Aimco Brakes Pulse Tool UXT UXRT AlphaT Series Pulse Unit Repair Manual

							 
 
 
 
 
 
 PO Box 16460, Portland, OR  97292-0460  503-254-6600  Fax 503-255-2615  
 
 
 
 
 
 
 
 
 
UX-T, UXR-T and ALPHA-T Series 
Pulse Unit Repair Manual 
 
 
 
 
 
 
 
 
 
 
ISO 9001: 2015 Certified  
						

							 
 
 
Contents 
 
 
 Page 
 Number 
 
1. Recommended Tools 4 
 
2. Pulse Unit Repair Jigs 5-7 
 
3. Disassembly and Reassembly of the Pulse Unit 8-12 
 
4. Fill, Draw & Torque Sheet 13 
 
5. Exploded View of the Pulse Unit 14 
 
6. Recommended Maintenance 17 
 
 
  
						

							 
- 4 -  
 
Recommend Tools 
 
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 of Channel Locks or 
Adjustable Jaw Pliers 
 
9. Medium Honing Stone 
 
10. 220 Grit Wet/Dry Sandpaper 
 
11. Lap Plate 
 
12. Loc-Tite #242 
 
13. Arbor Press 
 
14. VC-101-2A Vacuum Tank 
 
15. VCE-1-1 Vacuum Extractor 
 
16. 1cc and 3cc Glass Syringe 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
17. CFC Free Degreaser/Cleanser 
 
18. Loc-Tite Accelerator 
 
19. Large Needle for Syringe 
 
20. Two Torque Wrenches:  0-200 ft. lbs. and 
50-600 ft. lbs. 
 
21. Universal Repair Fixture 
 
22. Pulstar Pulse Unit Fluid 
 
23. O-Ring Installation Tools 
 
24. Setting in of Torque Adjuster 
 
25. Auditor Series Monitor and Transducers 
with the UFT Joint Simulators  
 
26. Needle Nose Pliers 
 
27. Propane Torch  
						

							 
- 5 -  
 
  
Pulse Unit Repair Jigs 
 
 
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 & Pressing in the Accumulator   Part 
Number 
 
Tools Jig is Used With  
150-972-5-1 
 
ALPHA-T47 
 
ALPHA -T52 
 
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  
						

							 
- 6 -  
 
Pulse Unit Repair Jigs (cont.) 
 
 
Glass Syringe   Part 
Number 
 
Tools Jig is Used With  
188-902-0-2 (1cc) 
 
All Models  
915-176-0 (3cc) 
 
All Models  
195-179-0 (Needle) 
 
All Models 
 
Pulse Unit Fluid   Part 
Number 
 
Tools 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 Used With  
990-319-0-1 
 
U-310SD 
 
U-350D 
 
U-350SD   
990-320-0-1 
 
UX-500 
UX-900 
 
UX-602 
UX-612 
 
UX-620 
UX-622 
 
UX-800 
 
990-320-2-1 
 
UX-700     
990-971-0-1 
 
UXR-1000 
UXR-1820 
 
UX-1300 
 
UX-1400 
 
UX-1620 
 990-972-0-1  UXR-2000  
 UXR-2000S  UXR-2400S  UXR-3000S  
  
						

							 
- 7 -  
 
Pulse Unit Repair Jigs (cont.) 
 
 
Jig For Placing Anvil C/W Driving Blades Into Liner   Part 
Number 
 
Tools 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 
 
195-440-9-1 
195-440-9-0 
 UXR-1820  UXR-T1820   
 
194-440-8-1 
194-440-8-0 
 UXR-2000  UXR-T2000   
 
176-440-5-1 
176-440-5-0 
 UXR-2400S  UXR-T2400S   
 
175-440-2-1 
175-440-2-0 
 UXR-3000S  UXR-T3000S   
 
Universal Pulse Unit Repair Fixture   Part 
Number 
 
Tools Used With  
PTRF-1-1 
 
All Models 
 
Vacuum Extractor   Part 
Number 
 
Tools Used With  
VCE-1-1 
 
All Models 
  
						

							 
- 8 -  
 
Disassembly and Reassembly of the Pulse Unit 
 
UX-T, UXR-T & Alpha-T Series 
 
A. Disassembly/Reassembly of Pulse Unit 
 
1. Remove the front casing from the tool. 
 
2. Remove the Oil Fill Plug and vacuum the oil out of the Pulse Unit with the VCE-1-1 Vacuum 
Extractor. 
 
3. 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 a left-hand thread. 
 
4. Place Pulse Unit assembly onto the correct size base plate and between the clamp plates of the 
PTRF-1-1.  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. 
 
5. Set a 1/2” breaker bar into the setter; this is a left-handed thread indicated by an arrow on the 
Liner Casing Setter. 
 
6. Loosen and remove the Liner Casing Setter.  Remove the Pulse Unit from the repair fixture. 
 
7. 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) Properly discard the oil in the Pulse Unit.  
c) In the UX-T series, remove the Spring and Ball under the Relief Valve.  
d) Remove the Piston from the Rear Liner Plate on the UX-T series.  
e) Remove the Rollers from the Anvil on the UXR-T series. 
 
8. Rotate the Anvil until the bevel lines of the Anvil are parallel with the contacting lines inside the 
Liner.  Push the Anvil out of the Liner to remove the Anvil, Driving Blades, and Springs from 
assembly. 
 
9. Remove the Front Liner Plate and Liner from the Liner Casing.  Note:  Always remove these two 
at the same time or the Front Liner Plate may become lodged in the Liner Casing. 
 
10. On the UX-T and ALPHA-T series, remove the Front Liner Plate from the Liner.  Using a small 
screwdriver, pry between the Torque Adjuster and the Pin in the Liner to separate the Front 
Liner Plate from the Liner. 
 
a) Remove the two Locator Pins in the front of the Liner.  
b) On the ALPHA-T80, remove the snap ring in the front of the Front Liner Plate; on the 
UX-T1620, remove the Snap Ring in the front of the Front Liner Plate by locating a small 
opening by the Oil Filler Plug.  Remove the Spacer, Supporter Ring, and Teflon seal. 
 
11. On both the UX-T and ALPHA-T series, remove the Torque Adjuster from the Liner by turning 
clockwise.  Now remove the Pin that holds the Relief Valve in the Liner and push the Relief 
Valve out the back 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 Front Liner Plate. 
  
						

							 
- 9 -  
 
Disassembly and Reassembly of the Pulse Unit (cont.) 
 
 
B. Inspection 
 
1. Front Liner Plate 
 
a) If light scarring on plate surface is present, resurface on Lap Plate in a figure eight motion 
with 220 grit sandpaper (wet or dry) using honing oil as a buffer.  Note:  All markings must 
be removed. 
 
b) If heavy scars or burring are present and cannot be resurfaced smooth, replace parts as 
needed. 
 
2. Rear Liner Plate 
 
a) If light scarring is present, resurface plate on lap in the same manner as above.  Note:  All 
markings must be removed. 
 
b) Check the connecting hex for wear.  If rounded out, replace and inspect the female hex of 
the rotor in the same manner. 
 
c) If heavy scarring or burrs are present on the plate surface and cannot be resurfaced on Lap 
Plate, replace parts as needed. 
 
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 on Lap Plate by lapping the 
length of the blade and rolling with the contour. 
 
e) Light horizontal grooves on the side of the blade is normal wear. 
 
f) Check 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, liner will not produce 
accurate pressure for torque output.  Replace.  
						

							 
- 10 -  
 
Disassembly and Reassembly of the Pulse Unit (cont.) 
 
 
6. Torque Adjuster/Relief Valve 
 
a) Check the adjuster for straightness; also check Allen end for cracking, damaged, or stripped 
threads.  If damage is present, replace. 
 
b) Check the Ball seat for oblonging. 
 
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 is present, replace Anvil. 
 
d) If uneven wear from socket is present, replace Anvil. 
 
e) Check anvil at contact point with O-ring in front liner plate.  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. 
 
9. Thoroughly clean all parts and blow dry. 
 
10. Replace all O-rings, Springs, Supporter Rings, and Teflon seals.  This can be easily done by 
purchasing a Pulse Unit Repair Kit. 
 
C. Reassembly 
 
1. Using blow gun, clean parts of any remaining solvent or lint. 
 
2. Install the Teflon Seal and Supporter Ring on the UX-T and UXR-T and the O-ring and 
Supporter Ring on the ALPHA-T. 
 
a) UX-T and UXR-T series have a Teflon seal.  Slide skirt down onto Anvil.  On the UX-
T1620, the Teflon seal and Supporter Ring go into the front of the Front Liner Plate.  
Reinstall the Spacer and Snap Ring into the Front Liner Plate on the UX-T1620.  On the 
UXR-T2000, install the Supporter Ring and Teflon seal into the Front Liner Plate, NOT 
onto the Anvil. 
 
b) On the ALPHA-T80, install the O-Ring and the Supporter Ring into the front of the Front 
Liner Plate.  Install the Spacer and Snap Ring into the Front Liner Plate. 
 
3. Install the O-ring onto Relief Valve and install Relief Valve through the back of the Liner, lining 
up the slot in the Relief Valve with the Pin Hole in the Liner.  Install Pin and Torque Adjuster 
into Relief Valve.