BAND-IT IT5000-AB 3/8 User Manual
IT5000-AB
Owner’s
Manual
3/8” Junior
®
Tool
IT5000 A B 0 0 0
Base part number
Product level
Revisions are not
compatible
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
Tool revision
Revisions are
compatible
www.BAND-IT-IDEX.com
Other options:
0 – None (standard)
1 – Feedback system
Trigger options:
0 – Standard thumb trigger
1 – Connection for a remote trigger
(trigger not supplied)
Packaging options:
0 – Tool with all accessories (standard)
1 – Tool only
Document # I17795 Rev G
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P: 1-800-525-0758 F: 1-800-624-3925
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IT5000-AB
Table of
Contents
Warranty & Safety Guidelines 3
Air System 4-6
Parts Identification 7,22
Tool Overview 8
Setup & Assembly Instructions 9-11
Remote Operations & Fixturing Tips 12,13
3/8” Junior
Table of Contents Page
®
Tool
Operating Tips 14
Operating Instructions 15
Troubleshooting 16-20
Maintenance 21-28
Data Feedback System 29-38
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street Denver, CO 80216-0307 USA
P: 1-800-525-0758 F: 1-800-624-3925
www.BAND-IT-IDEX.com
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Document # I17795 Rev G
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All rights reserved
IT5000-AB
Warranty &
Safety Guidelines
Warranty:
For Warranty information visit the following URL
www.BAND-IT-IDEX.com/Warranty.html
Safety Guidelines
• Read this manual and become familiar with the tool before installing any
clamps.
• Protective eyewear should be worn when connecting and disconnecting
the tool to compressed air sources and during operation.
3/8” Junior
®
Tool
• Wear appropriate gloves for handling steel while operating this tool,
applying stainless steel clamps and removing scrap clamp tail.
• Clamp tensioning can be immediately stopped by releasing the tool
trigger system.
• When applying clamps, care should be taken to insure fingers and loose
clothing are not in the way of the clamp being applied.
• Never attempt to clamp objects which have a potential to burst, shatter
or otherwise cause bodily harm.
• Disconnect air supply and electrical power prior to maintenance and
disassembly of tool components.
• Liquids or lubricants should never be put into the air lines.
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street Denver, CO 80216-0307 USA
P: 1-800-525-0758 F: 1-800-624-3925
www.BAND-IT-IDEX.com
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Document # I17795 Rev G
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IT5000-AB
Air System
The IT5000 is a pneumatic tool that needs a clean and dry air supply. The BAND-IT Air
Controller Module includes a filter to meet these requirements. For proper tool
performance, the air requirements at the inlet to the BAND-IT Air Controller Module of
the IT5000 must be:
Inlet Supply Pressure, PSI [kPa] 100 [690] 140 [965]
Inlet Supply Air Flow, SCFM [L/s] 1.5 [0.71]
Particle Size In Air Supply (microns) 5
Air Moisture Content 20% RH
Tension Pressure Setting, PSI [kPa] 60 [410] 90 [620]
Cut-off Pressure Setting, PSI [kPa] 100 [690] 110 [760]
Note – An Air Booster Unit is now available to meet air pressure requirements.
Please have tool model and serial #’s available when calling the factory for
service assistance. Contact BAND-IT-IDEX customer service, 303-320-4555.
3/8” Junior
Item Min Max
®
Tool
Caution – Do not exceed a Tension pressure of 90 PSI (620 kPa). Pressures
above that may cause premature clamp failure.
Inlet air supply
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
Air Controller Module
Cut-off Pressure
Regulator
www.BAND-IT-IDEX.com
Tension
Pressure
Regulator
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IT5000-AB
Air System
Inlet Air Supply
Quick Disconnect
Use one of two
quick-disconnects
supplied or remove
and use 1/4” NPT
fitting
Air Shut-Off Valve
Air Controller Module
Cut-off
Outlet
Exhaust
Muffler
3/8” Junior
Tension
Outlet
®
Tool
Filter
Fluid Drain
Cut-off
Pressure
Gauge
Air Filter Environment:
Standard Filters/Regulators
incorporate polycarbonate bowls and/or
observation windows. DO NOT use in
an environment that will expose the
above mentioned components to
synthetic fluids, organic solvents,
chemicals, cutting lubricants, thread
lock solutions or similar materials.
Cut-off Pressure
Regulator
Factory set to 105 PSI
(725 kPa)
Do not adjust
Release
Valve
Tension
Pressure Gauge
Tension Pressure
Regulator
Pull Regulator
Knob and twist to
adjust tension,
push to lock
Mounting Bracket
Unit may be mounted
on wall or bench
Note: Air Controller Module
must be mounted and operated
in a horizontal position.
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street Denver, CO 80216-0307 USA
P: 1-800-525-0758 F: 1-800-624-3925
www.BAND-IT-IDEX.com
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IT5000-AB
Air System
3/8” Junior
The standard IT5000 shipping container includes: Air Controller
Module, IT5000 tool body, coiled air line, owner’s manual and tool kit.
(tools with packaging option 1 include the tool and manual only)
Pressure conversion: bar = kPa / 100
Initial Setup - Pneumatics
• Connect the tool body to the Air Controller Module using the included Coiled Hose
Assembly. The hose assembly includes both a clear and black hose. Each hose
end includes a female and male fitting, arranged to prevent reversing of
connections.
• Connect Air Controller Module to air source (assure air supply meets
requirements on page 4) and turn RED Shut-off Valve counter clockwise to
pressurize tool (supply position).
• Cut-off Pressure: 105 PSI (760 kPa) recommended. Make sure the Cut-off
Pressure Gauge located on the left side of the module reads a pressure of 100
PSI min and 110 PSI max.
®
Tool
• Tension Pressure: 85 PSI (585 kPa) recommended. The Tension Pressure
Gauge monitors the tension applied to the clamp tail. Recommended air pressure
at the Tension Gauge should be 60-90 PSI (410-620 kPa) for BAND-IT 3/8” JR
clamps.
• Caution: Tension pressures above 90 PSI (620 kPa) may cause premature clamp
failure and/or tool wear.
Setting the Tool Air Pressure
The tension pressure directly affects the force applied to the clamp.
To correctly set the air pressure from the air controller module going to the tool, hook up
the air supply to the tool. Activate the tool by depressing the trigger for a few seconds. Reread the pressure when the tool is at rest and adjust again if necessary. Repeat until the
desired pressure is shown on the tension pressure gage.
Tension pressure may need to be adjusted depending on the application.
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
www.BAND-IT-IDEX.com
Document # I17795 Rev G
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4799 Dahlia Street Denver, CO 80216-0307 USA
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IT5000-AB
Parts
Identification
Tool Hanger
Mounting
Holes
Operating
Trigger
IT5000-AB Tool Body
Model I.D.
Plate
3/8” Junior
Quick Connect
Air Couplings
®
Tool
(Do not add
lubricants)
Tension
Cylinder
Cut-off
Cylinder
Reset
Button
Tool Head
with Cutter
Knife and
Blade
Flip Cover
Head Screws
Important: Before disassembling tool, be sure to
shut-off air supply on theAir Controller Module.
Flip Cover
Tightening Screw
Serial #
Location
Quick Release Pins
Maintenance
Flip Cover
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street Denver, CO 80216-0307 USA
P: 1-800-525-0758 F: 1-800-624-3925
www.BAND-IT-IDEX.com
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IT5000-AB
Tool
3/8” Junior
Overview
Pneumatic System:
The pneumatic valves and cylinders contain seals and o-ring components which can
experience accelerated wear associated with the quality of the air supply. Worn cylinder orings allow air to bypass the pistons in the cylinders, affecting the performance of the tool
and cause the output force of the tool to drift. Although cylinders are permanently
lubricated, premature wear can be caused by contaminants in the air supply or the presence
of water and oil. The tool’s internal valves can also be affected by contaminants in the air
lines causing a valve malfunction.
BAND-IT recommends the use of an Air Booster System to address the potential problems
associated with low air supply. In addition to filtering and drying the air supply, it will assure
pressure of 100 -110 PSI (690-760 kPa) improving the consistency of tool performance.
®
Tool
Tool Function:
The IT5000 tool utilizes the conditioned air supply to actuate the mechanical linkage. The
linkage activates a gripping system which tensions the 3/8” BAND-IT Junior Clamps. This
tension output of the tool can vary depending upon the air pressure supplied to the tool. If the
pressure is increased, the output force increases.
During the tension cycle, the tool continues to tension the band until the pre-set tension is
achieved. The tool stops tensioning when the pressure in the tension cylinder equals the inlet
tension pressure coming from the air controller module. After the tool has achieved the preset
tension, its valve switches over to the cutoff cycle. The gripping system retains force on the
clamp until a knife is actuated forming a Junior-style lock and shearing the excess clamp tail
scrap.
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street Denver, CO 80216-0307 USA
P: 1-800-525-0758 F: 1-800-624-3925
www.BAND-IT-IDEX.com
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Setup &
IT5000-AB
Assembly
Instructions
Handle adjustment:
• Using 1/4” hex key (supplied), adjust
the Support Arm/Handle to
ergonomically match the operators
hand.
• Be sure not to adjust the Handle too far
outward (beyond interlocking legs) or
the handle will not function properly or
provide support to the operator.
3/8” Junior
®
Tool
Hanger Support Instructions:
1. An aluminum hanger (accessory
option) can be utilized for
supporting the tool.
2. The hanger should be installed (as
shown) into the two threaded holes.
3. Secure the hanger against the tool
body with the two supplied screws.
4. A light application of vibratite is
already included on the screw’s
thread.
Hanger Mount
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street Denver, CO 80216-0307 USA
P: 1-800-525-0758 F: 1-800-624-3925
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Setup &
IT5000-AB
Assembly
Instructions
Three additional fixture mounting holes are available
to assist with mounting the IT5000. Thread size is
#10-32 for each of the holes. Usable thread depth is
.400” for two of the three fixture holes. One hole is
utilized to attach and lock the tool body halves
together. This hole may also be used for fixturing,
provided the #10-32 cap screw is replaced with a
similar threaded screw with appropriate thread
length secure the two halves together in addition to
fixturing.
3/8” Junior
Fixture Mounting LocationsFixture Locating Points
®
Tool
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street Denver, CO 80216-0307 USA
P: 1-800-525-0758 F: 1-800-624-3925
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Note: Hole locations
are .750” to
centerline of holes
and edge of tool as
indicated by the
detail to the left.
Document # I17795 Rev G
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BAND-IT-IDEX, Inc. 2009
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Setup &
IT5000-AB
Assembly
Instructions
Part of insuring that the tool is producing a strong lock is making sure that it approaches
the application correctly and is fixtured to allow repeatability of application. The tool
should approach the surface tangent to where the buckle of the band is to be applied.
The tool should be allowed to float 1/8” – 1/4” above the surface to allow the buckle to
move to the proper position for cut-off. Once the tool begins tensioning, the band will
pull the tool down to the surface.
3/8” Junior
®
Tool
1/8” – 1/4”
Buckle LocationPivot Point
As the band is tensioning, the tool may rotate clockwise up to 5 degrees about the pivot
point (Green Arrow). During the cut-off cycle, the tool must be allowed to rotate counterclockwise up to 35 degrees (Blue Arrow). Because of this movement, BAND-IT
recommends that the tool be mounted in a fixture that will provide adequate
rotation during both cycles.
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street Denver, CO 80216-0307 USA
P: 1-800-525-0758 F: 1-800-624-3925
www.BAND-IT-IDEX.com
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© Copyright
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Remote Operations
& Fixturing Tips
IT5000 Orientation Requirements:
• The IT5000 tool has a number of Tool/Clamp/Object Being Clamped
orientation requirements that must be followed in order to reach an acceptable
end result.
• In concept, the fixture maker should attempt to replicate the natural human
wrist/elbow/shoulder motions that would occur when operating the tool in the
hand-held configuration, allowing the tool to float along a plane through the
entire Tension (pull-up) and Cut-Off (lock) process.
The tool MUST:
• Contact the object being clamped without restricting or forcing.
IT5000-AB
3/8” Junior
®
Tool
Suggestions Include:
• The tool fixture should be able to accommodate some longitudinal rotational
movement, i.e. “wrist like”, at the final moment of applied tension. The
purpose being, to allow the tool freedom of movement to orient itself in its best
natural orientation as relates to the clamp and the object-being-clamped.
• A home or neutral position should be established at the optimal final position
with +/- 10-12½ degrees of rotational freedom being allowed from the pivot
point.
• The tool fixture should be able to accommodate some extensive movement,
i.e. “elbow like”, during the tension phase to allow the tool to be “pulled” up to
the object being clamped.
• Deviations from accommodating the natural inclination of the tool/clamp/object
being clamped, may negatively impact the integrity of the final assembly. The
clamp should fully rest upon the object being clamped at the time of final
tension and cut-off. If the tool can not reach the object being clamped and
attempts to cut-off, the clamp and/or lock may not form optimally.
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street Denver, CO 80216-0307 USA
P: 1-800-525-0758 F: 1-800-624-3925
www.BAND-IT-IDEX.com
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