IT4000-AB Owner’s Manual 5/16” Band-Lok Tool IT4000 A B 0 0 Base part number 0 Other options: 0 – None (standard) Product level Revisions are not compatible Trigger options: 0 – Standard thumb trigger 1 – Connection for a remote trigger (I17490, Foot Control Kit, is available to purchase separately) Tool revision Revisions are compatible Packaging options: 0 – Tool with all accessories (standard) 1 – Tool only BAND-IT-IDEX, Inc. www.BAND-IT-IDEX.
IT4000-AB Table of Contents 5/16” Band-Lok Tool Table of Contents Warranty & Safety Guidelines Page 3 Air System 4-6 Parts Identification 7,22 Tool Overview 8 Setup & Assembly Instructions 9-11 Remote Operations & Fixturing Tips 12,13 Operating Tips 14 Operating Instructions 15 Troubleshooting 16-20 Maintenance 21-28 BAND-IT-IDEX, Inc. www.BAND-IT-IDEX.
IT4000-AB Warranty & Safety Guidelines 5/16” Band-Lok Tool Warranty: For Warranty information visit the following URL www.BAND-IT-IDEX.com/Warranty.html 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.
IT4000-AB Air System 5/16” Band-Lok Tool The IT4000 is a pneumatic tool that needs a clean and dry air supply. The BAND-IT Air Controller Module includes a filter to meet these requirements. For proper tool performance, the air requirements at the inlet to the BAND-IT Air Controller Module of the IT4000 must be: Item Min Max Inlet Supply Pressure (PSI) 100 140 Inlet Supply Air Flow (SCFM) 1.
IT4000-AB Air System 5/16” Band-Lok Tool Air Controller Module Inlet Air Supply Cut-off Outlet Tension Outlet Quick Disconnect Use one of two quick-disconnects supplied or remove and use 1/4” NPT fitting Air Shut-Off Valve Cut-off Pressure Gauge Exhaust Muffler Filter Fluid Drain Release Valve Cut-off Pressure Regulator Factory set to 110 PSI Do not adjust Air Filter Environment: Standard Filters/Regulators incorporate polycarbonate bowls and/or observation windows.
IT4000-AB Air System 5/16” Band-Lok Tool The standard IT4000 shipping container includes: Air Controller Module, IT4000 tool body, coiled air line, owner’s manual and tool kit. (tools with packaging option 1 include the tool and manual only) Initial Setup - Pneumatics • 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.
IT4000-AB Parts Identification 5/16” Band-Lok Tool IT4000-AB Tool Body Tool Hanger Mounting Holes Model I.D. Plate Quick Connect Air Couplings (Do not add lubricants) Tension Cylinder Cut-off Cylinder Operating Trigger Serial # Location Reset Button Tool Head with Cutter Knife and Blade Quick Release Pins Maintenance Flip Cover Flip Cover Head Screws Flip Cover Tightening Screw Important: Before disassembling tool, be sure to shut-off air supply on the Air Controller Module. BAND-IT-IDEX, Inc.
IT4000-AB Tool Overview 5/16” Band-Lok Tool Pneumatic System: The pneumatic valves and cylinders contain seals and o-ring components which can experience accelerated wear associated with quality of the supply. Worn cylinder o-rings allow air to bypass the pistons in the cylinders, affecting the performance of the tool and cause the output force of the tool to drift.
Setup & Assembly Instructions IT4000-AB 5/16” Band-Lok Tool Handle adjustment: • Using 1/4” 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. Hanger Support Instructions: 1. An aluminum hanger (accessory) can be utilized for supporting the tool. 2.
Setup & Assembly Instructions IT4000-AB 5/16” Band-Lok Tool Fixture Locating Points Fixture Mounting Locations Three additional fixture mounting holes are available to assist with mounting the IT4000. Thread size is #10-32 for each of the holes. Usable thread depth is .400” for two of the three fixture holes. One hole is utilized to attach and lock the tool body halves together.
Setup & Assembly Instructions IT4000-AB 5/16” Band-Lok Tool Part of insuring that the tool is producing a strong lock is making sure that it approaches the application correctly and is fixtured to allow 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.
IT4000-AB Remote Operation & Fixturing Tips 5/16” Band-Lok Tool IT4000 Orientation Requirements: • The IT4000 tool has a number of Tool/Clamp/Object Being Clamped orientation requirements that must be followed in order to reach an acceptable end result.
IT4000-AB Remote Operation & Fixturing Tips 5/16” Band-Lok Tool IT4000 Configured for Remote Actuation: • The IT4000 with trigger option 1 and is a modified version of the base unit. A tool with trigger option 0 is manually operated via the incorporated thumb actuation lever. 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.
IT4000-AB Operating Tips 5/16” Band-Lok Tool Clamp Installation: When installing a clamp, a random visual check to verify the presence of a locking lip after the clamp has been applied is recommended. The lip is the locking element of an installed band. The IT4000 forms a dimple into the band at the buckle edge with the knife.
IT4000-AB Operating Instructions 5/16” Band-Lok Tool 2.5” 1. Insert clamp tail into tool as shown. Clamp tail length extending into tool must be at least 2.5” (6.4 cm) long. The head of the tool should rest against the buckle. Note - Do not activate tool while inserting clamp tail. This can cause clamp tail to jam in the Tension Block Assembly. 2. Begin tensioning clamp by pushing and holding down operating trigger 3.
IT4000-AB Troubleshooting 5/16” Band-Lok Tool Tool fails to fully tension 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 in the Tension Block Assembly. Check tension pressure setting on Tension Pressure Gauge of Air Controller Module. Adjust pressure per the settings in the Setup & Assembly Instructions section found on (pages 9-11).
IT4000-AB Troubleshooting 5/16” Band-Lok Tool Tool fails to cut off clamp tail: • The Inlet Air Pressure may be low. Check air supply to Air Controller Module. Cut-off Pressure Gauge should indicate 105 PSI minimum, 110 PSI maximum. See pages 4 - 6 for air supply requirements. • The scrap clamp tail from the previous clamp may not have been removed. Press the Reset Button to release the tension on the clamp and remove the scrap clamp tail. • The Cutter Blade or Knife may be worn.
IT4000-AB Troubleshooting Matrix Symptom Tool will not tension properly (i.e. slipping, slow etc.) 5/16” Band-Lok Tool Probable cause Recommended Fix Page Rear tension block slipping, Remove and inspect gripper block assembly. Replace as therefore tool does not required. reach cut off tension. Front gripper slipping Remove and inspect front gripper and gripper guide arm. Replace if worn. Dirty front and rear gripper Remove and clean contact surfaces surrounding grippers.
IT4000-AB Troubleshooting Matrix Symptom 5/16” Band-Lok Tool Probable cause Tool will not cut Linkage components off clamp tail - damaged, causing Continued. interference Cut-off cylinder seal damaged or leaking Cut off pneumatic air leak Loose clamp after cut-off Page Remove tool left side body and verify linkage mechanism. Remove and replace damage as required or contact BANDIT. Remove left side tool body and verify seal integrity 27 * Verify Coiled Hose Assembly is free of air leaks.
IT4000-AB Troubleshooting Matrix Symptom Clamp will not insert into tool 5/16” Band-Lok Tool Probable cause Control Module air pressure valve is in "off" position. Clamp tail inside tool Knife is in down position. Handle will not adjust Wrong clamp type for tool Handle nut is damaged/misaligned. Recommended Fix Page Rotate Control Module valve to open position. Verify gauges read air pressure and check all air connections.
IT4000-AB Maintenance 5/16” Band-Lok Tool Tool Preventative Maintenance: The tool has some wear components that must be checked and replaced on a certain schedule. BAND-IT has developed a Preventative Maintenance (PM) schedule to help facilitate these requirements. If tools are experiencing difficulties during function or there audible air leaks coming from inside the handle, the tool should be returned to BAND-ITIDEX, Inc. for servicing.
IT4000-AB Maintenance 5/16” Band-Lok Tool Production tools will experience wear of specific parts. Preventative maintenance, including regular cleaning and lubrication, will reduce the replacement frequency of these parts. To maximize life, use synthetic gel lubricant containing Teflon. See (pages 22-28) for tool maintenance. When repairing tools, threaded fasteners should be secured using a small amount of Loctite, Blue - Medium strength being careful to apply sparingly.
IT4000-AB Maintenance 5/16” Band-Lok Tool Knife Assembly Replacement: A) Remove Cutter Blade as described on page 17. B) Remove the 2 Knife Pin access screws. These are special length screws. Important: When repairing tools, threaded fasteners should be secured using Loctite, Blue - Medium strength. To remove Cutter Knife Pin the Knife Assembly must be in its uppermost position indicated by the Cutter Knife Pin in line with the access hole. If not aligned, connect the tool to the Air Controller Module.
IT4000-AB Maintenance 5/16” Band-Lok Tool Tension Block Assembly Maintenance: Remove the Maintenance Flip Cover by loosening the Maintenance Cover Tightening Screw and Flip Cover Screws on the Maintenance Flip Cover and removing both Quick Release Pins as shown on page 17.
IT4000-AB Maintenance 5/16” Band-Lok Tool • Remove the Maintenance Flip Cover. Examine all moving parts and linkages for wear. • Using an air nozzle, gently clean the parts of any dirt and metal filings in the tensioning cavity. • Using cotton swabs or a short bristled brush, continue to wipe away any foreign debris and purge once again with the air nozzle. • After thoroughly cleaning all moving parts, re-lubricate all surfaces. Following are lubrication instructions.
IT4000-AB Maintenance 5/16” Band-Lok Tool 4) Lubricate the removed cover as shown with red arrows above. Also, lubricate the tool body, linkage and Tension Block Assembly as shown on page 27. 5) Inspect all mechanical linkage for lubrication, proper placement and refit cover. 6) Secure the tool side cover by inserting and tightening (2) #10 – 32 X 4” length cap screws through the Cylinder Housing and into the Cover.
IT4000-AB Maintenance 5/16” Band-Lok Tool Lubrication – Follow recommended intervals – Use a synthetic gel lubricant containing Teflon for the internal parts as shown and described. Lubricate all pivot points and internal surfaces of maintenance flip cover with a light coating of the lubricant. Caution – Excessive amounts of lubricant may result in gripper slippage, requiring a full repeat of cleaning process.
IT4000-AB Maintenance 5/16” Band-Lok Tool Procedure to adjust the timing of the clamp tail cut-off: The Timing Valve will be affected over time by contaminants in the air system. Moisture, dirt particles, oil and solvents can cause blockage or fluctuations in the tool performance. Cycle should be .5 – 1.0 seconds. 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.
