BAND-IT UL9010 User Manual

UL9010 Ultra
-
Lok
Tool
Operating
UL9010
Instructions
Warranty, Safety Guidelines, Contents 2
Setup Instructions 3-4
Settings 5
Parts List 6
Troubleshooting 7
Assembly Instructions 8
Clamp Application
Ultra-Lok Tool
Table of Contents
Free-End 9-10
Preformed 11
Maintenance 12-13
Blade Change 14
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Document # P44987 Rev. N
BAND-IT-IDEX, Inc. 2011
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Warranty, Safety
UL9010
Guidelines, Contents
Ultra-Lok Tool
Warranty:
Refer to website for warranty information: 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
When applying clamps, care should be taken to make certain that fingers are not in the way of the clamp being applied. 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: When clamping a hose end, remember that a tighter clamp keeps the fitting more secure, but excess tension could 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.
Clamping objects other than hose requires similar precautions.
CAUTION: Improperly tightened clamps may result in dangerous hose assemblies, which could cause injuries or property damage.
CAUTION: 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.
Contents
Assembled
Tool
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Page 2 of 14
Parts List
Assembled Tool
Syringe Pouch
Hex Key, 5/32"
Hex Key, 3/16"
Hex Key, 1/4"
Manuals, Tool & Drill
Carrying Case
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Note:
see pages 5,
6, and 8 of this manual
.
Tool Body
Drill
Tension Block Position
Forward
Adapter Clamp
Tool Head
Adapter
Gear Selector
Setup
UL9010
Instructions
Ultra-Lok Tool
Warning:
Always wear safety glasses when operating this tool. Keep both hands away from clamp being tensioned. Use common sense, squeezing force of ¾” clamp can reach as high as 2 tons. Never attempt to clamp objects which can shatter, or otherwise cause bodily harm.
Read safety instructions and operator’s manual of the METABO electric drill. Check to make sure drill is properly
set up for use with BAND-IT Ultra-Lok tool as follows:
Drill spindle has adapter clutch (BAND-IT # M03990) installed in place of standard drill chuck.  Gear selector must be on slow (setting 1), and set as shown on page 4.  Impact drive must be disengaged and set to (drill symbol).
1. Plug drill into standard 115V AC, 60 Hz outlet. If using and extension cord, a 14 gauge cord is suggested for lengths up to 50 feet, 12 gauge cord required if running longer than 50 feet, 10 gauge cord if running over 100 feet.
2. To mount drill onto BAND-IT Ultra-Lok tool: First use the two #10-32 x 3/8” screws supplied with tool to tighten tool adapter body to the tool. With adapter clamp on tool adapter body, insert drill into back of tool through the adapter clamp. Turn drill manually to desired position in relation to tool. Press the drill firmly into tool. Actuate drill if necessary to engage drill safety clutch (M03990) to tension screw. Tighten clamp screw while keeping the drill firmly pressed against the tool. To remove drill from tool: loosen the clamp screw and pull drill away from the tool. NOTE: When tightening the adapter clamp screw, safety clutch (M03990) must be engaged with tension screw inside of BAND-IT tool.
3. This tool was designed for, and can only be used with BAND-IT Ultra-Lok clamps. Do not attempt to use on any other type of clamp, it may damage tool. Note: An optional adapter can be purchased to apply ½” Ultra-Lok clamp,
Use only with BAND-IT ¾” Ultra-Lok Free-End and Preformed Clamps
Viewing Slot
(also lubrication syringe access)
Band Slot
Adapter
M07687
M08288
Clamp Tension Screw
(always set to 1)
M23587
Reverse Selector Switch
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Setup Instructions
Ultra-Lok Tool
NOTE: Alignment is critical for proper tool function.
UL9010
Tension Screw
Safety Clutch
When installing the tool on the drill, be careful to align the end of the Tension Screw with the slot in the end of the safety clutch, as shown above.
Note: Some components are not visible in this illustration.
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2
Important:
Torque
Speed
UL9010
Settings
to attain correct tension when installing clamps. Tension output may be somewhat different depending on condition and wear of internal components from tool to tool on same setting.
Pre-set tension is achieved when drill stops and on some models, may pulsate. Excessive pulsation (more than twice) will result in more tension applied to the clamp.
The UL9010 tool is designed to work mounted securely to the Metabo drill Model SBE 900 IMPULS. Use of any other drill may result in unsatisfactory performance, hazards to the operator and/or the tool, or unsafe clamps. Use of alternate drills must be approved in writing by the Director of Engineering at BAND-IT-IDEX, Inc. Disregard of this caution voids the warranty of the tool and releases BAND-IT of any and all liabilities arising from such misuses.
BAND-IT-IDEX, Inc. A Unit of IDEX Corporation 4799 Dahlia Street Denver, CO 80216-0307 USA Ph: 1-800-525-0758 Fax: 1-800-624-3925
Ultra-Lok Tool
Recommended Drill Settings:
(Speed-Torque)
½” ¾” Single Wrap C-2 D­Double Wrap D-2 E-4 *Preformed D-2 E-4
Selector
NOTE: These torque settings are suggested settings only, individual tools should be adjusted for the clamping application.
*IMPORTANT: Larger sizes of preformed clamps (5" and up) may require a lower setting to avoid over­stressing the lock and creating potentially unsafe assemblies. Inspect lock per instructions on pages 9-11.
Changing the speed setting will alter tension output. Drill switch must be depressed fully by the operator
Use of Alternate Drills
CAUTION!
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Selector
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Parts List
Notes: Apply Item 31 (Grease) 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.
Part M09887, Shear Plate has two cutting edges. This part can be rotated to use the second edge prior to replacement.
NOTE:
Part M09387, (Optional) ½” Shear Plate ­Required replacement for # 33 M09887 shear plate in order to install ½” wide Ultra-Lok Clamps
Item Part Number Quantity Description
1 M00587 1 Tool Head, Fin. UL 2 M09787 1 Cutter Blade, UL 3 M08687 1 Cutter Knife, UL 4 M08987 1 Cam, Cut-off, UL 5 M09087 1 Tension Block, Mach., UL
6 UL1219 1
7 M00987 1 Tension Screw, Fin. 8 M08887 1 Gripper, UL
9 M01787 1 Plate, Back, Cast/Fin. 10 M09187 1 Gripper Guide, UL 11 M02387 1 Plate, Release, cast/fin. 12 M00287 1 Roller, Cut-off, Fin. 13 M01388 1 Pin, .187 Dia X 1.50 Long, Fin. 14 M05387 1 Bearing Tip, Fin. 15 M06587 1 Ball, ¼” Diameter 16 M02287 1 Tip, Load Bearing, Fin. 17 M04387 1 Tripper Bracket, Cast/Fin. 18 M07387 1 Body, Left, Finished, UL 19 M07487 1 Body, Right, Finished, UL 20 M07587 2 Wear Plate, Fin. 21 M05787 2 Screw, Socket Head Cap, ¼ X 1” 22 J67287 4 Screw, Socket Head Cap, ¼ X ½” 23 M06187 4 Screw, Socket Head Cap, #10-32 X 3/8” 24 M02487 2 Screw, Spring Plunger, ¼-20 25 A33887 1 Spring, Compression, .180 X .813 Long 26 A53587 2 Spring, Compression, .300 X 1.00 Long 27 M01487 1 Pin, Dowel, ¼ Dia X 1.50 Long 28 M08187 4 Washer, .128 ID X .238 OD 29 M08087 4 Rivet, Blind, .125 X .328 Long 30 M07987 2 Threaded Insert, #10-32 31 I16387 - Lubricant, Super Lube w/ Teflon 32 C23199 - Lubricant, Moly, Syringe 33 M09887 1 Shear Plate, ¾”, UL 34 M09387 1 Shear Plate, ½”, UL (Optional) 35 M07687 1 Tool Adapter #1 36 M08288 1 Adapter Clamp
Handle Assembly: Includes Handle, Handle Grip, and Pins
UL9010
Ultra-Lok Tool
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2 Places
4 Places
Troubleshooting
Troubleshooting
UL9010
23
30
4 Places
Ultra-Lok Tool
6
18
6
4
28
4 Places
20
19
29
1. Lock slips down in buckle: Verify tightness of blade mounting screws. If lock on clamp is still not adequate, reduce tension on tool by setting torque control knob to a lower number or reduce speed of the drill. (See “Setting up proper tension”)
2. Drill makes loud, rapid clicking noise: Make sure hammer drill setting is off and indicator is pointing to drill symbol. (Hammer symbol on selector knob pointing to back).
3. Drill makes whining noise when clamp gets tight: The drill is equipped with its own internal safety clutch. If this clutch disengages usually above torque setting 6, reduce torque setting and lubricate tension screw. Do not confuse this clutch with the coupling between drill and tool.
4. Safety clutch between drill and tool releases prematurely: Make sure tool is fully seated on drill and safety clutch is fully engaged with tip of tension screw. (Loosen clamping screw and re-tighten while pressing tool into drill). See page 4, if problem still remains, replace tension screw (BAND-IT # M00987).
Note: To prevent safety clutch wear, do not over-use. When tensioning clamp, let 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.
5. If tool does not cut off on initial setting:
Step 1: Pull trigger of tool after engaging cutter blade.
22
4 Places
Tension Block
Tension Block ASSY
ASSY
See page 6 for parts list
See page 6 for parts list
Head Unit
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.
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assembled
32
31
15
31
ASSEMBLY INSTRUCTIONS
9
Brush lubricant evenly
7 32
on threads
UL9010
Ultra-Lok Tool
Tension Gripper Assembly
4
31
Lubricate both sides
2 Places
21
17
Tool Head Assembly
Component under spring
11
load when assembled
25
24
2 Places
16
8
13
5
31
2 Places
26 31
All around inside profile both sides
2 Places
Component under spring load when
10
27 31
1
32
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14
31
Inside knife cavity
12 31
3
33
*
2
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Page 8 of 14
* M09387 (Optional) ½” Shear Plate Insert can be substituted for M09887
See page 6 for parts list
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Incorrect position of
wrapped clamps have more
Push all the
Correct
position of
DO NOT
Start 1.5” from buckle to
Clamp Application
UL9010
Free-End Clamps
Warning: Always wear safety glasses when operating tool.
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.
4. Position the clamp on the object you are clamping. Pull the wrapped clamp hand-tight. Slightly bend the tail up to keep the clamp in place.
2. Wrap tie around object to be clamped. Insert the tie through buckle once for single-wrap or twice for double-wrap. Double­than 3 times the loop-tensile strength.
FEATHER the drill’s TRIGGER when tensioning a clamp. USE FULL SPEED OF TOOL
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 clutch indicated by a loud ratcheting sound leads to premature wear of tension screw.
Ultra-Lok Tool
3. If desired, you may pre-form a clamp in the same fashion as step 2, or use a preformed clamp in place of a Free-End.
way forward to a solid stop. DO NOT JAM THE CUT-OFF HANDLE FORWARD BEYOND INTENDED TRAVEL DURING OPERATION
6. 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. Do not force tool against clamp; it may result in a folded clamp tail. Break away clamp tail (if necessary) by bending it up and down. Tap down buckle shroud to complete clamp. Tool is ready for next clamp.
ensure adequate tension screw engagement
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tool while tensioning
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Page 9 of 14
tool while tensioning
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FRONT VIEW
SIDE VIEW
Important:
Section View
Section View
Clamp Application
UL9010
Free-End Clamps
Inspect buckle on completed clamp and tap down buckle shroud.
buckle, remove clamp and install a new one at reduced tension by lowering the drill clutch torque setting.
Proper clamp
Installation
Lock sheared in center and formed inside shroud
Defective Clamp
installation
Lock has slipped back under sheared buckle surface
Visually inspect lock formed in band as shown. If lock has slipped under the sheared surface of the
Completed Free-End
Clamp with buckle
shroud tapped down
as required
Ultra-Lok Tool
Completed Free-End Clamp
(Visually inspect lock)
Buckle Shroud
Shear Surface
Completed clamp should appear as shown.
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Important:
Front View
SIDE VIEW
Section View
Section View
Clamp Application
UL9010
Preformed Clamps
Ultra-Lok Tool
Place clamp in desired position on object to be clamped. Follow steps 5 and 6 on page 9. Inspect lock in buckle on completed clamp, and then tap down buckle shroud as shown below.
Proper Clamp
formation
Lock sheared in center and formed inside shroud
Completed Clamp
(Visually inspect lock)
Shear Surface
Improper lock
formation
Lock has slipped back under sheared buckle surface
buckle, remove clamp and install a new clamp at reduced tension by lowering the drill clutch torque setting.
Visually inspect lock formed in band as shown. If lock has slipped under the sheared surface of the
Tap down buckle shroud to complete clamp
Completed UL Pre-
formed Clamp with
buckle shroud tapped
down as required
When applying clamps on soft, thick-walled hose, tension clamp then wait a full 30 seconds. Clamps may be retensioned by squeezing the actuator switch 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.
Buckle Shroud
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#C23199
Maintenance
1. Lubricate tension screw with molybdenum disulfide lubricant or equivalent approximately every 500 clamps. Make sure the tension block is all the way forward against the tool head. Insert tip of the Lubricating syringe into slot on top of tool body. Press the tip against the tension screw just behind the tension block and squeeze out approximately ½” 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 tension setting, inspect and repack front bearing with same lubricant. Turn load bearing tip and small bearing tip over for a new bearing surface.
Bearing Lubrication Detail
UL9010
Ultra-Lok Tool
Lubricating Syringe Reorder
Small Bearing Tip Item 14
Access hole to push out components (use paper clip)
3. To gain access to bearing components: With the tension body already separated from the power drill, 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 all components and examine for wear. If ball or bearing tips appear heavily worn, replace with new parts. Note: ¼” ball is made from hard tungsten carbide material, do not replace with regular ball bearing. (A 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 rearwards. Tighten screws to approximately 120 in-lbs.
5. When replacing worn blade follow instructions above to properly re­assemble bearing components.
Blade Item 2
¼” Ball Item 15
Blade Cavity (must be packed with lubricant)
Load Bearing Tip Item 16
Tension Screw Item 7
Tool head Item 1
Tool body
Blade mounting
screws
Item 21
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UL9010
Maintenance
Ultra-Lok Tool
6. To replace gripper: Make sure tension block is all the way forward against the tool head. Remove drill. Remove tool adapter body. Remove only one side of the tool body, not both. Slide gripper out sideways and replace with a new one. Reattach tool body side. Caution: Do not push or move tension block while gripper is out of tool.
Tool Head Item 1
Move tension block all the way forward against the tool head.
Gripper Item 8
Tension Screw Item 7
This tip must align with the safety clutch (M03990) on the Metabo drill. See page 4.
Adapter Clamp Item 36
Tool Adapter #1 Item 35
7. 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 body from the Ultra-Lok tool. Remove blade and load bearing tip from tensioning screw (see bearing detail). Remove only one side of the tool body, 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 body 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 ‘METABO’ repair center in your area. Be sure to remove BAND-IT safety clutch (M03990) from drill.
METABO Drill is covered solely by the Metabo warranty as described in the Metabo literature. BAND-IT does not extend any warranty of any kind to the drill.
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Figure 2
Optional ½” Tool
UL9010
Blade Change
Ultra-Lok Tool
To change out the UL9010 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. (Adapter change-out: 3-5 minutes)
1. Prior to separation from power drill, back off tension block assembly ½” from head unit. See page 7.
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 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 1) Remove the ¾” adapter plate from the blade.
4. Align the ½” adapter 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 1)
Note: To convert tool back to ¾”, replace ½” insert with ¾” insert (M09887) and follow same instructions. Be sure to retain unused shear plate for later use.
5. Attach the blade and ½” adapter 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 adapter cap screw located on the aluminum collar.
7. This tool is not designed to work with traditional band and buckle designs. Must use only BAND-IT Ultra-Lok clamps.
Blade Cap Screw (M05787) Qty. 2
¼” Ball (M06587)
Bearing Tip (M05387) Blade (M09787)
Optional ½” Insert (M09387) Orient as shown
Blade (M09787)
Figure 1
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