Aimco Brakes Pulse Tool UX450 500 612 Alpha45 50 60 Repair Manual

 
 
 
 
 
 
 PO Box 16460, Portland, OR  97292-0460  503-254-6600  Fax 503-255-2615  
 
 
 
 
 
 
UX-450, 500 & 612 and 
ALPHA-45, 50 & 60 Series 
Pulse Unit Repair Manual 
 
 
 
 
 
 
 
 
 
 
 
 
 
ISO 9001: 2015 Certified  

 
 
 
Contents 
 
 
 Page 
 Numbers 
 
1. Recommended Tools Needed for Repair 4 
 
2. Pulse Unit Repair Fixtures 5-6 
 
3. Disassembly and Reassembly of the Pulse Unit 7-10 
 
4. Fill & Draw Sheet 11 
 
5. Exploded View of the Pulse Unit 12-13 
 
6. Recommended Maintenance 14 
 
  

 
  - 4 - 
 
Recommended Tools Needed for Repair 
 
 
1. One Set T-handle Metric Allen Wrenches  
2. Flat-Bladed Screwdrivers  
3. 10 oz. Ball Peen Hammer  
4. One Set Pin Punches  
5. One Set O-Ring Picks  
6. 6” Adjustable End Wrench  
7. 12” Adjustable End Wrench  
8. Medium Pair Channel Locks or Adjustable 
Jaw Pliers  
9. Medium Honing Stone  
10. 220 Grit Wet/Dry Sandpaper  
11. Lap Plate  
12. Loc-Tite #242  
13. CFC Free Degreaser-Cleanser  
14. Loc-Tite Accelerator  
15. Arbor Press  
16....

 
  - 5 - 
 
Pulse Unit Repair Fixtures 
 
 
Jig for Setting Teflon Seal  
Part 
Number 
 
Tools Jig is Used With 
178-319-8-1 
995-512-0-1 
UX-450 
UX-622 
UX-500 
ALPHA-50 
UX-612 
ALPHA-60 
 
178-350-9-2 
995-512-0-1 
UX-450D 
UX-622D 
UX-500D 
ALPHA-50D 
UX-612D 
ALPHA-60D 
 
194-319-3-1 UX-T900 UX-T1000 UX-T1300 ALPHA-90 
199-319-6-1 UX-T1620    
995-500-0-1 UXR-T2000    
 
Jig for Holding and Pressing in the Accumulator  
Part 
Number 
 
Tools Jig is Used With 
155-972-2-1 ALPHA-T45 ALPHA -T50...

 
  - 6 - 
 
Pulse Unit Repair Fixtures (cont.) 
 
 
Pulse Unit Fluid  
Part 
Number 
 
Tools Jig is Used With 
PULSTAR All models except ALPHA-T45, T50, and UBP-7 Series 
SPF-OIL ALPHA-T45, T50, and UBP-7 Series only 
 
Jig Set-In O-Ring  
Part 
Number 
 
Tools Jig is Used With 
990-319-0-1 U-310SD U-350SD U-350SD UX-800 
990-320-0-1 
 
UX-500 
UX-900 
UX-620 
UX-622 
UX-620 
UX-622 
 
990-320-2-1 UX-700   UX-1620 
990-971-0-1  UXR-1000 
UXR-1820 
UX-1400 UX-1400 UXR-3000S 
990-972-0-1 UXR-2000...

 
  - 7 - 
  
Disassembly and Reassembly of Pulse Unit 
 
UX-450, 500, 612 & 622 
ALPHA-50 & 60 
 
 
Disassembly of Pulse Unit 
 
1. Remove the front casing from the tool; all are left-hand thread except for the UX-622.  
2. Turn the Torque Adjuster in until it stops and remove the Snap Ring from the front of the Pulse Unit by 
putting a pick behind the Snap Ring at the Torque Adjuster.  Now remove the Torque Adjuster by turning it 
counter-clockwise.  
3. Remove the Oil Fill Plug and vacuum the oil out...

 
  - 8 - 
 
Disassembly and Reassembly of Pulse Unit (cont.) 
 
 
3. Liner Casing Setter  
a) Wire wheel outer threads to remove old Loc-Tite.  
b) Resurface bottom setting surface (level) using Lap Plate and 220 grit sandpaper.  
4. Driving Blades  
a) Check the contour surface of the blades for scars or burring.  
b) If driving blade is scarred below the contour surface, fluid will pass underneath the blade at contact 
points, resulting in inaccurate pressure in the liner and low torque output.  
c)...

 
  - 9 - 
 
Disassembly and Reassembly of Pulse Unit (cont.) 
 
 
Reassembly  
1. Using blow gun, clean parts of any remaining solvent or lint. 
 
2. Install O-Rings and Supporter Rings onto Torque Adjuster and Oil Fill Screw. 
 
3. Set the Rear Liner Plate onto a 6mm Allen wrench and install the two, short Locating Pins and the Liner.  
Note:  The Liner has no top or bottom.  
4. Install Driving Blades and Springs into Anvil.  Place in Driving Blade Setter.  
5. Install Anvil and Driving Blades into...

 
  - 10 - 
Disassembly and Reassembly of Pulse Unit (cont.) 
 
 
3. Put the Pulse Unit in the Vacuum Tank to purge all air out of the Pulse Unit, proceed to step #7.  If you do 
not have a vacuum tank, proceed to step #4.  
4. Fill the 3cc Syringe with fluid.  Turn Syringe upside-down and push the plunger to purge all air from the 
Syringe. 
 
5. Insert the Needle on the Syringe and insert it into the Oil fill hole.  Fill the Pulse Unit completely with fluid 
from the bottom up, slowly.  
6. Fill 1cc...