Aimco Brakes Pulse Tool ULT Series Repair Manual
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PO Box 16460, Portland, OR 97292-0460 503-254-6600 Fax 503-255-2615 ULT Series Repair Manual ISO 9001: 2015 Certified
– 2 – Contents Page Number 1. Recommended Tools 2 2. Special Repair Fixtures 3-5 3. Disassembly and Reassembly of the Pulse Unit 6-10 4. Disassembly and Reassembly of the Air Motor 11-13 5. Disassembly and Reassembly of the Shut-off Valve Section 14-15 6. Fill & Draw Sheet 16 7. Troubleshooting 17 8. Preventative Maintenance 18 Recommend Tools 1. Set of Picks 2. Standard Pliers 3. 6” Open-End Adjustable Wrench 4. 20” Open-End Adjustable Wrench 5. Hog Ring Pliers (250G Proto) 6. Set of Screwdrivers 7. Set of Punches 8. Dead Blow Hammer 9. 13 oz. Ball Peen Hammer 10. Three Ton Arbor Press 11. Set of V-Blocks 12. Three Ton Hydraulic Press (only needed if you are not using the PTRF-1-1) 13. Lap Plate 14. Parts Cleaning Tank 15. Wire Wheel 16. Service Removable Thread Locker (242 Blue Loctite) 17. PTRF-1-1 Universal Pulse Unit Repair Fixture 18. VC-101-2A Vacuum Tank 19. VCE-1-1 Vacuum Extractor 20. 1cc Glass Syringe and 0.5cc Glass Syringe 21. Pulstar Oil
Special Repair Fixtures for Repair of ULT Series Tools – 3 – Part Number Tool Model Disassembly and Reassembly of Valve Cover 145-019-6-5 ULT-30D, 40, 50 & 60 147-019-6-5 ULT-70 & 80 147-019-8-5 ULT-90 & 100 130-019-2-5 ULT-130 & 150 128-019-2-5 ULT-180 Disassembly and Reassembly of Casing Connector 144-036-0-5 ULT-30D 147-036-2-5 ULT-40, 50 & 60 143-036-8-5 ULT-70 115-036-3-5 ULT-80 147-036-8-5 ULT-90 148-036-2-5 ULT-100 130-036-2-5 ULT-130 130-036-4-5 ULT-150 Insert of the Driving Blades 144-440-0-0 144-440-0-1 ULT-30D 190-440-6-0 190-440-6-1 ULT-40, 50 & 60 194-440-2-0 194-440-2-1 ULT-70 115-440-3-0 115-440-3-1 ULT-80 194-440-3-0 194-440-3-1 ULT-90 194-440-6-0 194-440-6-1 ULT-100 130-440-2-0 130-440-2-1 ULT-130 130-440-4-0 130-440-4-1 ULT-150 128-440-2-0 128-440-2-1 ULT-180
Special Repair Fixtures for Repair of ULT Series Tools – 4 – Part Number Tool Model Anvil Sleeve for Installation of SU-Ring 178-319-8-1 ULT-40, 50, 60 & 70 194-319-3-1 ULT-90 178-350-9-1 ULT-40D, 50D & 60D TM-Type Tools Part Number Tool Model Disassembly and Reassembly of Valve Cover 851-017-1-5 ULT-30D, 40, 50 & 60 851-007-1-5 ULT-70 851-011-1-5 ULT-90 Repairing with the PTRF Part Number Tool Model Disassembly and Reassembly of Liner Casing Setter PTRF-039 ULT-40, 50, 60 & 70 PTRF-040 used with the PTRF-039 ULT-90 PTRF-041 used with the PTRF-039 ULT-100 PTRF-042 used with the PTRF-039 ULT-30D PTRF-044 used with the PTRF-039 ULT-130 PTRF-045 used with the PTRF-039 ULT-150 PTRF-046, PTRF-047 used with the PTRF-039 ULT-180
Special Repair Fixtures for Repair of ULT Series Tools – 5 – Repairing Without the PTRF Part Number Tool Model Stand to Hold the Pulse Unit 144-905-0-3 ULT-30D 145-905-6-3 ULT-40, 50 & 60 194-905-0-3 ULT-70 194-905-3-3 ULT-80 147-905-8-3 ULT-90 148-905-2-3 ULT-100 194-905-4-3 ULT-130 130-905-4-3 ULT-150 128-905-2-3 ULT-180 Disassembly and Reassembly of Liner Casing Setter 144-906-0-5 ULT-30D 147-906-2-5 ULT-40, 50 & 60 147-906-6-5 ULT-70 147-906-3-5 ULT-80 147-906-8-5 ULT-90 148-906-2-5 ULT-100 130-906-2-5 ULT-130 130-906-4-5 ULT-150 128-906-2-5 ULT-180 Press Bar for Rear Liner Plate 197-901-7-9 ULT-30D 196-901-4-9 ULT-40, 50 & 60 190-901-6-9 ULT-70 143-901-9-9 ULT-80 & 90 194-901-2-9 ULT-100 194-901-6-9 ULT-130 & 150 195-901-9-9 ULT-180
Disassembly and Reassembly of Pulse Unit – 6 – 1. Remove the Front Casing (left- hand thread) from the tool. 2. Remove the Purple Cushion from the Pulse Unit and the Pulse Unit from the Handle. Be sure not to lose the Adjustment Spacer, Spring, and/or Oper- ating Rod that are between the Handle and Pulse Unit. 3. Remove the Oil Fill Plug and extract all of the oil with the VCE-1-1 from the Pulse Unit. Note: The Oil Fill Plug on the ULT-30D is in the Rear Liner Plate. 4. Place the Pulse Unit in the PTRF-1-1 or the Stand for Holding Pulse Unit and remove the Liner Casing Setter using the PTRF-039, PTRF-040, PTRF- 041, PTRF-042 or Disassembly and Assembly of Liner Casing Setter (right-hand thread). 5. While holding the Pulse Unit with the Anvil up, tap on the Anvil with a Dead Blow Hammer to remove the Rear Liner Plate, Anvil, Driving Blades, Driving Blade Rollers, Relief Valve Spring, Relief Valve Ball, Check Valve Spring, and Check Valve Ball. Now remove the Piston from the Rear Liner Plate. 6. Remove the Front Liner Plate and Liner from the Liner Casing. You can use the Anvil with a set of V-Blocks on the Arbor Press by placing the Anvil driver end-first through the Front Liner Plate and pressing on the back of the Anvil to push the Front Liner Plate and Liner out of the Liner Casing. Note: Always make sure that the Front Liner Plate and Liner come out of the Liner Casing as one piece or you may cause serious damage to the Liner Casing. Never push too hard on the Arbor Press. Always push the Front Liner Plate and Liner back and forth in the Liner Casing until the Front Liner Plate and Liner move freely from the Liner Casing. 7. Separate the Front Liner Plate and Liner. Note: On the ULT- 30D, 40, 50 & 60 series tools, the Front Liner Plate is made up of two pieces: the Front Liner Plate and the Liner Casing Spacer. 8. Remove the Relief Valve Spindle (left-hand thread), Relief Valve Pin, Relief Valve, Accumulator, Accumulator Spring, and Locator Pins from the Liner. 9. Remove all O-rings and Sup- porter Rings. Clean and inspect all parts. Resurface only those parts having burs on them. If any parts show deep grooving or surface wear, they will need to be replaced. Disassembly of Pulse Unit
Disassembly and Reassembly of Pulse Unit – 7 – 1. You will find all O-rings, Supporter Rings, and Springs needed for rebuild of the Pulse Unit in a Pulse Unit Repair Kit (PRK). To order a PRK, you would order the model number of tool plus dash PRK (i.e., ULT-70-PRK). 2. Lubricate all O-rings with Pulstar Oil. 3. Install the O-ring on the Relief Valve using the O-ring Install Fixture and install the Relief Valve into the Liner lining up the slot in the Relief Valve with the hole in the Liner and install the Relief Valve Pin. Note: Be careful not to cut the O-ring on the Relief Valve. 4. Install the Accumulator O-ring and Supporter Ring onto the Accumulator using an O-ring Install Fixture and install the Accumulator Spring and Accumulator into the Liner. 5. Install the Relief Valve Spindle into the Relief Valve and install the O-ring on the Relief Valve Spindle (left-hand thread) and Supporter Ring into the Front Liner Plate. Note: The Sup- porter Ring is not used on the ULT-40, 50 & 60. 6. Install two Locator Pins into the front of the Liner. 7. Install the Anvil SU-ring and Supporter Ring into the Front Liner Plate and install the Front Liner Plate onto the Liner. Note: Make sure that you work the Relief Valve Spindle O-ring up into the Front Liner Plate by turning the Relief Valve Spindle back and forth. Note: On the ULT-30D, 40, 50 & 60 series, you install the Liner Casing Spacer onto the Liner. Install the Front Liner Plate after the Anvil and Driving Blades have been installed into the Liner. 8. Install the Driving Blade Springs, Driving Blades, and Driving Blade Rollers into the Anvil and into the Driving Blade Install Fixture. 9. Put the proper Anvil Sleeve Fixture over the drive end of the Anvil and install the Anvil into the Liner and through the Front Liner Plate removing the Driving Blade Install Fixture. As you do this, make sure to keep the Nylon piece of the Driving Blade Install Fixture tight against the Anvil. 10. Install two Locator Pins into the rear of the Liner, the Check Valve Spring and Check Valve Ball into the back of the Anvil and the Relief Valve Ball and Relief Valve Spring into the back of the Relief Valve in the Liner. Assembly of Pulse Unit
Disassembly and Reassembly of Pulse Unit – 8 – 11. Install the O-ring onto the Rear Liner Plate and install the Rear Liner Plate onto the Liner. Note: If the Check Valve Cover was removed from the Rear Liner Plate when reinstalling the Check Valve Cover back into the Rear Liner Plate, make sure that the hole in the side of the Check Valve Cover is 180 degrees out from the hole inside of the Rear Liner Plate, 90 degrees out on the ULT-150 and ULT-180 only, and apply a light coat of Loctite 603 to the Check Valve Cover before installing. 12. Holding the hex end of the Rear Liner Plate in a vise, install the Front Liner Plate O-ring and now install the Liner Casing over the Anvil and onto the assembly. 13. Clean the threads on the Liner Casing and Liner Casing Setter with a degreaser or Isopropyl Alcohol. Put a small amount of thread locker (i.e., Loctite 242) on the Liner Casing Setter and install into Liner Casing. Note: If you use Isopropyl Alcohol to clean the threads, it will cause the thread locker to set-up in about 10-15 minutes. 14. Now, using the PTRF-1-1 and following the Fill and Draw sheet, apply the proper amount, press load to the Rear Liner Plate, and tighten the Liner Casing Setter to the proper torque. Note: Make sure that you use the proper Press Cap when applying the press load to the Pulse Unit. 15. Once you are sure that the thread locker has set-up: Make sure that the Torque Adjuster is turned all the way out counter- clockwise, fill the Rear Liner Plate with Pulstar oil, and insert the Piston stepped-end down into the Rear Liner Plate. Put the Pulse Unit into the VC-101- 2A Vacuum Fill Tank, making sure that the Pulstar oil is about one-half of an inch below the oil fill hole on the Pulse Unit. Note: The ULT-30D goes into the Tank Anvil-side down. 16. Now, cycle the Vacuum Fill Tank. Note: The gauge on the tank should read 29 in.Hg. or above. 17. Now, pull the Pulse Unit out of the Vacuum Fill Tank. Tip the Pulse Unit on its side to remove the excess oil from the top of the Pulse Unit so that it is level with the top of the oil fill hole. Following the Fill & Draw sheet, remove the recommended cc’s of oil from the Pulse Unit and install the Oil Fill Plug. Note: Make sure that you pull up lightly on the plunger of the syringe as you put the needle into the Pulse Unit. This will keep you from displacing the oil out of the Pulse Unit when you put the needle into the Pulse Unit. 18. Install the Purple Cushion onto the front of the Pulse Unit.
Disassembly and Reassembly of Pulse Unit – 9 – Make sure that the Adjusting Spacer, Spring, and Operating Rod are back in the Handle and install the Pulse Unit and Casing onto the Handle. Note: The torque for the Front Casing is 16-24 Nm for the ULT-30D ~ ULT-80, 25-38 Nm for the ULT- 90 ~ ULT-150 and 13-19 Nm for the ULT-180. Apply Loctite 222 to threads on the Casing Connector. 19. You are now ready to test the tool.
Disassembly and Reassembly of Pulse Unit – 10 – ULT-Pulse Unit Part Number Description Part Number Description 1 Liner Casing 19 Locator Pin 2 Front Liner Plate O-Ring 20 Anvil Supporter Ring 3 Front Liner Plate 21 Anvil SU-Ring 3A Liner Casing Spacer 22 Accumulator 4 Torque Adjuster O-Ring 23 Accumulator O-Ring 5 Torque Adjuster Supporter Ring 24 Accumulator Supporter Ring 6 Torque Adjuster 25 Accumulator Spring 7 Relief Valve Pin 26 Liner 8 Relief Valve 27 Anvil 9 Relief Valve O-Ring 28 Accumulator Cover 10 Relief Valve Ball 29 Driving Blade Spring 11 Relief Valve Spring 30 Check Valve Spring 12 Locator Pins 31 Check Valve Ball 13 Anvil 32 Check Valve Cover 14 Driving Blade 33 Rear Liner Plate 15 Driving Blade Roller 34 Rear Liner Plate O-Ring 16 Oil Plug 35 Piston 17 Oil Plug Supporter Ring 36 Piston O-Ring 18 Oil Plug O-Ring 37 Liner Casing Setter