Band-it Ultra-Lok UL4000-BUltra-Lok UL4000-B220 Operating Instructions Manual

Page 1
20
Operating
Cordless Ultra
-
Lok
Tool
Instructions
Table of Contents
Warranty, Safety Guidelines, Contents 2
Setup Instructions 3-4
Settings 5
Parts List 6
Troubleshooting 7
Assembly Instructions 8
UL4000-B
UL4000-B2
Ultra-Lok Tool
Clamp Application
Free-End 9-10
Preformed 11
Maintenance 12-13
Blade Change 14
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 2
UL4000-B
20
Warranty, Safety Guidelines, Contents
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
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.
UL4000-B2
Ultra-Lok Tool
Assembled
Tool
Additional Battery
Pack
Battery Charger
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Contents
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Page 2 of 14
Parts List
Assembled Tool
Battery Charger
Additional Battery Pack
Syringe Pouch
Hex Key, 5/32"
Hex Key, 3/16"
Manuals, Tool & Drill
Carrying Case
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Page 3
UL4000-B
20
Drill
Tool Body
Drill
Tension Block Position Viewing Slot
Forward
Adapter Collar
IT
Tool He
ad
Setup Instructions
UL4000-B2
Ultra-Lok Tool
Warning:
Always wear safety glasses when operating this tool and keep both hands and clothing away from clamp being tensioned. Squeezing force of 3/4" clamp can reach as high as 2 tons. Never attempt to clamp objects which can shatter, or otherwise cause bodily harm.
1. Read safety instructions and operator’s manual for the Bosch 37618-01 or Bosch GSR 18 VE-2LI 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 # M21790) 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, tighten the Tool Body Adapter on the Tension Tool with 20–30 in-lbs. Place the Adapter Clamp over the Tool Body Adapter. Orient the Drill Clutch Pin horizontally (see p. 4). 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 (see p. 4), and rotate Tension Tool to the desired orientation. Position Tool Body Adapter to butt-up against the shoulder of the handle mounting surface. Slide the Adapter Clamp 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# M09387) has been installed in the head in place of the 3/4" Shear Plate.
Use only with BAND-IT 3/4" and 1/2" Ultra-Lok Free-End and Preformed Clamps
(also lubrication syringe access)
Band Slot
Adapter
M06287
Torque Dial
M08388
Speed Selector
M09599 (110V) or M09699
Reverse Switch
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Page 4
UL4000-B
20
Orient
Drill
Clutch
Setup Instructions
NOTE: Alignment is critical for proper tool function.
Pin horizontally
UL4000-B2
Ultra-Lok Tool
Tension Screw
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
Note: Some components are not visible in this illustration.
Be careful to align the end of the Tension Screw with the slot in the end of the Drill Clutch, as shown above.
Drill Clutch
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Page 5
20
Settings
Drill Model
Recommended Drill Torque Dial Settings:
37618-01 / GSR 18 VE-2LI
Clamp Size ½" ¾"
Speed Clutch Speed Clutch Single Wrap Double Wrap *Preformed
(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.)
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.
Important: Changing speed settings will alter tension output. Drill Switch 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 holes just under cut-off handle. The tool features a built-in disengaging mechanism to prevent tension screw from jamming up. Excessive use of this feature will wear the Drill Clutch mechanism and/or Tension Screw out prematurely.
1 22 1 24 1 24 2 25
1 24 2 25
Use of Alternate Drills
CAUTION!
This tool is designed to work mounted to the Bosch 37618-01 or Bosch GSR 18 VE-2LI cordless drill. Use of any other drills in place of this Bosch drill 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.
UL4000-B
UL4000-B2
Ultra-Lok Tool
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Page 6
UL4000-B
20
Notes:
Parts List
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
Item Part Number Qty 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 2 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, UL, ½” (Optional) 35 M06287 1 Adapter, UL4000-B 36 M08388 1 Collar, Adapter, UL4000-B
Handle Assembly: Includes Handle, Handle Grip, and Pins
UL4000-B2
Ultra-Lok Tool
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Page 7
20
Troubleshooting
Trouble
-
Shooting
6
2 Places
30
UL4000-B
UL4000-B2
Ultra-Lok Tool
18
28
4
6
23
4 Places
29
4 Places
19
22
4 Places
Tension Block
20
Assembly
Head Unit
See page 6 for parts list
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.
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.
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.
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Page 8
UL4000-B
20
assembled
32
31
15
31
Assembly Instructions
9
Brush lubricant evenly
7 32
on threads
17
Tool Head Assembly
Tension Gripper Assembly
5
16
UL4000-B2
Ultra-Lok Tool
26 31
2 Places
Component under spring load when
10
4
31
Lubricate both sides
2 Places
27 31
21
Component under spring
11
load when assembled
25
2 Places
24
1
8
13
31
Inside knife cavity
12 31
31
All around inside profile both sides
2 Places
* M09387 (Optional) ½” Shear Plate Insert can be substituted for M09887
3
32
14
33
*
2
See page 6 for parts list
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Page 9
UL4000-B
20
Push all
wrapped clamps have more
Correct position of tool
Incorrect position of tool
DO NOT
Clamp Application 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 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.
while tensioning
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
6. Do not force the tool against the
7. Pull the cut-off handle forward to cut
8. Tap down buckle shroud to complete
clamp; it may result in a folded clamp tail.
tail off and form a lock, then return handle to the down position. Reverse drill and feed clamp tail out of tool.
clamp. Tool is ready for next clamp.
UL4000-B2
Ultra-Lok Tool
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
the way forward to a solid stop
while tensioning
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Page 10
UL4000-B
20
FRONT VIEW
SIDE VIEW
complete clamp
Important:
S
ection View
Clamp Application Free-End Clamps
UL4000-B2
Ultra-Lok Tool
Inspect buckle on completed clamp and tap down buckle shroud.
Good Clamp
Completed Free-End Clamp
(Visually inspect lock)
Lock sheared in center and formed inside shroud
Bad Clamp
Lock has slipped back under sheared buckle surface
buckle, remove clamp and install a new one 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
Completed Free-End
Clamp
Tap down buckle shroud to
Completed clamp should appear as shown.
Buckle Shroud
Shear Surface
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Page 11
20
Clamp Application
Important:
Front View
Side View
Section View
Preformed Clamps
UL4000-B2
Ultra-Lok Tool
Place clamp in desired position on object to be clamped. Follow steps 5 and 6 on page 9. Inspect buckle on completed clamp and tap down buckle shroud as shown below.
Good Clamp
Lock sheared in center and formed inside shroud
Completed Clamp
(Visually inspect lock)
Shear Surface
Bad Clamp
Lock has slipped back under sheared buckle surface
buckle, remove clamp and install a new one 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
Completed Clamp
Tap down buckle shroud to complete clamp
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 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.
UL4000-B
Buckle Shroud
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Page 12
UL4000-B
20
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
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
Bearing Detail
1/4" Ball M06587
Load Bearing Tip M02287
Tool Head Item 1
UL4000-B2
Ultra-Lok Tool
Lubricating Syringe Reorder #C23199
Tool Body
Access Hole to push out components (use paper clip)
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 re­assemble bearing components.
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Blade M09787
Blade Cavity, must be packed with lubricant
Tension Screw M00987
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Page 12 of 14
Blade Mounting
Screws
M05787
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Page 13
UL4000-B
20
Bosch Drill
Item 36
Maintenance
UL4000-B2
Ultra-Lok Tool
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.
Tool Head M00587
This tip must align with the drill clutch (M21790) on the drill. See page 4.
Move tension
block all the way
forward against
the tool head
Gripper
M08887
Tension
Screw
M0098
Collar, Adapter, UL4000-B
Adapter, UL4000-B Item 35
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 (M21790) from 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.
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Page 14
UL4000-B
20
Figure 2
Blade Change Optional 1/2" Tool
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.
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 1) 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 1)
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.
Blade Cap Screw (M05787) Qty. 2
Optional 1/2" Shear Plate (M09387) Orient as shown
Blade (M09787)
Figure 1
1/4" Ball (M06587)
Bearing Tip (M05387) Blade (M09787)
UL4000-B2
Ultra-Lok Tool
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