Aimco Brakes Pulse Tool ULT Series Repair Manual
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Disassembly and Reassembly of Air Motor – 11 – 1. Remove the Casing (left-hand thread), Pulse Unit, Spacer, Spring, and Operating Rod from the Handle. 2. With the Casing Connector Fixture, remove the Casing Connector (left-hand thread) from the Handle. 3. Remove the Front Air Motor Plate, Rotor, Cylinder, Blades, Rear Air Motor Plate, O-ring, and Rear Plate Spacer from the Handle. 4. Remove the O-rings from inside of the Handle. 5. Remove the Bearings from the Front and Rear Air Motor Plates. The Bearing is a press fit into and over the Rotor on the Rear Air Motor Plate. 6. 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. 1. You will find all Bearings, O-rings, Blades, and Filter needed for rebuild of the Air Motor in an Air Motor Repair Kit (RK). To order an RK, you would order the model number of tool plus dash RK (i.e., ULT-70RK). 2. Coat one-third of the Bearings with a good quality grease (i.e., Chevron Moly Grease EP NLG1 2). 3. Press the Rear Plate Bearing into the Rear Plate and over the Rotor at the same time except on the ULT-150. The Bearings on the ULT-150 are Loctited into the Front and Rear Plate with Loctite 603 and the Rear Plate and Bearing are then pressed onto the Rotor. Note: You should not be able to see any light between the Rear Plate and the Rotor and the Rotor should turn freely when you have it set right. 4. Put a light coat of air motor oil on the Blades and install them in the Rotor. 5. Put the Cylinder down over the Rotor and onto the Rear Plate with exhaust holes up. 6. Press the Front Plate Bearing into the Front Plate and install the Front Plate onto the Cylinder and Rotor. 7. Install the O-ring and Rear Plate Spacer onto the Rear Air Motor Plate. 8. Lightly oil the O-rings and install them into the Handle. Disassembly of Air Motor Assembly of Air Motor
Disassembly and Reassembly of Air Motor – 12 – 9. Line up the pin on the side of the Front Plate with the cut-out on the inside of the Handle and install the Air Motor into the Handle. 10. Install the Casing Connector into the Handle. The recommended torque for the ULT-30 - 80 is 45 Nm +/-5, for the ULT-90 is 50 Nm +/-5, for the ULT-100-130 is 60 Nm +/-5, and for the ULT- 150 is 65 Nm +/-5. Make sure to use a good service removable thread locker on the Casing Connector. 11. Install the Operating Rod, Spring, Adjusting Spacer, Pulse Unit, and Casing on the Handle. Make sure to use a good service removable thread locker on the Casing Connector. 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. 12. The tool is ready to test.
Disassembly and Reassembly of Air Motor – 13 – ULT- Air Motor Part Number Description Part Number Description 1 Casing Connector 10 Rear Air Motor Plate 2 Piston Reset Spring 11 Rear Air Motor Bearing 3 Front Air Motor Bearing 12 O-Ring 4 Nylon Ball Plug 13 Rear Plate Spacer 5 Roll Pin 14 Front Air Motor Plate 6 Blade 15 Rotor 7 Roll Pin 16 Handle O-ring 8 Air Motor Cylinder 17 Handle 9 Front Air Motor Bearing
Disassembly and Reassembly of the Shut-off Valve Section – 14 – 1. Remove the Valve Cover using the Valve Cover Fixture (right- hand thread) from the back of the Handle. 2. Remove the Supporter Ring, Cushion Spacer, Shut-off Valve, Supporter Ring, Shut-off Valve Spring, and Ball from the Handle. 3. Remove the Valve Plug from the side of the Handle and remove the Shut-off Valve Bushing from inside of the Handle. 4. Clean and inspect all parts. Replace all worn or damaged parts. 1. Lightly lubricate all O-rings and install on Shut-off Valve Bushing. 2. Install the Shut-off Valve Bushing into the Handle. Make sure to line up the hole in the side of the Shut-off Valve Bushing with the hole on the side of the Handle. 3. Install the Valve Plug snugly into place, making sure not to over-tighten the Valve Plug or you could damage the O-ring and the tool will not shut-off. Note: The Valve Plug should be torqued to 1.0-1.5 Nm. 4. Install the Ball, Spring, Supporter Ring, Shut-off Valve, Cushion Spacer, Supporter Ring, and Valve Cover. Note: The Valve Cover should be torqued to 20-30 Nm for the ULT-30D ~ ULT-80 and 30-40 Nm for the ULT-90 ~ ULT-180. 5. You are ready to test the tool. Disassembly of Shut-Off Valve Section Assembly of Shut-Off Valve Section
Disassembly and Reassembly of the Shut-off Valve Section – 15 – ULT-Shut-off Valve Part Number Description Part Number Description 1 Valve Plug 9 O-Ring 2 Handle 10 Supporter Ring 3 O-Ring 11 Cushion Spacer 4 Shut-off Valve Spring 12 Operating Rod 5 Supporter Ring 13 Shut-off Valve Ball 6 O-Ring 14 Shut-off Valve 7 O-Ring 15 Valve Cover 8 Shut-off Valve Bushing
ULT Series Fill & Draw Sheet
– 16 –
Key Model of this Tool Group Full Volume of Liner Oil in Pulse Unit (approx.)
Volume to be Removed from the Full Volume (approx.)
Torque to Tighten Liner Casing Setter (approx.)
Torque to Tighten Liner Casing Setter (approx.)
Load to Press on Rear Liner Plate
Load to Press on Rear Liner Plate
Hydraulic Press P.T.R.F.
Model cc’s cc’s NM Ft-Lbs Tons Ft-Lbs/ Nm
ULT-30 (D)(S) 5.0 0.30+/-.01 85+/-5 63+/-4 1 20/27 ULT-40(S)(D) & 50(S)(D)(C), 5.6 0.35 -.04 85+/-5 63+/-4 1 20/27
ULT-60(S)(D)(C) 6.2 0.45+/-.05 85+/-5 63+/-4 1 20/27 ULT-70(S)(C)(CH) 8.8 0.70+/-.05 110+/-5 81+/-4 2 40/54 ULT-80 12.0 0.85+/-.05 110+/-5 81+/-4 2 40/54 ULT-90 14.0 1.00+/-.05 150+/-5 110+/-4 3 60/81 ULT-100 21.5 1.60+/-0.1 185+/-10 137+/-7 3 60/81 ULT-130 24.0 1.60+/-0.1 185+/-10 137+/-7 3 60/81 ULT-150 31.5 2.20+/-0.1 200+/-10 148+/-7 3.5 70/95 ULT-180 39.0 3.30+/-0.1 260+/-10 192+/-7 4 80/108
ULT Series Troubleshooting – 17 – Trouble Cause Solution No Shut-off Low Air Pressure Make sure that you have 85 PSI at the tool while running the tool. Low Oil in the Pulse Unit Add .10cc of oil and/or re- tank the Pulse Unit. Air Motor Dry; No Lubrication Lubricate the Air Motor. Loss of Power in the Air Motor Reset the Air Motor. Premature Shut-off Shut-off Valve Ball Pushed into Spring Reset the Ball in the Shut-off Valve Bushing. Too Much Oil in the Pulse Remove .10cc of oil from the Pulse Unit. Spring between the Pulse Unit and the Air Motor Weak or Missing Replace Spring with new one or with a stronger one. Spacer between the Pulse Unit and the Air Motor Missing Replace the Spacer. The Pulse Unit should only move .20mm in the Casing. Too Much Air Pressure Air Pressure should be 85 PSI Dynamic. Low Torque Air Motor Dry; No Lubrication Lubricate the Air Motor. Loss of Power in the Air Motor Reset the Air Motor. Spring between the Pulse Unit and the Air Motor Weak or Missing Replace Spring with new one or with a stronger one. Low Oil in the Pulse Unit Add .10cc of oil and/or re- tank the Pulse Unit. Low RPMs Exhaust Filter Dirty Replace the Filter in the Silencer. Air Motor Dry; No Lubrication Lubricate the Air Motor. Loss of Power in the Air Motor Reset the Air Motor.
Recommended Preventative Maintenance – 18 – It is recommended that after every 200,000 pulsing seconds or 180 days, the fluid in the tool’s pulse unit be changed. At such time, it is also recommended to grease the bearings in the air motor. If the presence of water is noted, it is recommended that a small amount of oil be run through the air motor to wash out any rust residue in the air motor. It is also recommended that after every 400,000 pulsing seconds or 365 days, that a Pulse Unit Repair Kit be installed in the pulse unit. This also allows the inspection of hard parts in the pulse unit.
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