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. VC-101-2A Vacuum Tank  
17. VCE-1-1 Vacuum Extractor 
 
18. 1cc Glass Syringe  
19. Large Needle For Syringe  
20. Two Torque Wrenches 0-200 ft. lbs.  
 
21. Universal Repair Fixture  
22. Pulstar Pulse Unit Fluid   
23. O-Ring Installation Tools  
24. Removal of Air Motor Connector 
(UX-450 through UX-612)  
25. UTA-204 and UMS/Joint Simulators UFTs  
26. Needle Nose Pliers  
27. Propane Torch  
28. Teflon Seal Setter  
29. Bearing Removal Jig  
30. Bearing Setter  
						

							 
  - 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 UBP-7 UBP-T7 
 
Jig for Disassembly & Assembly of Casing Connector  
Part 
Number 
 
Tools Jig is Used With 
196-294-6-5 U-310SD    
192-035-4-5 U-350D U-350SD   
177-036-6-5 UX-450 &  
ALPHA-60 
UX-500 &  
ALPHA-T45 
UX-612 &  
ALPHA-T50 
ALPHA-50 
 
Jig for Setting Torque Adjuster  
Part 
Number 
 
Tools Jig is Used With 
195-907-3-1 UX-1000 UX-1300 UX-1400 UX-1620 
 
Vacuum Filler Tank  
Part 
Number 
 
Tools Jig is Used With 
VC-101-2A All Models 
 
Glass Syringe  
Part 
Number 
 
Tools Jig is Used With 
188-902-0-2 (1cc) All Models 
915-176-0 (3cc) All Models 
J17416GX3 (Needle) All Models  
						

							 
  - 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 UXR-2400S UXR-2400S UX-800 
 
Jig for Placing Anvil C/W Driving Blades into Liner  
Part 
Numbers 
 
Tools Jig is Used With 
190-440-6-1 
190-440-6-0 
UX-500 
UX-622 
UX-602 
 
UX-612 UX-620 
194-440-2-1 
194-440-2-0 
UX-700 UX-800 UX-T700 UX-T800 
194-440-3-1 
194-440-3-0 
UX-900 UX-T900   
194-440-6-1 
194-440-6-0 
UX-1000 UX-1300 UX-T1000 UX-T1300 
195-440-6-1 
195-440-6-0 
UX-1400 UX-1620 UX-T1400 UX-T1620 
 
Universal Pulse Unit Repair Fixture 
 
Part 
Number 
 
Tools Jig is Used With 
PTRF-1-1 All Models 
 
Vacuum Extractor 
 
Part 
Number 
 
Tools Jig is Used With 
VCE-1-1 All Models 
 
  
						

							 
  - 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 of the Pulse Unit with the VCE-1-1 Vacuum Extractor.  
4. Set the Liner Casing Setter, located at the rear of the Pulse Unit, onto the correct size pins in the blocks of 
the setter.  Note:  This is left-hand thread.  
5. Place the Pulse Unit assembly onto the correct size base plate and between the clamp plates.  Run the press 
rod down into the setter and secure it with the lock nut.  It is not necessary to put any pressure on the press 
rod.  Tighten the clamp screws thus securing the Pulse Unit.  
6. Set a 1/2 inch breaker bar into the setter.  This is a left-handed thread indicated by an arrow on the Liner 
Casing Setter.  
7. Loosen and remove the Liner Casing Setter.  Remove the Pulse Unit from the repair fixture.  
8. Remove the Rear Liner Plate.  
a) If suction is too great, tap the drive end of the Anvil on bench and loosen Rear Liner Plate.  
b) Remove the two locator pins from the rear of Liner.   
9. Rotate the Anvil until the bevel lines of the Anvil are parallel with the contacting lines inside the Liner.  
Push the Anvil and Driving Blades out of the Liner.  
10. Remove the Front Liner Plate and Liner from the Liner Casing.  Note:  You may have to tap the rear of the 
Liner Casing on the bench top to remove the Front Liner Plate.  
11. Remove the two Locator Pins in the front of the Liner.  
12. Remove all O-rings and Supporter Rings from the parts.  Remove the Anvil, O-ring or Teflon seal and 
Supporter ring, located inside the Liner Casing. 
 
Inspection  
1. Front Liner Plate  
a) If light scarring on the plate surface is present, resurface on Lap Plate in a “figure eight motion” with 
220 grit (wet or dry) sandpaper using honing oil as a buffer.  Note:  All markings must be removed.  
b) If heavy scars or burring are present and cannot be resurfaced to a smooth finish, replace the part as 
needed.  
2. Rear Liner Plate  
a) Do not resurface this plate.  There will be a seating mark from the Anvil and when this gets deeper than 
.05mm in depth, replace the part.  
						

							 
  - 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) If there is heavy scarring (cuts below contour surface) replace it.  
d) Light scarring on contour surface is normal wear.  Clean surface of the Lap Plate by lapping the length 
of the blade and roll with the contour.  
e) A light horizontal groove on the side of the blade is normal wear.  
f) Check the plate ends of the blade for grooving.  If heavy grooving, always replace the blades as a set.  
5. Liner  
a) Inspect inner horizontal and vertical blade seats for scars and burring.  
1. Light scarring is normal wear.   
2. Heavy scars will cause the fluid to pass by the driving blade and the liner will not produce accurate 
pressure for torque output.  Replace.  
6. Torque Adjuster  
a) Check the adjuster for straightness and check the Allen end for cracking, damaged or stripped threads.  
If damage is present, replace.  
7. Liner Casing  
a) Check for internal scars and burring.  
b) Check internal threads for burrs.  
8. Anvil  
a) Check plate surface of Anvil.  If light scarring or uneven wear is present, resurface with medium oil 
stone using honing oil as a buffer.  
b) If heavy scarring is present and cannot be resurfaced smooth, replace Anvil.  
c) If chips or cracking are present, replace Anvil.  
d) If uneven wear from socket is present, replace Anvil.  
e) Check Anvil at contact point with O-ring or Teflon Seal.  If there is an indentation present on Anvil at 
this point, Anvil should be replaced.  
f) Check Anvil for scarring from Anvil bushing.  If heavy scarring is present, replace Anvil.  
1. Thoroughly clean all parts and blow dry.  
2. Replace all O-rings, Springs, Supporter Rings, and Teflon seals.  This can be easily done by 
purchasing a Pulse Unit Repair Kit.  
						

							 
  - 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 Liner.  
6. Install the two long Locating Pins into the Liner, and install the Front Liner Plate with the five holes down 
towards the Liner. 
 
7. Install Rear Plate O-ring. 
 
8. Install the Anvil Sleeve for the Teflon Seal.  Note:  There is an Anvil Sleeve for the 1/4 inch hex Anvil and 
the 3/8 inch square Anvil.  
9. Using the Teflon Seal Insertion Tool, insert the Teflon Seal into the front of the Liner Casing on the UX-450, 
500, and 612.  Insert the O-Ring and Supporter Ring on the ALPHA-45, 50, and 60. 
 
10. Install the Liner Casing making sure to line the holes in the Liner Casing with the Oil Fill Screw hole and 
Torque Adjuster hole in the Front Liner Plate.  
11. Clean all oils from the threads of Liner Setter and Liner Casing.  Lightly coat the threads with a good 
cleaner/degreaser.  Put a light coat of a good quality thread locker on the threads of the Liner setter and 
thread it into the Liner Casing.  
12. Set the Liner Casing Setter, located at the rear of the Pulse Unit, onto the correct size pins in the blocks of 
the setter.  Note:  This is left-hand thread. 
 
13. Place Pulse Unit assembly onto the correct size base plate and between the clamp plates.  Run the press rod 
down into the setter and secure it with the lock nut.  It is not necessary to put any pressure on the press rod.  
Tighten the clamp screws securing the Pulse Unit.  
14. Set a 1/2 inch torque wrench into the setter and tighten the Liner Setter to the recommended torque shown 
on the chart.  
15. Remove the Pulse Unit from the repair fixture. 
 
Fluid  
1. Recommended fluid is AIM/Uryu Pulse Unit Fluid part number Pulstar. 
 
Hand and Vacuum Tank Filling Procedure  
1. Rotate the Anvil until the Driving Blade is visible in the Oil Filler Opening, then turn the Anvil 1/8 of a 
turn.  This places the Driving Blades at an open position. 
 
2. The Pulse Unit is now set for maximum fill.  Any measurable change in fluid level will affect the torque 
output and the consistency of the tool.   
						

							 
  - 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 Syringe with fluid and again purge all air bubbles.  
7. Remove the Pulse Unit from the Vacuum Tank.  
8. Install the Torque Adjuster and the Snap Ring.  Turn Torque Adjuster back up against the Snap Ring.  
Note:  This is the smaller of the two threaded holes. 
 
9. Rotate Anvil until Driving Blade is again visible in Oil Filler Opening and turn Blade 1/8 of a turn from 
opening.  
10. Fill 1cc Syringe with 0.5cc of fluid for accurate drawing of fluid.  
11. Wipe off excess fluid from the top of the unit.  The oil level should be at the top of the Oil Filler Plug Hole 
before drawing. 
 
12. Using the 1cc Syringe, draw out the specified amount of fluid per specifications for each model (see chart). 
 
13. Thread Oil Filler Plug into hole and tighten.  
14. You are now ready to test the Pulse Unit. 
 
Torque Adjustment  
1. To properly adjust the torque:  Turn the Adjuster clockwise using a 1.5mm Allen wrench until the Adjuster 
Valve bottoms-out then back off one turn (counter-clockwise) for maximum torque.  
2. Reverse procedure for minimum torque.  Note:  Never leave the adjuster in the bottom-out position, as this 
will cause erratic torque and vibration.