IT5000-C and IT6000-C Tool

IT5000-C and IT6000-C Tool
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
IT5000-C / IT6000-C
3/8” BAND-IT ® Pneumatic IT Tools
Patent Pending
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 1 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Table of Contents
Topic
Page Description
Safety
Safety Guidelines / Warranty
Introduction
Air System
Tool Operation
Maintenance
Trouble Shooting
Page #
3-5
Tool Overview
6
Model Identification
6
Tool / Component Identification
7-8
Air System Requirements / Settings
9 - 11
Adjustable Support Arm / Handle
12
IT Tool Orientation Requirements
13
Fixture Mounting Requirements
14
Remote Actuation Configuration
15
Tie / Clamp Installation Procedure
16
Tie / Clamp Inspection
17
Preventative Maintenance
18
Replacement Parts
19
Maintenance
20 – 25
Cutoff Timing Adjustment
26
Unable to Achieve Tension
27
Tool Symptoms
28
See P48950 manual for Data Feedback System option.
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 2 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Safety Guidelines / Warranty
This equipment has been tested by BAND-IT-IDEX and is safe to use providing that the
proper safety precautions are observed.
DANGER—Misuse of this equipment may result in serious injury to personnel.
• Only use the equipment for its intended purpose, as described in this manual
• Do not attempt to operate the equipment with covers removed
• Refer to the installation section before installing machine
• Do not operate machine with wet hands
Please read this entire manual before unpacking, setting up or operating this equipment.
Pay attention to all danger and caution statements. Failure to do so could result in serious
injury to the operator or other personnel, or damage to the equipment.
CAUTION—This equipment generates moderate levels of audible noise when in use.
• Ensure that it is installed in a location where operating noise will not cause disturbance.
Symbols:
Caution – Refer to accompanying documents
Caution – Risk of electric shock
It is the task of the employer to warn his or her staff of risks, to train them on prevention of
accidents, and to provide necessary safety equipment and devices for the operator’s safety.
Before starting to work with the machine, the operator should check the features of the
machine and learn all details of the machine’s operation. The machine should only be
operated by staff members who have read and understand the contents of this manual.
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 3 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Directives de sécurité / Garantie
Cet équipement a été examiné par BAND-IT et est sûr pour employer fournir qu'on observe les
mesures de sécurité appropriées.
Danger-Abusez de cet équipement peut avoir comme conséquence des dommages sérieux au
personnel.
•Utilisez seulement l'équipement pour son but prévu, comme décrit en ce manuel. N'essayez pas
d'actionner l'équipement des couvertures étant coupées
•Reliez seulement à l'alimentation électrique correcte, comme indiqué de la plaque de contrôle
•Référez-vous à la section d'installation avant d'installer la machine
•N'actionnent pas la machine avec les mains humides
Veuillez lire ce manuel entier avant de déballer, installer ou actionner cet équipement. Prêtez l'attention
à tous les rapports de danger et d'attention. Le manque de faire ainsi a pu avoir comme conséquence
les dommages sérieux à l'opérateur, ou tout autre personnel, ou les dommages à l'équipement.
Attention-Cet équipement produit des niveaux modérés du bruit audible en service.
Assurez-vous qu'il est installé dans un endroit où le bruit de fonctionnement ne causera pas la
perturbation.
Symboles :
Attention - référez-vous aux documents d'accompagnement
Attention - risque de décharge électrique
C'est le charger de l'employeur pour avertir son personnel des risques d'accidents, pour les former sur
la prévention des accidents, et de fournir l'équipement et les dispositifs nécessaires de sûreté pour la
sûreté de l'opérateur.
Avant de commencer à travailler avec la machine, l'opérateur devrait vérifier les dispositifs de la
machine et apprendre tous les détails de l'opération de machine. La machine devrait seulement être
actionnée par les membres de personnel qui ont lu et comprendre le contenu de ce manuel.
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 4 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Safety Guidelines / Warranty
Normal operating conditions are defined as:
• For Indoor Use ONLY
• Temperature range from 5°C to 40°C
• Max relative humidity 80% for temperatures up to 31°C, decreasing linearly to 50%
at 40°C
• Conforms to Applicable Rated POLLUTION DEGREE 1
• Correct illumination for safety of operator (ISO 8995-89)
Additional 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.
• Wear appropriate gloves for handling steel while operating this tool, applying steel
clamps and removing scrap clamp tail.
• Clamp tensioning can be immediately stopped by releasing the tool trigger. If a remote
trigger is used, the system must be connected to allow for immediate disabling of the tool.
• 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.
Warranty:
For warranty information, up-to-date literature, and all tool instructions, go online at:
http://www.band-it-idex.com/
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 5 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Tool Overview
This machine is designed to automatically install clamps with repeatability and control.
• The tool consists of a tension system and a cutting system, both pneumatically controlled.
• The pneumatic system can be adjusted to provide appropriate clamp force for different
applications. As the tension pressure is increased, the output force of the tool 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, a valve switches over to the cutoff cycle.
• The gripping system retains force on the clamp until the knife is actuated, which forms a
locking feature and cuts the excess clamp tail.
• The optional data system can read out the pressure in the pneumatic system to provide
performance data of the tool. See P48950 manual for Data Feedback System option details.
Model Identification
IT6000
C
0
0
0
Other options:
IT6000 – 3/8” Tie-Lok Ties
0 – Standard Tool
IT5000 – 3/8” JR Clamps
1 – Data Feedback System
Product model: Revisions are
not compatible
Trigger options:
Packaging options:
0 – Standard thumb trigger
0 – Tool with standard accessories
1 – Connection for a remote trigger
(tool trigger disabled)
1 – Tool only
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 6 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Tool / Component Identification
Handle Cover
Operating Trigger
Handle
Quick Connect Air Couplings
(Do not add lubricants)
Tool
Reset
Tension
Cylinder
Cut-Off
Cylinder
Tool
Mounting
Locations
Serial #
Location
Tool Body
and Cover
Tool Head with
Knife and Cutter
Blade (see below)
Maintenance Cover w/
Tension Block Assembly
IT5000-C / 3/8” JR Clamps
IT6000-C / 3/8” Tie-Lok Ties
“JR” on Cutter Blade
“TL” on Cutter Blade
No Punch in Knife
Punch in Knife
3/8” JR Clamp
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 7 of 29
3/8” Tie-Lok Tie
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Identification of Standard Accessories
Coiled Air Lines
Air Controller
Module
Packaging Option 0: Box includes IT tool, owners manual, air controller module,
coiled air line, hex keys and fittings
Packaging Option 1: Box includes the IT tool and manual only
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 8 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Air System Requirements
For proper tool performance, the air requirements at the inlet to the BAND-IT Air Controller
Module of the 3/8” BAND-IT Pneumatic IT Tool must be:
Item
Min
Max
Inlet Supply Pressure in PSI (kPa)
100 (690)
140 (965)
Inlet Supply Air Flow in SCFM (L/min)
1.5 (0.71)
Filtered air particle size (microns)
5
Air Moisture Content
20% RH
Warning - Failure to follow the below specifications may cause significant damage to
internal tool components.
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.
The BAND-IT Air Controller Module includes a filter to meet particle requirements.
BAND-IT recommends the use of an Air Booster System to address the potential problems
associated with low air supply, including:
•filters and dries the air supply
•assures pressure of 100 -110 PSI (690-760 kPa)
Contact BAND-IT-IDEX Customer Service at 1-800-525-0758 or 303-320-4555 for more
information.
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 9 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Air Controller Module
Cut-off Air Pressure
Gauge and Outlet
Air Shut-Off
Valve
Tension Air Pressure
Gauge and Outlet
Inlet Air
Supply
¼” NPT
Filter
Fluid Drain
Release Valve
Mounting
Bracket
Filter Warning:
DO NOT expose the filter bowl
to synthetic fluids, organic
solvents, chemicals, cutting
lubricants, thread lock
solutions or similar materials.
Cut-off Air Pressure
Regulator
Factory set to 105
PSI (725 kPa)
Tension Air Pressure
Regulator
Pull Regulator Knob
and twist to adjust
tension, push to lock
Note: The module must be mounted and operated in a horizontal position as shown to prevent
filter malfunction.
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 10 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Air System Settings
Initial Setup – Pneumatic Settings
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 “Air
System Requirements” page) and turn RED Shut-off Valve to pressurize tool (supply
position).
IT5000-C / 3/8” JR Clamps
IT6000-C / 3/8” Tie-Lok Ties
Cut-Off
Pressure
Tension
Pressure
Cut-Off
Pressure
Tension
Pressure
Minimum
100 PSI
(690 kPa)
60 PSI
(410 kPa)
100 PSI
(690 kPa)
50 PSI
(345 kPa)
Recommended
105 PSI
(725 kPa)
85 PSI
(585 kPa)
105 PSI
(725 kPa)
70 PSI
(480 kPa)
Maximum
110 PSI
(760 kPa)
90 PSI
(620 kPa)
110 PSI
(760 kPa)
75 PSI
(520kPa)
Caution: Tension pressures above the specified settings may cause premature
clamp failure and/or tool wear. Refer to the “Tool / Component Identification” page
to verify the tool model.
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, connect the
air supply to the tool. Activate the tool by depressing the trigger for a few seconds. Re-read
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 to provide adequate tension for the specific
application.
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 11 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Adjustable Support Arm / Handle for Hand Use
• Using a 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.
Hex Key
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 12 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
IT Tool Orientation Requirements
The BAND-IT Pneumatic IT Tool has a number of 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.
Part of insuring that the tool is producing a strong lock is making sure that it approaches the
application correctly and the fixture configuration allows 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.
• As the band is tensioning, the tool may rotate clockwise up to 5 degrees about the pivot
point in direction 1 (Green Arrow).
• During the cut-off cycle, the tool must be allowed to rotate counter-clockwise up to 35
degrees in direction 2 (Blue Arrow).
• BAND-IT recommends that the tool be connected to a weight balancer or be
mounted in a fixture that will provide adequate rotation during both cycles
1
Typically
20°- 25 °
2
1/8” – 1/4"
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 13 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Fixture Hanger
The tool comes with a hanger installed on the top face to mount to a weight balancer. When
removed, there are four M5 threads that can be used to secure the tool to a fixture. The
included tool hanger may be attached to any of the mounting holes as shown below.
Caution: do not allow screws to extend deeper than 7/16” (0.438”) into the tool
body. Longer screws will interfere with the internal components of the tool and
cause tool to jam.
Weight
Balancer
IT Tool
Fixture Mounting Holes
Three
additional
fixture
mounting holes are available
to assist with mounting the
tool. Thread size is M5 for all
holes.
One hole is utilized to attach
and lock the tool body cover
to the tool body. This hole
may also be used for a fixture,
provided the M5 cap screw is
replaced with a similar screw
with
appropriate
thread
length.
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 14 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Remote Actuation Configuration
•
A tool with trigger option 0 is manually operated via the thumb button. A tool with trigger
option 1 is configured to allow remote operation via palm button or other device permitting
the tool to be incorporated into the customer’s fixture or assembly process.
•
The modification consists of deactivating the thumb lever actuation switch and installing two
6-ft X 1/8” O.D. hoses with quick disconnects to accomplish the same task via the use of a
remote actuation device such as a palm button that can provide a pneumatic signal to pilot
the tension control valve.
•
Various actuation devices can be incorporated based upon end user requirements. Basic
schematic for 2-way & 3-way valves included below. The valve should be set up in the
normally closed mode and upon opening the circuit a supply of air is provided.
•
The customer is responsible for incorporating this tool into their process. BAND-IT-IDEX is
available to provide advice and recommendations.
Remote trigger: 2-way valve
Hose from tool
(male quick disconnect)
Actuate to
stop tool
Actuate to
start tool
Multiple Triggers
Hose from tool
(male)
Supply Hose from
tool 90-120 PSI (female quick disconnect)
If more than one trigger is used,
connect in series. All need to be
actuated to run the tool.
Remote trigger: 3-way valve
Hose from
tool (male)
Actuate to
stop tool
Actuate to
start tool
Supply Hose from
tool 90-120 PSI
(female)
Supply Hose from
tool 90-120 PSI
(female)
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 15 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Tie / Clamp Installation Procedure
1.
Insert tie / clamp tail into tool as shown. The
tail length extending into tool must be at least
2.5” (6.4 cm) long. The standoffs on the cutter
blade should rest against the buckle. Note Do not activate tool while inserting clamp
tail. This can cause tie tail to jam in the
Tension Block Assembly.
2.
Begin tensioning tie by pushing and holding
down operating trigger or by using the remote
trigger system. If the trigger is released, the
tool will cease operation if the desired tension
has not been achieved.
3.
Band should be applied to a uniform solid
surface allowing the buckle adequate support
during the clamp locking and clamp tail cut-off
operation.
4.
While tensioning clamp, allow the tool to move
freely. Continue to hold down operating trigger
until tool completely tensions and cuts off
clamp. Release trigger after cut off.
5.
After clamp is completed, clamp tail scrap
must be removed from tool. Clamp tail scrap
is not ejected automatically. Tool is now ready
for next tie/clamp.
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 16 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Tie / Clamp Inspection
The IT6000-C forms a locking dimple into the
Tie-Lok tie with the punch and cuts the
remaining tail. When installing a Tie-Lok tie,
a visual check is recommended to verify the
presence of a locking dimple after the tie has
been applied.
Locking Dimple
The IT5000-C forms a locking lip on the
preformed JR clamp and cuts the remaining
tail. When installing a JR clamp, a visual
check is recommended to verify the
presence of the locking lip after the clamp
has been applied.
Locking Lip
By controlling and monitoring the items that are needed to form a good lock, an operator
can help insure that the clamp will be applied correctly without having to inspect every
assembly. The key issues are:
•
•
•
•
Adequate air pressure and volume
Appropriately setting the tension and cutoff air pressure for the application
Following the recommended Preventative Maintenance schedule
Mounting the tool on a weight balancer or custom fixture
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 17 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Dimple Clip Guide
• The dimple clip is designed to eliminate the occurrence of undetectable loose ties.
It thus creates an easy to identify good vs. bad tie installation.
• Installing the clip
– Step 1: Locate clip on front of tool head
– Step 2: Install M4x5 screw to hold clip in place. Do not exceed 6 newton meters
(N-m) torque. [ 53 inch pounds (in-lb) ] Over tightening will cause the screw thread
to strip.
INCORRECT
CORRECT
• Tool orientation is critical to proper function. The tool must be aligned so the clip is
contacting the workpiece while the clamp is being tensioned in order to make sure
the buckle locates inside clip during assembly.
• If the blade is contacting the workpiece during clamp tensioning, the clip will
overshoot the buckle. When the buckle slides under the clip, the dimple lock
cannot form and the tie will be loose. There will also be a sharp edge after cutoff.
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 18 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Trouble Shooting Guide: Unable to Achieve Tension
If the tool fails to fully tension the clamp:
Failure to fully tension the clamp can be caused by a variety of factors. The two
most common factors are incorrect tension pressure and problems with the grippers.
•
Check tension pressure setting on Tension Pressure Gauge of Air Controller Module.
Adjust pressure per the settings found in the “Air System Settings” page.
Evaluate the clamp tail dimple pattern. If elongated dimples are present, the problem
may be with the Tension Block or Front Gripper.
•
Front Gripper
Clamp tail dimple pattern
indicates a problem
Normal clamp tail dimple
pattern.
•
•
•
•
•
Tension Block
If a problem is indicated, follow the instructions in the “Maintenance” section to remove
and inspect the tension block assembly and the front gripper.
Examine the Tension Block and Tension Gripper for damage or wear.
Examine the Front Gripper area for foreign debris and/ or buildup of metal shavings.
Ensure that the four cutter blade screws are tightened.
If excessive damage or wear is determined, replace the worn parts.
A worn out tension block:
Edge is no longer sharp, or is chipped
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
A worn out tension gripper:
Ridges are worn off in some sections
www.BAND-IT-IDEX.com
Page 19 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Preventative Maintenance
The tool has components that must be checked and/or replaced on a regular schedule. If
tools are experiencing difficulties during function or there are audible air leaks coming from
inside the handle, the tool should be returned to BAND-IT-IDEX for service.
Clamps
Installed
Every 25,000
Every 50,000
Every 100,000
Maintenance
Item
Maintenance
Action
Maintenance Cover (pg. 20)
Clean & Re-Lubricate
Tension Block and Gripper (pg. 21)
Inspect, Clean, Re-Lubricate
Front Gripper (pg. 22)
Clean & Re-Lubricate
Cutter Blade & Blade Screws (pg. 22)
Inspect & Replace if necessary
Tool Cavity, Tool Head, Linkages (pg. 23)
Clean & Re-Lubricate
Knife and Dimple Punch (pg. 24)
Inspect & Replace if necessary
Tool
Return to BAND-IT for checkup
Certain applications may require intervals to be adjusted. Consult BAND-IT-IDEX for more
information.
For best performance and to extend tool life:
• Follow preventative maintenance and parts replacement instructions at appropriate service
intervals.
• Do not remove factory applied lubrication from inside tool unless performing a thorough
maintenance procedure and then replacing with fresh lubricant immediately.
• Do not use degreaser in the tool body.
• Do not spray any lubricant or cleaner into the Quick Connect Air Couplings.
• Use nominal recommended tension setting (see “Air System Settings” page). Tension
pressures above the specified settings may cause premature clamp failure and/or tool wear.
• For maintenance beyond what is described in this manual, consult BAND-IT-IDEX Customer
Service at 1-800-525-0758 or 303-320-4555 .
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 20 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Maintenance: Replacement Parts
Production tools will experience wear of specific parts. Preventative maintenance, including
regular cleaning and lubrication, will reduce the replacement frequency of these parts. When
repairing tools, threaded fasteners should be secured using a small amount of Loctite, Blue Medium strength.
The recommended lubricant for the tool is Chevron Rykotac Grease EP.
Part #
Description
I51065
Maintenance Cover Assembly: includes assembled maintenance
cover, two clevis pins, two retaining rings (pg. 20)
I51066
Tension Block Assembly: includes tension block, tension gripper,
tension pin, and 2 springs (pg. 21)
I51067
IT6000-C Knife Assembly Kit: includes assembled knife, dimple
punch, and spring pin (pg. 24)
I51069
IT6000-C Cutter Blade with four screws (pg. 22)
I51070
IT5000-C Knife (pg. 24)
I51073
IT5000-C Cutter Blade with four screws (pg. 22)
Please have both the tool model and serial numbers available when calling the factory for
service or assistance. Contact BAND-IT-IDEX Customer Service at 1-800-525-0758 or
303-320-4555 for more information.
Part numbers are subject to change.
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 21 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Maintenance: Maintenance Cover
Important: Before disassembling tool, be sure to shut-off air supply on the
Control Module.
Note: This tool uses metric fasteners.
1) Remove the two e-style
retaining rings and two clevis
pins. Remove the
maintenance cover.
2) Remove the tension block
assembly by lifting it out of
tension arm slot. Tension block
may come out with
maintenance cover.
3) Fully clean and lubricate inside
of maintenance cover as
shown.
Lightly lubricate all
points indicated
with red arrows.
Tension
Block
Assembly
Maintenance Cover
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
***Continued on next page***
www.BAND-IT-IDEX.com
Page 22 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Maintenance: Tension Block Inspection & Replacement
Disassembly & Inspection:
1)
2)
3)
4)
Remove the two Compression Springs.
Remove Tension Gripper and Tension Block pin from the Tension Block.
Tension Gripper — Look for worn spots or other damage.
Tension Block — Look for damaged edge on insert or other damage. See the “Trouble
Shooting Guide: Unable to Achieve Tension” page for details.
Reassembly:
1)
2)
3)
4)
Thoroughly clean out any accumulated debris from inside the Tension Block
Lubricate the surfaces shown with red arrows
Install the Tension Gripper and Tension Block Pin in the Tension Block.
Reinstall the Compression Springs
Tension Block
Compression Springs
Lightly lubricate all outside surfaces
of tension block and surfaces
indicated with red arrows.
Tension Block Pin
Tension Gripper
Clean out any
accumulated debris
from the slot in the
Tension Block
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
Insert
Note: Ensure no lubrication is present in
the center of Tension Gripper (indicated
by the circled area)
www.BAND-IT-IDEX.com
Page 23 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Maintenance: Cutter Blade Inspection & Replacement
Removal & Installation:
1)
Remove the four M4 screws with a 3mm hex
key. This can occur with the tool fully
assembled.
2)
Pull the cutter blade off of the two alignment pins
in the tool head.
3)
Inspect cutter blade for chips and excessive
wear on cutting edge. Replace if blade is
causing unacceptable clamp cut-off. Clean any
shavings or debris that have built up on cutter
blade.
4)
Scrape out all accumulated shavings and debris
from inside the front gripper where the ball
bearing is inserted. The part can be pulled back
and out of the tool head slot.
5)
Lubricate ball bearing after cleaning.
6)
To re-install cutter blade, use alignment pins and
install the four M4 screws with blue Loctite.
Cutter Blade
Ball
Bearing
Front Gripper
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 24 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Maintenance: Tool Body and Linkages
1) Remove the three cap screws (4mm hex) and the one flat head screw (3mm hex) as
shown.
2) Remove the side cover after screws are removed. The side cover is a close fit and may
require a screwdriver to pry off near the tension arm.
3) Examine the mechanical linkages for over-all condition such as dirt, metal filings, liquid
contamination and lubrication.
Pry Here
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 25 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Maintenance: Knife Inspection & Replacement
1)
2)
3)
4)
5)
6)
7)
Remove the one cutoff link and two pins shown
Remove the tool head by removing one flat head screw (3mm hex) on opposite side
Remove tool head assembly by sliding it along keyway in tool body
Lift cutter arm and knife assembly out of tool head
Push the pin out of knife assembly to remove the cutter arm
Inspect cutting edge for chips and excessive wear. Make sure knife is well lubricated.
For IT6000-C only: the Dimple Pin height should be 0.120” minimum. Inspect dimple pin
for excessive wear.
Note: Be careful not to let ball bearing fall out of gripper guide. Further cleaning of the gripper
guide and ball bearing can occur here if necessary.
Step 4
Step 5
Step 1
Lightly lubricate all
sides of cutting knife.
Cutting Edge
Step 3
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
Dimple Pin Height
0.120” Minimum
www.BAND-IT-IDEX.com
Page 26 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Maintenance: Lubrication
Important: Before disassembling tool, be sure to shut-off air supply on the
Control Module.
Note: This tool uses metric fasteners.
The recommended lubricant is Chevron Rykotac Grease EP.
1)
2)
3)
4)
Lubricate tool cavity as shown with red arrows below. Also, lubricate the inside surfaces of
the maintenance cover (shown below).
BAND-IT recommends lubrication every 25,000 clamps. Dirty environments may require
more frequent intervals.
Inspect all mechanical linkages for lubrication and proper placement. Refit cover.
Secure the tool side cover by inserting and tightening the screws to 20-30 in-lbs removed
on the previous page’s steps. Use medium strength Loctite on the two flat head screws to
prevent the fasteners from loosening.
Lightly lubricate all points
indicated with red arrows.
Tool Cavity
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 27 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Maintenance: Cutoff Timing Adjustment
1)
Remove the two cap screws in the Handle Cover with a 4mm hex key. Remove cover and
lay aside during their removal.
2)
The valve used to adjust timing is highlighted in the picture below.
3)
To adjust: Loosen jam nut, and turn adjustment screw clockwise to increase the cutoff delay
and counter-clockwise to decrease the cutoff delay. Once the delay is set, tighten the jam
nut against the adjustment screw.
4)
To test and verify proper adjustment: Connect the tool to the Air Control Module, then turn
supply valve on. Gently kink the coiled air supply tube connected to the bottom Quick
Connect Air Coupling, then activate the Tool Trigger. This action causes the tool to cut off,
allowing the timing to be reviewed. Adjusting the Timing Screw in by ½ turn will slow the
tool’s cut-off action. Adjusting the Timing Screw out by a half turn increases the speed of
the cut-off activation. Repeat this entire step until timing is set at a 0.5 – 1.0 second delay.
Caution: Setting timing to less than 0.5s may result in loose clamps.
Cutoff Timing
Valve
Notes:
-Cut-off timing set too short will not allow the clamp to achieve the desired tension before
switching to the cut-off function causing a loose clamp. Clamping on softer objects requires
a longer timing.
-Cut-off timing set too long may slow production and cause operator to twist the tool during
application. This may damage tool and/or clamp.
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 28 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
Operating
Manual
IT5000-C / IT6000-C
3/8” IT Tool
Trouble Shooting Guide: Tool Symptoms
Symptom
Items to check
Suggested fix
Tool does not cycle
when the trigger is
pressed
Do the gages on the control
module show pressure?
Check incoming supply pressure.
Turn the air shutoff valve ON.
Check for pinched air lines under
the handle cover.
Tool tightens clamp, but
cutoff does not activate
After the tool stalls, does
nothing further happen? (no
sound of the cylinder moving)
Check for pinched air lines.
Check cutoff timing.
Does the cylinder sound as
though it moves, but the knife
does not extend?
Remove the side body and verify
all links are present and
connected.
Verify there is a knife installed.
Tool attempts to cutoff
and lock the clamp
before it is tight
Is the cutoff timing too short?
Adjust cutoff timing.
Is the tool struggling to pull up
the clamp?
Increase tension pressure.
Lubricate the tool.
Tool fails to cut or lock
clamp
Check tension and cutoff
pressures
Adjust pressure regulators if not
set at specification. Verify that
the hose from the tension
regulator enters the bottom port
of the tool.
Check knife and blade for
excessive wear or chips on the
cutting edges.
Replace as necessary.
Contact BAND-IT-IDEX Customer Service at 1-800-525-0758 or 303-320-4555 for
repair on any issues not addressed above.
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
F: 1-800-624-3925
www.BAND-IT-IDEX.com
Page 29 of 29
Document # P48850 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2014
All rights reserved
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