-Heavy-duty sealed sensor
-Integrated into air motor for durability
-Single mounting screw, easily replaced
MANUFACTURER’S INFORMATION
DESCRIPTION OF EQUIPMENT AND INTENDED USE
The new AUTOBOX®ABXS-3L Hose Tractor design keeps all
the same eld proven features and adds integrated sensing
technology.
The ABXS-3L Hose Tractor is designed to automatically feed
lances and optimize cleaning with integrated, user-adjustable,
speed controls. It also tracks lance position in the tube and
detects and clears blockages. The Hose Tractor utilizes a
heavy-duty synchronous belt with a durable polyurethane cover
to control the rate at which the hoses and Banshee tools are
advanced or retracted inside the tubes.
This Hose Tractor was developed for “Hands Free” heat
exchanger tube cleaning applications. It is recommended it be
used with the StoneAge®Banshee line of self-rotary waterblast
tools.
The ABXS-3L Hose Tractor was designed to accommodate up
to three simultaneous ex lances ranging in size from 3/2 to 8/4
matched with the appropriate BN9.5, BN13, BN15, or BN18 size
Banshee.
The guide assembly provides anti-withdrawal protection, and
precise tube pitch adjustment.
STOP SENSORS
HUB BAR
LANCE SPEED AND POSITION
SENSOR
BELT SPEED AND
POSITION SENSOR
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 nal
dismantling of the machine, as dened by applicable national law(s). Updated manuals can
be downloaded at: https://www.stoneagetools.com/manuals
StoneAge Inc.
466 S. Skylane Drive
Durango, CO 81303, USA
Phone: [phone]
Toll Free: 866-795-1586
www.stoneagetools.com
StoneAge NL
Reedijk 7Q
3274 KE Heinenoord
Netherlands
(+31) (0) 85 902 73 70
[email protected]
StoneAge UK
Unit 3
Crucible Business Park
Woodbury Lane
Norton
Worcester
Worcestershire, WR5 2DQ
United Kingdom
[phone]
[email protected]
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SPECIFICATIONS
HOSE TRACTOR (ABXS-3L) Imperial Metric
Weight: Without rear block, guide, and pins 52.6 lbs 24 kg
With rear block, stop sensor, pins, NO GUIDE 56.4 lbs 26 kg
Complete; with 3 guide tubes, collet, and, stop sensors 68.2 lbs 31 kg
Dimensions: Tractor (only) 11.35 x 11.64 x 16.99 in. 288.3 x 295.5 x 431.5 mm
Tractor with Hose Guide and 12 in. guide tubes 11.35 x 11.64 x 34.29 in 288.3 x 295.5 x 870.9 mm
Feed Rate: dependent upon application and hose size 0.3 - 3.0 ft/sec 91 - 914 mm/sec
Push/Pull Force 15 -150 lbs (5-75 lbs per lance) 7-68 kg (2-23 kg per lance)
System Air Consumption 50 cfm at 100 psi 1416 lpm at 6,8 bar
Manway Access: 18 in. 457 mm
HOSE GUIDE ASSEMBLY (ABXS 160)
Weight: With guide tubes and stop sensor, NO COLLET 11 lbs 5 kg
Without collet or guide tubes, WITH STOP SENSOR 8 lbs 3.6 kg
Dimensions: 5.39 x 4.8 x 12.5 in. 137 x 122 x 317.5 mm
Pitch Adjustment Range (Dual) 5/8 - 5.0 in. 16 - 127 mm
Pitch Adjustment Range (Triple) 5/8 - 2.5 in. 16 - 64 mm
CONTROLLER (CTRL-101) AND
POWER HUB (PH-A0302A00C20)
For detailed up to date information on these components.
https://www.stoneagetools.com/assets/pdf/manuals
LIGHTWEIGHT POSITIONER (LWPS-100-X) For detailed up to date information on these components.
https://www.stoneagetools.com/assets/pdf/manuals
4.00 in.
101.6 mm 12.50 in.
317.5 mm
12.50 in.
317.5 mm
16.99 in.
431.5 mm
16.8 in.
426.7 mm
30.83 in.
783.2 mm
11.35 in.
288.3 mm
11.64 in.
295.5 mm
34.29 in.
870.9 mm
3.45 in.
87.7 mm
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EC DECLARATION OF CONFORMITY
Manufacturer: StoneAge Incorporated
466 South Skylane Drive
Durango, CO 81303
USA
Authorized Representative: StoneAge Netherlands BV
Reedijk 7Q
3274 KE Heinenoord
Netherlands
Sander de Korte, Customer Service Manager
Declare that: AutoBox® Hose Tractor (ABXS-3L)
for high pressure water cleaning of system parts.
Is compliant with the following Directives and Standards:
EU- Machinery Directive (2006/42/EC)
EU- RoHS Directive (2011/65/EU)
EU- EMC Directive (2014/30/EU)
EN ISO 12100:2010 (e) Safety of machinery – General principles for design – Risk assessment and risk reduction
EN ISO 4414:2010 (en) Pneumatic Fluid Power – General rules and safety requirements for systems and components
EN 55011:2009 Industrial, scientic and medical equipment - Radio-frequency disturbance characteristics - Limits and methods of measurement
EN 60204-1:2018 Safety of machinery– Electrical equipment of machines
This device complies with part 15 of the FCC rules and Industry Canada ICES-003. Operation is subject to the following two conditions:
(1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may
cause undesired operation.
The Technical File for AutoBox® Hose Tractor (ABXS-3L) is maintained at:
StoneAge Incorporated, 466 South Skylane Drive, Durango, CO 81303, USA and was compiled by the Engineering Manager.
The Technical File is available through the Authorized Representative.
This Declaration of Conformity is issued under the exclusive responsibility of StoneAge Incorporated.
________________________________________ 09/29/21
StoneAge Incorporated, Durango, CO, USA Date
Liz Mancuso, Director of Engineering
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UK DECLARATION OF CONFORMITY
Manufacturer: StoneAge Incorporated
466 South Skylane Drive
Durango, CO 81303
USA
Authorized Representative: StoneAge UK
Unit 3
Crucible Business Park
Woodbury Lane
Norton
Worcester
Worcestershire, WR5 2DQ
United Kingdom
Steve Ellis, Managing Directory StoneAge UK
Declare that: AutoBox® Hose Tractor (ABXS-3L)
for high pressure water cleaning of system parts.
Is compliant with the following Directives and Standards:
S.I. 2008:1597 - Supply of Machinery (Safety) Regulations 2008
S.I. 2012:3032 - Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment Regulations 2012
S.I. 2016:1091 - Electromagnetic Compatibility Regulations 2016
S.I. 2008:1597 Safety of machinery – General principles for design – Risk assessment and risk reduction
S.I. 2008:1597 Pneumatic Fluid Power – General rules and safety requirements for systems and components
S.I. 2016:1091 Industrial, scientic and medical equipment - Radio-frequency disturbance characteristics - Limits and methods of
measurement
S.I. 2016:1091 Safety of machinery– Electrical equipment of machines
S.I. 2016:1091 Electromagnetic Compatibility (EMC) standard for radio equipment and services; Part 1: Common technical requirements;
Harmonized Standard for Electromagnetic Compatibility
The Technical File for AutoBox® Hose Tractor (ABXS-3L) is maintained at:
StoneAge Incorporated, 466 South Skylane Drive, Durango, CO 81303, USA and was compiled by the Engineering Manager.
The Technical File is available through the Authorized Representative.
This Declaration of Conformity is issued under the exclusive responsibility of StoneAge Incorporated.
________________________________________ 09/29/21
StoneAge Incorporated, Durango, CO, USA Date
Liz Mancuso, Director of Engineering
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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.
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 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.
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 RESPONSIBILITY OF THE INSTALLER/OPERATOR
to conduct a job specic risk assessment prior to use. Job specic
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.
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
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
specic risk assessment to dene 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 rst aid
facilities at the operation site.
PPE may include:
• Eye protection: Full face visor
• Foot protection: Kevlar® 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 specic
risk assessment
SAFETY LABEL DEFINITIONS
The AUTOBOX®(ABXS-3L) Hose Tractor has the potential to
cause serious injury if ngers, hair, or clothing become caught
between the hose rollers or drive belts. Be sure to head the Hand
Entanglement Roller Labels.
DO NOT OPERATE WITH THE DOORS OPEN. ENSURE THAT
ALL FOUR DOOR PINS ARE SECURED PRIOR TO OPERATION.
Maximum operating air pressure is 100 psi
(6,8 bar). Never exceed 125 psi (8,6 bar)
supply pressure. Exceeding 125 psi (8,6
bar) supply pressure may result in injury
to the Operator and/or damage to the
equipment.
WARNING AND SAFETY INSTRUCTIONS
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WARNING
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 specied 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
®
(ABXS-3L) 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.
• The Lightweight Positioner must be securely fastened to the tube
bundle, and the Guide Assembly and Tractor must be securely
fastened to the Lightweight Positioner prior to operation.
• 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 Controller should be located in a safe location where the
Operator has good visibility of the tool entering the exchanger
tubes. The AUTOBOX
®
(ABXS-3L) Hose Tractor and Controller
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
®
(ABXS-3L) 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
®
(ABXS-3L) Hose Tractor lift with
care to prevent bodily injury.
• Do not operate the AUTOBOX
®
(ABXS-3L) Hose Tractor while
either side door is open.
PRE-RUN SAFETY CHECK
Refer to WJTA-IMCA’s, 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 specic risk assessment and act on the resulting
actions.
• Adhere to all site specic 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, lances, 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 an anti-withdrawal device (back-out
preventer), whip checks (hose whips), and the appropriate
hose stop collet are installed and set up properly. They
must be veried, secured, tested, and performance
conrmed before operating at high pressure.**
• Ensure the doors of the AUTOBOX® (ABXS-3L) Hose Tractor are
closed and securely latched.
• Test the Controller before operating the AUTOBOX
®
(ABXS-3L)
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.
WARNING AND SAFETY INSTRUCTIONS
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AUTOBOX® (ABXS-3L) HOSE TRACTOR
AND (ABXS 160) HOSE GUIDE
SHOWN IN THE SYSTEM ASSEMBLY
POWER HUB
(PH-A0302A00C20)
AUTOBOX®
HOSE TRACTOR
(ABXS-3L)
CONTROLLER
(CTRL-101)
LIGHTWEIGHT
POSITIONER
(LWPS-100)
HIGH PRESSURE
WATER HOSES
NOT INCLUDED
PRESSURE
TRANSDUCER KIT
(PT 641)
20K DUMP ASSEMBLY
NOT INCLUDED
WATER SUPPLY HOSE
NOT INCLUDED
HOSE STOPS
(HSS-121.1-XX)
NOTICE
Heat exchanger tube bundle face, shown for
graphic representation only. NOT included in
assembly.
FULL SYSTEM ASSEMBLY - OVERVIEW
GUIDE ASSEMBLY
(ABXS 160)
ABXS TRACTOR CONTROL LINE
BUNDLE
(CBL EA15F-1RB6PP-2PL10-1PL5)
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AUTOBOX® (ABXS-3L) HOSE TRACTOR WITH
HOSE GUIDE AND CONTROL LINE BUNDLE
AUTOBOX®HOSE TRACTOR
(ABXS-3L)
ABXS-3L SYSTEM ASSEMBLY - OVERVIEW
GUIDE ASSEMBLY
(ABXS 160)
15FT (4.5m) ABXS TRACTOR CONTROL LINE BUNDLE
(CBL EA15F-1RB6PP-2PL10-1PL5)
SEE THE PART DIAGRAM SECTION IN THIS MANUAL
FOR DETAILED PART INFORMATION
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HOSE STOP COLLET
(MULTIPLE SIZES AVAILABLE)
HOSE STOP CLAMPS
(MULTIPLE SIZES AVAILABLE)
GUIDE TUBES
(MULTIPLE SIZES AVAILABLE)
MOUNTING
BRACKET
PITCH ADJUST
LEVERS
QUICK RELEASE PIN
TUBE CLAMP
ALUMINUM
HOUSING
HOSE GUIDE ASSEMBLY
(ABXS 160)
StoneAge (SA) PART NUMBER GUIDE TUBE REFERENCE CHART
GUIDE TUBE BANSHEE INSIDE DIAMETER, LENGTH
ABX 115-12 BN9.5 .459 in / 11.7 mm, 12.5 in. / 318 mm
ABX 115-36 BN9.5 .459 in / 11.7 mm, 36 in. / 914 mm
ABX 116-12 BN13 .546 in / 13.9 mm, 12.5 in. / 318 mm
ABX 116-36 BN13 .546 in / 13.9 mm, 36 in. / 914 mm
ABX 117-12 BN15 .674 in / 17.1 mm, 12.5 in. / 318 mm
ABX 117-36 BN15 .674 in / 17.1 mm, 36 in. / 914 mm
ABX 119-12 BN18 .745 in / 18.9 mm, 12.5 in. / 318 mm
ABX 119-36 BN18 .745 in / 18.9 mm, 36 in. / 914 mm
HOSE GUIDE ASSEMBLY (ABXS 160) - OVERVIEW
StoneAge (SA) PART NUMBER COLLET AND HOSE STOP REFERENCE CHART
HOSE O.D. SPIR STAR PARKER COLLET SIZE
COLLET PART
NUMBER HOSE STOP SIZE
HOSE STOP
PART NUMBER
.27-.41 in
(7 mm - 10 mm)
3/2 2240D-02 .297 in. / 7.5 mm ABX 171-297 .27-.34 / 7-9 mm HSS 121-27-34
3/4, 4/2 2240D-025, 2440D-02 .328 in. / 8.3 mm ABX 171-328 .27-.34 / 7-9 mm HSS 121-27-34
3/6, 5/2 2240D-03 .406 in. / 10.3 mm ABX 171-406 .34-.42 / 9-11 mm HSS 121-34-42
.44-.50 in
(11 mm - 13 mm)
4/4 2448D-025 .438 in. / 11.1 mm ABX 171-438 .34-.42 / 9-11 mm HSS 121-34-42
4/6, 5/4 .460 in. / 11.7 mm ABX 171-460 .42-.50 / 11-13 mm HSS 121-42-50
6/2 2240D-04, 2640D-025 .484 in. / 12.3 mm ABX 171-484 .42-.50 / 11-13 mm HSS 121-42-50
6/4 2440D-04, 2740D-025 .516 in. / 13.1 mm ABX 171-516 .50-.56 / 13-14 mm HSS 121-50-56
.52-.61 in
(13 mm - 16 mm)
5/6, 8/2 2240D-05, 2740D-03 .547 in. / 13.9 mm ABX 171-547 .50-.56 / 13-14 mm HSS 121-50-56
5/6H, 8/4 .594 in. / 15.1 mm ABX 171-594 .56-.61 / 14-16 mm HSS 121-56-61
2440D-05 .625 in. / 15.9 mm ABX 171-625 .56-.61 / 14-16 mm HSS 121-56-61
ABXS 161 ASSEMBLY,
HOSE CRIMP AND HOSE
STOP SENSOR PUCK
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HOSE GUIDE ASSEMBLY SET-UP
HOSE GUIDE ASSEMBLY
1. Select the appropriate Guide Tube size and length for the application from the chart at the bottom of the previous page.
• The length of the Guide Tubes for an exchanger bundle with no channel head is 12.5 in. (318 mm).
• A deeper channel head will require extended Guide Tubes. The depth of the channel head added to the 12.5 in. (318 mm) length will
give the desired tube length.
• Longer guide tubes are available if required for use with channel heads.
NOTICE
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 Lever and the two Pitch Adjust Levers, located on top of the Guide
Assembly. After selecting the appropriate Guide Tubes, install the Guide Tubes into the Guide Assembly.
3. Secure the Guide Tubes by tightening the Tube Clamp Lever and Pitch Adjust Levers, when the desired pitch has been set.
4. Select the appropriate Collet and Hose Stops from the chart on the previous page and reserve them for future Hose and Collet
installation instructions in this manual.
1, 2, or 3 HOSE LOADING POSITIONS
The AUTOBOX
®
(ABXS-3L) Hose Tractor can be used as a 1, 2, or, 3 Lance tool. The diagrams below show which Guide Tubes to load for
best performance. The numbered positions correspond with the indicator markings on the top of the Hose Tractor and the identiers in the
Controller interface.
WARNING
Appropriate size Collet selection is CRITICAL to ensuring proper backout prevention of the tool. Use the chart on the previous page to
select the proper Collet and Hose Stop sizes per hose diameter. Always conrm backout prevention performance before operating the
system at high pressure.
SINGLE HOSE LOAD
1 2 3 1 2 3 1 2 3
TRIPLE HOSE LOADDUAL HOSE LOAD
2
2
1
3
3
ABXS 161 ASSEMBLY,
HOSE CRIMP AND HOSE
STOP SENSOR PUCK
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ATTACH GUIDE ASSEMBLY TO LIGHTWEIGHT POSITIONER
1. Pull to open the Clamp Handle on the Vertical Carriage and slide the Tractor/Guide Tube Assembly into the Clamp Mount.
2. Leave 1/2” (13mm) between the end of the Guide Tube and the face of the exchanger.
3. Lock the Clamp Handle in place when the assembly is in position.
4. If the Clamp Handle feels too loose or too tight, it can be adjusted with a 5mm Allen Key. Follow the instructions on the decal on the
Vertical Drive. (Also shown below)
5. Loosen the Pitch Adjustment Levers and adjust the guide tubes until they are in line with pitch of the tubes in the bundle.
6. Tighten Tube Clamp and Pitch Adjustment Levers until tubes are secured in position.
HOSE GUIDE ASSEMBLY TO LIGHTWEIGHT POSITIONER SET UP
Heat exchanger
tube bundle face
1/2”
(13 mm)
2
1
3
5
6
4
Adjust position until the Guide Tube
is approximately 1/2 in. (13 mm) away
from the face of the heat exchanger.
PULL OPEN /
PUSH CLOSED
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HOSE TRACTOR (ABXS-3L) - OVERVIEW
AUTOBOX® HOSE TRACTOR
(ABXS-3L)
REVERSE
SPEED CONTROL
SENSOR
CONNECTION BLOCK
DUAL AIR
MOTORS
FORWARD
SPEED CONTROL
COLOR CODED PUSH LOCK
FITTINGS WITH DUST CAPS
REAR VIEW
HANDLE
PITCH
ADJUST LEVERS
QUICK EXHAUST
WITH SILENCER
DOOR PIN COLLET
REFERENCE CHART
HOSE STOP
AND SENSOR
DRIVE BELT GUIDE
ASSEMBLY
GUIDE
TUBES
HOSE STOP
COLLET
TUBE CLAMP
*ABX 305-50 BELT 50A 10MM (INSTALLED)
ABX 305-80 BELT 80A 25MM (INCLUDED)
FRONT VIEW
DOOR
ASSEMBLY
HOSE POSITION
INDICATORS
REPLACEABLE
FACE PLATE
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HOSE TRACTOR CONNECTIONS TO POWER HUB
POWER HUB
PNEUMATIC SUPPLY LINE CONNECTIONS
1. Remove the dust caps from the ttings on the AUTOBOX®
(ABXS-3L) Hose Tractor.
2. Connect the Hose Bundle to the Power Hub
Match the colored tubing to the corresponding color coded
ttings under the “Tractor” label. Connect the Pot Plug to the
receptacle marked “Tractor” and listen for a click. This ensures it
is water tight.
3. Blow out all Pneumatic Lines
Turn the Main Air Supply on. Use the Controller to activate
the Forward, Reverse, and Clamp functions. Use of dirty or
contaminated pneumatic hoses will cause component
damage and malfunction
4. Connect hoses to the Hose Tractor
Match the colored tubing to the corresponding color coded
ttings on top of the Hose Tractor. Connect the potted plug to
the receptacle marked “Tractor” on the back of the Hose Tractor
and listen for a click. This ensures it is water tight.
5. Test the Controller before operating the system with high
pressure water to verify the control valves move the hoses and
positioners in their intended directions, and that the dump valve
is working properly.
Tech Tip:
Ensure that Quick Exhausts and
Silencers are free of debris and
exhausting freely. Performance can
be greatly reduced should these
items be clogged.
SILENCERS &
QUICK EXHAUSTS
NOTICE
For Detailed Instructions and Setup of the Controller and Power
Hub Assemblies, see the Controller and Power User Manual.
https://www.stoneagetools.com/assets/pdf/manuals/
CONTROL LINE ENDS
Straight Electric
Cable End
16mm diameter
tubing
8mm diameter
tubing
CONTROL LINE BUNDLE (CBL EA15F-1RB6PP-2PL10-1PL5)
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DOOR
Always run the AUTOBOX®(ABXS-3L) 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. To close and lock the door, pull and twist the pull ring, then release it into the groove of
the pin. Verify the pin engages the door fully.
CAUTION
Make sure to lock both doors on each side of the Hose Tractor before operating AUTOBOX®
(ABXS-3L) Hose Tractor.
LOCKED
UNLOCKED
CLOSED DOOR POSITION
DOOR
PIN
DOOR
PIN
OPEN DOOR POSITION
DOORS AND PINS
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HIGH-PRESSURE HOSE
• The AUTOBOX®(ABXS-3L) Hose Tractor is designed to be used
with Parker Pro-Lance® and/or Spir Star Blast-Pro® hose ends.
Standard hose ends may not t into Hose Tractor and/or Guide
Tubes. NOTE: MAXIMUM hose end diameter must NOT ex-
ceed .74 in. (19 mm)
• 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.
NOTICE
Do not use a shrouded hose or hose with a steel protective cover.
This will cause severe damage to the Drive Belt and Idlers.
• 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 hoses synchronized at full retract and full extend positions.
• HOSE LENGTHS There are a many varieties of tube bundles that
will require additional hose length to be considered. This should
be veried prior to ordering high pressure hose for each job. The
calculation below determines the additional length necessary to keep
the assembly from lifting off the ground during operation. Provide the
tube bundle length and use the calculation below to determine the
total hose length.
HIGH PRESSURE HOSE LENGTH AND COLLET INSERTION
COLLET INSERTION
Remove Quick Release Pin and pull out existing Collet. Select
the appropriate Collet size for the diameter of the hoses. (See the
“Recommended Collets For Common Hose Sizes” plaque on the
top plate of the AUTOBOX®(ABXS-3L) Hose Tractor.) (Figure 1)
WARNING
Appropriate size Collet selection is CRITICAL to ensuring proper
anti-withdrawal prevention of the tool. See “Recommended Collets
For Common Hose Sizes” plaque on the top plate of the ABXS-3L
Tractor or the side of the vertical carriage on the Lightweight Positioner.
FIGURE 1
COLLET
QUICK
RELEASE PIN
B (TOTAL COMPONENT LENGTH) C (RECOMMENDED ADDITIONAL CONNECTION LENGTH)
ABX-3L-V2, Hose Guide, and Lightweight Positioner = 32.9 in / 836 mm 39 in / 991 mm
A
B
D
C
A (Tube Bundle Length in inches / mm) +
B (Total Length of components in inches / mm) +
C (Recommended Additional Connection Length in / mm)
=
D (Total required Length of hose in inches /mm)
EXAMPLE: The hose length equation for a 20ft (6096 mm) tube
bundle with ABXS-3L, Hose Guide, and Lightweight Positioner
would be as follows;
STANDARD: (20ft x 12 in/ft) + 32.9 in + 39 in = 311.9 in.
METRIC: 6096 mm + 836 mm + 991 mm = 7922 mm
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HOSE AND HOSE STOP INSTALLATION
HOSE AND HOSE STOP INSTALLATION
1. The HOSE CLAMP PRESSURE REGULATOR on the
Controller MUST BE TURNED TO ZERO pressure to make
room for the hoses to be installed. Use the left Joystick on the
Controller to highlight the Clamp Pressure setting. Then move
the left Joystick left or right to decrease or increase the pressure.
2. Insert the hoses, equipped with the waterblast tools, into the
mounting bracket on the side of the AUTOBOX®(ABXS-3L)
Hose Tractor until the engage the Drive Belt. Slightly increase the
pressure on the HOSE CLAMP PRESSURE REGULATOR to
extend the clamp rollers and clamp the hoses.
3. When the waterjet tools pass the Collet slot, install the Collet and
quick release pin.
WATERBLAST TOOL WITH
HOSE END MUST BE PAST
THE COLLET SLOT BEFORE
INSERTING THE COLLET
COLLET
REMOVED
HOSE CLAMP
PRESSURESETTING
+ / - PSI
HOSE
STOPS
MOUNTING
BRACKET
PULL TO CHECK
COLLET FUNCTION
WARNING
Do not fully release the hose clamp (decreasing pressure to zero) during
operation, or the AUTOBOX®(ABXS-3L) Hose Tractor will release the
hose and may create a dangerous runaway hose condition, which can
result in severe injury and/or death.
Crush Hazard. Keep hands, hair, and clothing clear of all moving
parts. Contact with moving parts can result in severe injury.
4. Pull on the hoses from the back of the AUTOBOX®(ABXS-3L) Hose
Tractor to ensure that the Collet does not allow the waterblast tool
back out of the Guide or Hose Tractor.
5. To install hose stops, drive waterblast tools through the exchanger
until the tips are 1-2” (25-51 mm) past the end of the tube bundle.
Loosely install the stop with the arrows pointing to the tractor, then
push them toward the mounting bracket and tighten in place.
NOTICE
If the Wear Indicator Grooves on the Replaceable Face Plate are gone,
continued long-term operation will signicantly reduce the life of the rear
stop sensor.
CLAMP PRESSURE
WATERBLAST
TOOL
COLLET
INSTALLED
REPLACEABLE
FACE PLATE
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Maintenance Item Frequency Maintenance Required
Drive Belt (See Belt Replacement
instructions in this manual)
After each use The Belts are very durable and should last several hundred hours. However,
it is recommended to inspect the Belt for wear and/or cracks at the
completion of each job. Replacement is required when the Belt is damaged.
If the performance of the belt is not functioning well for the conditions, try
replacing it with the alternate durometer belt (included).
NOTICE
Operation with a severely damaged belt will result in excessive damage to
the Idler rollers and drive sprockets.
All components the hoses pass
through, particularly face and guide
plates.
After each use Most wear parts are made from durable materials 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.
If the ABXS 183-001 face plate is not replaced in a timely manner, it will result
in damage and/or premature failure of the rear stop sensor. See next page
FWD, REV, LFT, RGT, UP, DOWN
ttings
After each use Apply a small amount of air tool oil directly into FWD, REV, LFT, RGT, UP,
DOWN ttings. Then, briey 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 ttings to keep moisture and dirt out.
NOTICE
Do not add oil to the Clamp (CLP) tting, as oil may accumulate in the air
cylinders and prevent them from fully retracting.
ABXS-3L (Inside) After each use When storing the unit, use compressed air to blow out any residual debris
and moisture. Use mild, soapy, low pressure, water to clean the machine in
order to remove corrosive materials.
DO NOT SPRAY WATER DIRECTLY AT OR SUBMERGE THE AIR MOTOR
BREATHER PORTS OR ELECTRONIC COMPONENTS. MAKE SURE ALL
DUST CAPS ARE IN PLACE AND ELECTRICAL SENSOR CONNECTIONS
ARE TIGHT PRIOR TO CLEANING.
HOSE TRACTOR (ABXS-3L) MAINTENANCE
The AUTOBOX®(ABXS-3L) Hose Tractor should be stored upright in a job box between jobs. When moving the AUTOBOX® (ABXS-3L)
Hose Tractor, lift with care to prevent bodily injury.
STORAGE, TRANSPORTATION, AND HANDLING
Contact StoneAge for Safety Data Sheets for material usage, a complete list of spare part numbers, and service instructions for the
AUTOBOX®(ABXS-3L) Hose Tractor and Controller.
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