BAND-IT UL4000-C User Manual

Page 1

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

Document # P08986 Rev. A

BAND-IT-IDEX, Inc. 2012

www.BAND-IT-IDEX.com

Page 1 of 14

UL4000-C

UL4000-C220

Ultra-Lok Tool

Operating Instructions

Cordless Ultra-Lok Tool

Table of Contents

Warranty, Safety Guidelines

Setup Instructions

3-4

Settings

Parts List

Tool Head Exploded Views

7-8

Clamp Application

Free-End

Clamp Inspection

Preformed

Maintenance

12-13

Blade Change

Page 2

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

Document # P08986 Rev. A

BAND-IT-IDEX, Inc. 2012

www.BAND-IT-IDEX.com

Page 2 of 14

UL4000-C

UL4000-C220

Ultra-Lok Tool

Warranty, Safety Guidelines

CAUTION!

This tool is designed to work solely mounted to the Bosch DDH181-01 or Bosch GSR 18 VE-2LI Professional cordless drill. Use of any other drills in place of these Bosch drills may result in unsatisfactory performance, hazards to the operator and/or the tool, or unsafe clamps. Disregard of this caution voids the warranty of the tool and releases BAND-IT of any and all liabilities arising from such misuses.

Use of Alternate Drills

Warranty

Refer to website for warranty information: http://www.band-it-idex.com/warranty.html

NOTE: Any performance data published herein is based on laboratory tests, which cannot duplicate conditions that may be encountered in field installations. Such conditions may vary results substantially from those shown (such as abuse in handling and installation, failure to follow recommended handling and installation practices, abnormal environmental conditions, disregard of operating instructions for BAND-IT tools or non-recommended combinations of BAND-IT products). BAND-IT cannot be responsible for performance characteristics from such variables.

Safety Guidelines

WARNING:

Always wear safety glasses when operating this tool and keep both hands and clothing away from clamp being tensioned. Squeezing force can reach as high as 2 tons. Never attempt to clamp objects which can shatter or otherwise cause bodily harm. Tensioning the clamp can be stopped immediately by releasing the trigger. Detailed instructions are in this manual and the operator is advised to read it and become familiar with operating the tool.

IMPORTANT FOR HOSE APPLICATIONS:

When clamping a hose end, remember that a tighter clamp keeps the fitting more secure, but excess

tension can damage the hose. Fitting stem must have prominent barbs for proper retention inside the hose, but must not be sharp to prevent cutting into the hose. Hose, fitting, and clamp must be compatible with each other and the environment used in. If in doubt, consult the hose or fitting manufacturer or call BAND-IT.

Improperly tightened clamps may result in dangerous hose assemblies, which could cause injuries or property

damage.

Abuse or use of a hose outside the manufacturers recommended conditions may cause it to quickly deteriorate

and become a safety hazard. This could result in serious injury or property damage. Inspect and test hose assemblies frequently.

Clamping objects other than hose requires similar precautions. Use only with BAND-IT 3/4" and 1/2" Ultra-Lok Free-End and Preformed Clamps

Page 3

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

Document # P08986 Rev. A

BAND-IT-IDEX, Inc. 2012

www.BAND-IT-IDEX.com

Page 3 of 14

UL4000-C

UL4000-C220

Ultra-Lok Tool

Setup Instructions

1. Read safety instructions and operator‟s manual for the Bosch DDH181-01 or Bosch GSR 18 VE-2LI Professional cordless Drill. Check to make sure drill is properly set up for use with Band-It Ultra-Lok tool as follows:

---- Drill spindle has a Clutch (Band-It # M31790) installed in place of the Drill Chuck.

---- See page 5 for recommended Drill speed and torque settings.

2. Charge Drill Battery according to the operator‟s manual.

3. To mount the Drill onto the Band-It Ultra-Lok Tool: First, using the two #10-32 x 3/8" screws (M06187), tighten the Tool Body Adapter (M06288) on the Tension Tool (UL0001) with 20–30 in-lbs. Place the Adapter Collar (M08388) over the Tool Body Adapter. Orient the Drill Clutch Pin (M07187) horizontally (see p. 4 Figure 2). Carefully place the Tool Body Adapter over the Drill Torque Dial. If there is any additional resistance, gently rotate the Tension Tool until the Tension Screw engages with the Drill Clutch (M31789) (see p. 4 Figure 3), and rotate Tension Tool to the desired orientation. Position Tool Body Adapter to butt-up against the shoulder of the drill. Slide the Adapter Collar against this shoulder and fasten to 40–60 in-lbs.

4. This tool was designed for, and can only be used with BAND-IT 1/2" and 3/4" wide Ultra-Lok clamps. Do not attempt to use on any other type of clamp style. Only use 1/2" wide clamps when the optional 1/2" Shear Plate (BAND-IT

# M09387) has been installed in the head in place of the 3/4" Shear Plate. See page 14 for ½” blade change

procedure.

Figure 1

Speed Selector

Drill

Torque Dial

Tool Body

Adapter

M06288

Drill

M19585 (110V) or M19685

Tension Block Position Viewing Slot

(also lubrication syringe access)

Forward Reverse Switch

Adapter Collar

M08388

Tool Head Band Slot

Drill Trigger

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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

Document # P08986 Rev. A

BAND-IT-IDEX, Inc. 2012

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Page 4 of 14

UL4000-C

UL4000-C220

Ultra-Lok Tool

Setup Instructions

Tension Screw M00987

NOTE: Alignment is critical for proper tool function.

Drill Clutch M31789

Align the end of the Tension Screw with the slot in the end of the Drill Clutch during assembly, as shown above.

Orient Drill Clutch Pin M07187 horizontally

Drill

UL Tool Body

Figure 2

Figure 3

Note: Tool Body Adapter and Adapter Collar are hidden for clarity.

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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

Document # P08986 Rev. A

BAND-IT-IDEX, Inc. 2012

www.BAND-IT-IDEX.com

Page 5 of 14

UL4000-C

UL4000-C220

Ultra-Lok Tool

Settings

Important: Changing speed and clutch settings will alter tension output. Drill Trigger should be depressed fully by the operator to attain correct, and consistent, tension when installing clamps. Tension output may vary from tool to tool, at the same setting, depending on condition and wear of internal components.

Caution: Improperly tightened clamps may result in dangerous assemblies, which could cause injuries or property damage.

Using correctly sized clamps (diameter) will, in most cases, eliminate the need to pull on clamp tail more than once. Tension Block moves approximately 5". On occasion, if needed, large size clamps can be installed by taking several bites (clamp tail feeds out through back of tool). Position of Tension Block, containing gripper, can be monitored through viewing slot just under cut-off handle. The tool features a built-in disengaging mechanism to prevent tension screw from jamming up. At the end of the Tension Block travel the safety clutch will engage and the user will hear a ratcheting sound. Excessive use of this feature will wear the Drill Clutch mechanism and/or Tension Screw out prematurely.

NOTE: These torque settings are suggested settings only; individual tools should be adjusted for the clamping application. Inspect lock per instructions on page 9-11.

Recommended Drill Torque Dial Settings:

Drill Model

DDH181-01/ GSR 18 VE-2LI Professional

Clamp Size

½"

¾"

Speed

Clutch

Speed

Clutch

Single Wrap

21 1 23

Double Wrap

23 2 25

*Preformed

23 2 25

(If a higher pull-up force is desired, set speed selector to “2”. Band-It

recommends hearing protection if this setting is used for an extended time.)

Page 6

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

Document # P08986 Rev. A

BAND-IT-IDEX, Inc. 2012

www.BAND-IT-IDEX.com

Page 6 of 14

UL4000-C

UL4000-C220

Ultra-Lok Tool

Parts List

Notes: Apply Item 31 (Super Lube) to: Item 4 (Cut-off Cam) Item 3 (Cutter Knife) at contact point with item 1 (Tool Head) Item 26 (Spring) before installation

Apply Item 32 (Grease) to: Item 7 (Tension Screw) threads and grooved end Item 2 (Cutter Blade) counter-bore only, after item 14 (Bearing Tip) has been installed.

Tighten the following: Item 23 (#10-32 Screws) to 60 – 70 in-lbs. Item 22 (1/4-28 Screws) to 90 – 110 in-lbs.

Adjust Item 24 (Plunger) for positive detent action when item 6 (Handle) is actuated.

Item

Part Number

Qty

Description

M00587

Tool Head, Fin. UL

M09787

Cutter Blade, UL

M08687

Cutter Knife, UL

M08987

Cam, Cut-off, UL

M09087

Tension Block, Mach., UL

UL1219

Handle Assembly: Includes Handle, Handle Grip, and Pins

M00987

Tension Screw, Fin.

M08887

Gripper, UL

M01787

Plate, Back, Cast/Fin.

M09187

Gripper Guide, UL

M02387

Plate, Release, cast/fin.

M00287

Roller, Cut-off, Fin.

M01388

Pin, .187 Dia X 1.50 Long, Fin.

M05387

Bearing Tip, Fin.

M06587

Ball, ¼” Diameter

M02287

Tip, Load Bearing, Fin.

M04387

Tripper Bracket, Cast/Fin.

M07387

Body, Left, Finished, UL

M07487

Body, Right, Finished, UL

M07587

Wear Plate, Fin.

M05787

Screw, Socket Head Cap, ¼ X 1”

J67287

Screw, Socket Head Cap, ¼ X ½”

M06187

Screw, Socket Head Cap, #10-32 X 3/8”

M02487

Screw, Spring Plunger, ¼-20

A33887

Spring, Compression, .180 X .813 Long

A53587

Spring, Compression, .300 X 1.00 Long

M01487

Pin, Dowel, ¼ Dia X 1.50 Long

M08187

Washer, .128 ID X .238 OD

M08087

Rivet, Blind, .125 X .328 Long

M07987

Threaded Insert, #10-32

I16387*

Lubricant, Super Lube w/ Teflon

C23199

Lubricant, Moly, Syringe

M09887

Shear Plate, ¾”, UL

M09387

Shear Plate, UL, ½” (Optional)

M06288

Tool Body Adapter, UL4000-C

M08388

Collar, Adapter, UL Cordless Drill

* Permatex P/N: 82325 or Equivalent

Page 7

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

Document # P08986 Rev. A

BAND-IT-IDEX, Inc. 2012

www.BAND-IT-IDEX.com

Page 7 of 14

UL4000-C

UL4000-C220

Ultra-Lok Tool

Exploded View

22 6 18

4 Places

28 6 20

2 Places

See page 6 for parts list

Tension Block

Assembly

Head Unit

Figure 4

Page 8

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

Document # P08986 Rev. A

BAND-IT-IDEX, Inc. 2012

www.BAND-IT-IDEX.com

Page 8 of 14

UL4000-C

UL4000-C220

Ultra-Lok Tool

Exploded Views

17 9 5

Component under spring load when assembled

10 7 32

Brush lubricant evenly on threads

2 Places

31 8 16

All around inside profile both sides

Tension Gripper Assembly

Tool Head Assembly

See page 6 for parts list

* M09387 (Optional)

½” Shear Plate Insert

can be substituted for M09887

2 Places

Lubricate both sides

2 Places

14 2 33 * 3

31 1 25

Component under spring load when assembled

Inside knife cavity

Figure 5

Figure 6

Page 9

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

Document # P08986 Rev. A

BAND-IT-IDEX, Inc. 2012

www.BAND-IT-IDEX.com

Page 9 of 14

UL4000-C

UL4000-C220

Ultra-Lok Tool

Clamp Application Free-End Clamps

Push all the way forward to a solid stop

1. Break off an Ultra-Lok Free-End tie from the roll. Slide the buckle onto band with indented arrows pointing in same direction and same side up. Slide buckle all the way onto band until it comes to a stop between the two buckle dimples at opposite end of tie.

2. Wrap tie around object to be clamped. Insert the tie through buckle once for single-wrap or twice for double-wrap. Double-wrapped clamps have more than 3 times the loop-tensile strength.

3. If desired, you may preform a clamp in the same fashion as step 2, or use a preformed clamp in place of a Free-End

4. Position the tie on the object you are clamping. Pull the wrapped tie hand-tight. Slightly bend the tail up to keep the clamp in place

5. Actuate Drill until Tension Block is all the way forward against the tool body. Set Drill to clock-wise rotation. With cut-off handle down as shown, insert clamp tail into tool head slot. Actuate Drill until Drill‟s built-in clutch disengages. If Tension Block comes near its end of travel, release actuator switch and reverse Drill to pull more on clamp tail. Excessive use of disengaging Drill Clutch indicated by a loud ratcheting sound leads to premature wear of tension screw.

6. Do not force the tool against the clamp; it may result in a folded clamp tail.

7. Pull the cut-off handle forward to cut tail off and form a lock, then return handle to the down position. Reverse drill and feed clamp tail out of tool.

8. Tap down buckle shroud to complete clamp. Tool is ready for next clamp.

Correct position of tool while tensioning

Incorrect position of tool while tensioning

DO NOT FEATHER the

drill’s TRIGGER

when tensioning a clamp. USE FULL SPEED OF TOOL

Page 10

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

Document # P08986 Rev. A

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Page 10 of 14

UL4000-C

UL4000-C220

Ultra-Lok Tool

Clamp Inspection

FRONT VIEW

Completed Free-End Clamp

(Visually inspect lock)

Buckle Shroud

Lock sheared in center and formed inside shroud

SIDE VIEW

Completed Free-End

Clamp

Tap down buckle shroud to complete clamp

Completed clamp should appear as shown.

Important: Visually inspect lock formed in band as shown. If lock has slipped under the sheared surface of the buckle, remove clamp and install a new one at reduced tension by lowering the Drill Clutch torque setting.

Shear Surface

Section View

Good Clamp

Bad Clamp

Lock has slipped back under sheared buckle surface

Figure 7

Figure 8

Inspect buckle on completed clamp and tap down buckle shroud.

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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

Document # P08986 Rev. A

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Page 11 of 14

UL4000-C

UL4000-C220

Ultra-Lok Tool

Clamp Application Preformed Clamps

NOTE FOR HOSE APPLICATIONS:

When applying clamps on soft, thick-walled hose, tension clamp then wait a full 30 seconds. Clamps may be re-tensioned by squeezing the Drill Trigger on the power unit a second time prior

to forming the lock and cutting the excess clamp tail. This allows hose to “settle” under the band

of the clamp. This hose material attribute is called Cold Flow. Finally, complete clamp by tapping down the buckle shroud as described above.

Trouble-Shooting

1. Lock slips down in buckle: Tighten blade mounting screws. If lock on clamp is still not adequate, reduce tension on tool by setting torque setting on the Drill Dial to a lower number.

2. Drill clutch releases prematurely: Make sure Tool is fully seated on Drill (per page 4). If problem persists, contact BAND-IT technical support.

3. If tool does not cut off on initial setting: Step 1: Pull trigger of tool after engaging cutter blade. Step 2: Increase torque setting slightly, and repeat tensioning band and engaging of cutter blade. Step 3: Repeat steps 1 and 2 until band cuts.

4. Tool does not fully tension clamp: Check battery charge level, replace if low. If problem persists check gripper assembly and tension screw for excessive dirt/grime build up.

Note: To mitigate Drill Clutch wear, do not over-use the Drill Clutch. When tensioning a clamp, let the Drill Switch go as Tension Block nears its end of travel. Reverse drill and send Tension Block all the way forward for a second pull on the band.

Place clamp in desired position on object to be clamped. Start at Step 4 on Page 9 Inspect buckle on completed clamp and tap down buckle shroud as shown on Page 10 Figures 7 and

Page 12

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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Page 12 of 14

UL4000-C

UL4000-C220

Ultra-Lok Tool

Maintenance

1. Approximately every 500 clamps lubricate Tension Screw with

molybdenum disulfide lubricant, or equivalent. Make sure Tension Block is all the way forward against the Tool Head. Remove cap from syringe and insert tip of syringe into slot on top of tool body. Press the tip against the Tension Screw just behind the Tension Block and squeeze out approximately 1/2" long bead of lubricant. Remove Syringe, and actuate tool without a clamp a couple of times to spread lubricant evenly on tension screw.

To order more lubricant, specify BAND-IT #C23199

3. To gain access to bearing components: remove blade Mounting Screws (2

places) and slide Blade free. Paper clip may be used to push bearing components out of Blade. Wipe lubricant from components. If ball or bearing tips appears heavily worn, replace with new one. Note: 1/4" ball is made from hard tungsten carbide material, do not replace with regular ball bearing. (Smooth indention from ball in the bearing tips is normal). To re-assemble bearing components: wipe blade cavity clean. Push small bearing tip into blade cavity. Apply lubricant to ball and push into Blade cavity and fill remaining space with lubricant. Push load bearing tip firmly into blade cavity, some lubricant will be squeezed out. Re-attach blade to Tool Head, making sure that load bearing tip extends into Tension Screw. While turning Blade Mounting Screws into Blade, push on Blade rear-wards. Tighten screws to approximately 120 in-lbs.

4. When replacing worn Blade follow instructions above to properly re-

assemble bearing components.

2. Every 500-1000 clamps, depending on torque setting, inspect and

repack front bearing with same lubricant. Turn load bearing tip and small bearing tip over for a new bearing surface.

Small Bearing Tip M05387

1/4" Ball M06587

Load Bearing Tip M02287

Access Hole to push out components (use paper clip)

Blade M09787

Blade Cavity, must be packed with lubricant

Tension Screw M00987

Bearing Detail

Blade Mounting

Screws

M05787

Tool Body

Tool Head Item 1

Lubricating Syringe Reorder #C23199

Figures 9 and 10

Figure 11

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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

Document # P08986 Rev. A

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Page 13 of 14

UL4000-C

UL4000-C220

Ultra-Lok Tool

Maintenance

5. To replace Gripper: Make sure Tension Block is all the way forward against the tool head. Remove drill.

Remove tool adapter body. Remove one side of the tool body or the other, not both. Slide Gripper out sideways and replace with a new one. Re-attach Tool Body side. Caution: Do not push or move Tension Block while Gripper is out of tool.

6. To replace Tension Screw: Move Tension Block all the way back (away from Tool Head) using drill in

tensioning mode (clock-wise). Remove Ultra-Lok Tool from Drill. Remove the Tool Adapter from the Ultra-Lok Tool. Remove Blade and load bearing tip from Tensioning Screw (see bearing detail). Remove one side of the Tool Body or the other, not both. Grasp the smooth barrel on Tension Screw and pull all the way forward until Tension Block is against the Tool Head. If Tension Screw is stuck, use a punch and tap the center of the screw from the back end of the tool. Turn Tension Screw out of Tension Block. Lubricate new Tension Screw with Molybdenum Disulfide lubricant, or equivalent. Install new Tension Screw in reverse order; making sure that back end of Tension Screw extends well beyond the back end of the Tension Block. Push the assembly all the way back and extend the round portion of the Tension Screw through holes on the tripper bracket and back guide plate. Reinstall Tool Body side. Reinstall Blade and tighten the Blade Mounting Screws approximately 120 in-lbs. Reattach Tool Adapter to Ultra-Lok Tool. Reattach Tool to Drill and drive Tension Block all the way forward.

Note: Drills needing repair must be forwarded to an authorized „Bosch‟ repair center in your area. Be sure to

remove BAND-IT drill clutch (M31789) from drill.

Tension

Screw

M00987

Move tension

block all the way

forward against

the tool head

Tool Head M00587

Gripper

M08887

Bosch Drill is covered solely by the Bosch warranty as described in the Bosch literature. BAND-IT does not extend any warranty of any kind to the drill.

Adapter, UL4000-C M06288

Collar, Adapter, UL Cordless Drill M08388

Screw, #10-

M06187

Figure 12

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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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Page 14 of 14

UL4000-C

UL4000-C220

Ultra-Lok Tool

Blade Change Optional 1/2" Tool

Figure 13

Figure 14

Optional 1/2" Shear Plate (M09387) Orient as shown

Blade (M09787)

Blade Cap Screw (M05787) Qty. 2

1/4" Ball (M06587)

Bearing Tip (M05387)

Blade (M09787)

To change out the tool to the 1/2" version, the following steps should be followed. *NOTE: Do not attempt to use 1/2" clamps with 3/4" head. (Shear Plate change-out: 3-5 minutes)

1. Prior to separation from power drill, back off Tension Block assembly 1/2" from head unit. See page 7 Figure 4.

2. Detach Tension Body from the Drill by loosening the single tensioning bolt on the aluminum collar and separating the two sections.

3. Remove the Blade from head by removing the two Cap Screws (M05787) from the top of the Head. It is not necessary to remove entire head from tool in order to remove blade. (Figure 13) Remove the 3/4" shear plate from the blade.

4. Align the 1/2" Shear Plate (M09387) with the Blade (M09787) so that the guide is facing up. Incorrect placement will not allow bands to be inserted into the Tool. (Figure 13)

Note: To convert Tool back to 3/4", replace 1/2" Shear Plate with 3/4" Shear Plate (M09887) and follow same instructions. Be sure to retain unused Shear Plate for later use.

5. Attach the Blade and 1/2" Shear Plate onto Head using the two previously removed Cap Screws. These Cap Screws must be tight to assure proper cut-off of clamp tails.

6. Re-attach Drill to Tension Body making sure the Drill and Tension Body are properly aligned, and tighten the single Blade Cap Screw located on the Adapter Collar.

7. These tools are NOT designed to work with traditional band and buckle designs. BAND-IT Ultra-Lok clamps

must be used.