Band-it UL4000-D Operating Instructions Manual

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UL4000-D

Operating Instructions

Cordless Ultra-Lok® Tool

ULTRA-LOK® TOOL

BAND-IT IDEX, Inc. Document # P09986 Rev. B A Unit of IDEX Corporation © Copyright

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UL4000-D

ULTRA-LOK® TOOL

Contents

Warranty and Safety Guidelines .................................................................................................... 3

Setup Instructions .......................................................................................................................... 4

Tool Settings .................................................................................................................................. 6

Parts List ........................................................................................................................................ 7

Exploded View ............................................................................................................................... 8

Clamp Application: Free-End Clamps .......................................................................................... 10

Clamp Inspection ......................................................................................................................... 11

Clamp Application: Preformed Clamps ........................................................................................ 12

Maintenance ................................................................................................................................ 13

Blade Change: Optional ½” Tool .................................................................................................. 15

BAND-IT IDEX, Inc. Document # P09986 Rev. B A Unit of IDEX Corporation © Copyright

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UL4000-D

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

Use of Alternate Drills

CAUTION!

This tool is designed to work solely mounted to the Metabo BS 18 LTX series cordless drill. Use of any other drills in place of these Metabo BS 18 LTX 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.

ULTRA-LOK® TOOL

Warranty and Safety Guidelines

BAND-IT IDEX, Inc. Document # P09986 Rev. B A Unit of IDEX Corporation © Copyright

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UL4000-D

1. Read safety instructions and operator’s manual for the Metabo BS 18 LTX cordless Drill. Check to make sure drill is properly set up for use with Band-It Ultra-Lok tool as follows:

a. Drill spindle has a Clutch Assembly (Band-It # UL4001) b. See page 6 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:

a. First, using the two #10-32 x 3/8" screws (M06187), tighten the Tool Body Adapter (M07697) on the

Tension Tool (UL0001) with 20–30 in-lbs. b. Place the Adapter Collar (M08288) over the Tool Body Adapter. c. Orient the Drill Clutch Pin (M07187) horizontally (see page, 5 Figure 2). d. Carefully place the Tool Body Adapter over the Drill’s collar. If there is any additional resistance, gently

rotate the Tension Tool until the Tension Screw engages with the Drill Clutch (M04298) (see page 5,

Figure 3), and rotate Tension Tool to the desired orientation. e. Position Tool Body Adapter to butt-up against the shoulder of the drill. f. 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 15 for ½” blade change procedure.

Figure 1

ULTRA-LOK® TOOL

Setup Instructions

BAND-IT IDEX, Inc. Document # P09986 Rev. B A Unit of IDEX Corporation © Copyright

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UL4000-D

Drill Clutch M04298

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

Tension Screw M00987

UL Tool Body

NOTE: Alignment is critical for proper tool function.

Orient Drill Clutch

Pin M07187

Figure 2: Align the pin within the drill clutch

Figure 3: Align the end of the Tension Screw with the slot in

the end of the Drill Clutch during assembly, as shown above.

ULTRA-LOK® TOOL

BAND-IT IDEX, Inc. Document # P09986 Rev. B A Unit of IDEX Corporation © Copyright

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UL4000-D

Recommended Drill Torque Dial Settings:

Drill Model

Metabo BS 18 LTX

Clamp Size

½"

¾"

Speed

Clutch

Speed

Clutch

Single Wrap

1 5 1

Double Wrap

1 6 1

*Preformed

1 6 1

Band-It recommends hearing protection if this setting is used for an extended time.

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.

Battery Recommendation: In order to maintain consistent tension when installing clamps, Band-It recommends that the drill be recharged once the indicator on the battery drops to 1 out of 4.

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.

ULTRA-LOK® TOOL

Tool Settings

BAND-IT IDEX, Inc. Document # P09986 Rev. B A Unit of IDEX Corporation © Copyright

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UL4000-D

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)

UL4001

Adapter and Clutch Assembly

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.

* Permatex P/N: 82325 or Equivalent

Tool Accessories:

UL4199 – UL Safety Strap: 15 lb capacity tool lanyard with single stainless carabineer. OSHA: 192.45 (h)(1) – Falling object protection

ULTRA-LOK® TOOL

Parts List

BAND-IT IDEX, Inc. Document # P09986 Rev. B A Unit of IDEX Corporation © Copyright

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UL4000-D

22 6 29

2 Places

Tension Block

Head Unit

Figure 4

ULTRA-LOK® TOOL

Exploded View

Assembly

BAND-IT IDEX, Inc. Document # P09986 Rev. B A Unit of IDEX Corporation © Copyright

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UL4000-D

17 9 5

Component

assembled

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)

M09887

2 Places

Lubricate both sides

2 Places

Component

Inside knife cavity

Figure 6

ULTRA-LOK® TOOL

under spring load when

under spring load when assembled

BAND-IT IDEX, Inc. Document # P09986 Rev. B A Unit of IDEX Corporation © Copyright

½” Shear Plate Insert

can be substituted for

Page 10

UL4000-D

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.

Incorrect position of tool while tensioning

Correct position of tool while tensioning

ULTRA-LOK® TOOL

Clamp Application: Free-End Clamps

BAND-IT IDEX, Inc. Document # P09986 Rev. B A Unit of IDEX Corporation © Copyright

Page 11

UL4000-D

Lock sheared in center and formed inside shroud

Section View

Good Clamp

Inspect buckle on the completed clamp and tap down the buckle shroud

FRONT VIEW

Completed Free-End Clamp

(Visually inspect lock)

Buckle Shroud

Shear Surface

Bad Clamp

Lock has slipped back under sheared buckle surface

Figure 7

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.

SIDE VIEW

Completed Free-End

Clamp

Tap down buckle shroud to complete clamp

Figure 8

ULTRA-LOK® TOOL

Clamp Inspection

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UL4000-D

1. Place clamp in desired position on object to be clamped.

2. Start at Step 4 on Page 10 and complete the same installation process

3. Inspect buckle on completed clamp and tap down buckle shroud as shown on Page 11 Figures 7 and 8.

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:

a. Step 1: Pull trigger of tool after engaging cutter blade. b. Step 2: Increase torque setting slightly, and repeat tensioning band and engaging of

cutter blade.

c. 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.

ULTRA-LOK® TOOL

Clamp Application: Preformed Clamps

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UL4000-D

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

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.

Tool Body

Tool Head Item 1

Lubricating Syringe Reorder #C23199

Bearing Detail

Figures 9 and 10

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).

4. 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.

Small Bearing Tip M05387

1/4" Ball M06587

Load Bearing Tip M02287

Access Hole to push Blade

M09787

Blade Cavity, with lubricant

Tension M00987

Blade Mounting

M05787

Figure 11

ULTRA-LOK® TOOL

Maintenance

out components (use paper clip)

must be packed

Screw

Screws

Page 14

UL4000-D

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.

Tension M00987

Move tension

Tool Head M00587

Gripper

Screw, #10-32

Figure 12

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 returned to Band-It.

ULTRA-LOK® TOOL

block all the way

forward against

the tool head

Screw

M08887

M06187

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UL4000-D

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.

Optional 1/2" Shear

Blade (M09787)

Blade Cap Screw 1/4" Ball (M06587)

Bearing Tip (M05387)

Blade (M09787)

Figure 14

Figure 13

ULTRA-LOK® TOOL

Blade Change: Optional ½” Tool

(M05787) Qty. 2

Plate (M09387) Orient as shown