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Aimco Brakes Pulse Tool AlphaT42 T62 Large Alpha AlphaT Air Motor Repair Manual
Aimco Brakes Pulse Tool AlphaT42 T62 Large Alpha AlphaT Air Motor Repair Manual
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PO Box 16460, Portland, OR 97292-0460 503-254-6600 Fax 503-255-2615 ALPHA - T 42 ~ T62 & 4 5 ~ 61 and Larger ALPHA & ALPHA - T Air Motor, Shut - off Section, and Angle Head Repair Manual www.aimco-global.com
Contents Page Number 1. Tools Needed for Repair 1 2. Air Motor Repair Fixtures 2 - 3 3. Disassembly and Reassembly of the Air Motor Se ction ALPHA - 45 ~ 61 & ALPHA - T42 ~ T62 - Straight & Pistol Handle 4 Exploded View of the Air Motor : ALPHA - 45 ~ 61 & T42 ~ T62 5 ALPHA & ALPHA - T Pistol Grip Handles 6 Exploded View of the Air Motor : ALPHA - 70 ~ 180 & T70 ~ T140 7 4. Disassembly and Reassembl y of the Shut - off Section ALPHA - T42S ~ T47S & ALPHA - T42 ~ T62 8 Exploded View of the Shut - off Valve Section : ALPHA - T42S & T47S 9 Exploded View of the Shut - off Valve Section : ALPHA - T42 & T62 10 ALPHA - T 11 Exploded View of the Shut - off Valve Section : ALP HA - T70 ~ T140 12 5. Repair and Adjustment of the Angle Head Pulse Tool 13 6. Exploded View of the Angle Head Section ALPHA - 70C, 70CH, T70C & T70CH 14 7. Recommended Maintenance 15
Tools Needed for Repair 1. One Set T - handle Metric Allen Wrenches 2. Flat - Blade d 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 Sandp aper 11. Lap Plate 12. Loc - Tit e #242 13. CFC Free Degreaser/ Cleanser 14. Loc - Tite Accelerator 15. Arbor Press 16. Two Torque Wrenches : 0 - 200 ft. lbs. and 50 - 6 00 ft. lbs . 17. Removal of Air Motor Connector ( UX - 450 through UX - 612) 18. Auditor Series Monit or and Transducers with UFT Joint Simulators 19. Need le Nose Pliers 20. Propane Torch 21. Teflon Seal Setter 22. Bearing Removal Jig 23. Bearing Setter
Air Motor Repair Fixtures Fixtures f or Disassembly & Rea ssembly of Casing Connector Part Number Tools Used With 161 - 036 - 6 - 5 ALPHA - 50(S)D ALPHA - 60(S)D ALPHA - 60(S)D 177 - 036 - 6 - 5 ALPHA - 60 ALPHA - 61 ALPHA - T45 ALPHA - T50 ALPHA - 45 ALPHA - 50 Fixtures f or Removal of Ball Bearing for Cylinder Rear Plate Part Number Tools Used With 982 - 401 - 0 - 2 ALPHA - 45 ALPHA - 50 ALPHA - 60 ALPHA - 61 ALPHA - T42 ALPHA - T52 ALPH A - T62 982 - 402 - 0 - 2 ALPHA - T70C ALPHA - 70 ALPHA - T70C ALPHA - T70 982 - 403 - 0 - 2 ALPHA - T80 ALPHA - T90 ALPHA - T100 982 - 404 - 0 - 2 ALPHA - T140 Fixtures f or Removal o f Ball Bearing f or Cylinder Front Plate Part Number Tools Used With 982 - 402 - 0 - 2 ALPHA - 45 ALPHA - 50 ALPHA - 61 ALPHA - T42 ALPHA - T47 ALPHA - T52 ALPHA - T62 982 - 951 - 0 - 2 ALPHA - T100 982 - 950 - 0 - 2 ALPHA - T70(S)(C) (CH) ALPHA - T80 ALPHA - T90 982 - 906 - 0 - 2 ALPHA - T140 ALPHA - 180 Fixtures f or Pressing i n o f Ball Bearing f or Cylind er Rear Plate Part Number Tools Used With 982 - 401 - 0 - 1 982 - 402 - 0 - 1 ALPHA - T70(S) ALPHA - T70(C)(CH) 982 - 403 - 0 - 1 ALPHA - 45 ALPHA - 50 ALPHA - 61 ALPHA - T42 ALPHA - T47 ALPHA - T52 ALPHA - T62 982 - 403 - 0 - 1 ALPHA - T80 ALPHA - T90 ALPHA - T100 982 - 951 - 0 - 1 ALPHA - T140 982 - 203 - 0 - 1 ALPHA - 180
Air Motor Repair Fixtures (cont.) Fixtures f or Pressing i n of Ball Bearing f or Cylinder Front Plate Part Number Tools Used With 982 - 402 - 0 - 1 ALPHA - 45(A) ALPHA - 50 ALPHA - 61 ALPHA - T42 ALPHA - T47 ALPHA - T52 ALPHA - T62 982 - 903 - 0 - 1 ALPHA - T70(S)(C) ALPHA - T70(CH) 982 - 950 - 0 - 1 ALPHA - T80 ALPHA - T90 982 - 906 - 0 - 1 ALPHA - T140 ALPHA - 180 982 - 951 - 0 - 1 ALPHA - T100
Disassembly and Reassembly of the Air Motor Section ALPHA & ALPHA - T 1. ALPHA - 45 ~ 61 and ALPHA - T42 ~ T62 - Straight & Pistol Handle A. Disassembly 1. Remove Front Casing and Pulse Unit. 2. Remove Casing Connector if it is on the model you are working on. 3. Take a hold of the Rotor and pull the whole Air Motor from the Handl e. 4. Remove the Front Plate. 5. Remove the Front Plate Bearing from the Front Plate. 6. Remove the Cylinder. 7. Remove the Blades. 8. Press Rotor out of Bearing and away from Rear Plate. 9. Remove Rear Plate Bearing from the Rear Plate. B. Inspection of Parts for We ar 1. Inspect Blades for splitting and side wear. Replace if worn. 2. Inspect Bearings for side play and knocking. Replace if worn. 3. Inspect Cylinder for waviness. Replace if worn. 4. Inspect Plates for grooving. Light marks can be l apped out using a figure - eight motion with 220 grit sand paper on a Lap Plate. If heavy grooving exists, replace. 5. Inspect the Rotor for any sharp edges in the Blade Slots and pitting and grooving on the Plate Surface. Light marks can be stoned with a mediu m oil stone. If deep m arkings exist, replace. 6. Thoroughly clean all parts and blow dry. C. Reassembly 1. Grease Rear Plate Bearing. Press into Rear Plate and over the rear of the Rotor a t the same time. 2. There should be a small amount of drag between the Rear Plate and th e Rotor. Some adjusting may be necessary. 3. Grease Front Plate Bearing and press into the Front Plate. 4. Oil Blades and install into the Rotor. 5. Slide Cylinder down over the Rotor lining up the po rts on the Rear Plate with the ports on the Cylinder . 6. Set Front Plate down over the Rotor and onto the Cylinder. 7. Holding the Rotor, slide the Air Motor into the Handle. 8. Thread the Casing Connector into the Handle; t his should be torqued to 25 ft. lbs. 9. Reassemble the Pulse Unit and Front Casi ng onto the tool.
Exploded View of the Air Motor ALPHA - 45 ~ 61 & T42 ~ T62 Part Number Description Part Number Description 1 2 3 4 5 6 7 8 Casing Connector Front Plate Bearing Front Plate Blades Rotor Roll Pi n Cylinder Roll Pin 9 10 11 12 13 14 15 Rear Plate Rear Plate Bearing O - Ring Handle Casing Nylon Ball Roll Pin Nylon Ball
Disassembly and Reassembly of the Air Motor Section (cont.) 2. ALPHA & ALPHA - T Pistol Grip Handles A. Disassembly 1. Remove the Front Casing and Pulse Unit. O n the T - Series, remove the Spacer and P iston Rod. 2. Remove the Hea d Cover and Head Cover Packing. 3. Hand Press the Air Motor out of the Casing. 4. Remove the Front Plate and the Front Plate Bearing. 5. Remove the C ylinder and Blades from the Rotor. 6. Press the Rotor out of the Rear Plate Bearing and away from the Rear Plate. B. Inspection 1. Same as in the ALPHA - 45 ~ 62 - S traight and Pistol H andle. 2. Inspect the O - Rings in the Handle for splitting or chipping and replace if necessary. C. Reassembly 1. Grease the Rear Plate Bearing and press into the Rear Plate and onto the rear of the Rotor at the same time. 2. There should be a small amount of drag between t he Rear Plate and Rotor. Some adjustment may be necessary. 3. Grease the Front Plate Bearing and press into the Front Plate. 4. Oil B lade and install into Rotor. 5. Install the Cylinder down over the Rotor and onto the Rear Plate, lining up the Port Holes and Roll Pin. Install the Front Plate bearin g - side up, down over the Rotor and onto the Cylinder. 6. Install the Air Motor as an assembly into the Handle. Li ne up the Roll Pin on the side of the Rear Plate with the Notch in the Handle and slide the Air Motor into place. 7. Install th e Head Cover G asket, Head Cover, and the Allen head bolts. Loc - Tite all bolts with service removable Loc - Tite. Cross - tighte n the bolts while rotating the Rotor with the Pulse Unit. 8. On the T - s eries, install the Piston Rod and Spacer. 9. Install Front Casing and Pu lse Unit.
Exploded View of the Air Motor ALPHA - 70 ~ 180 & T70 ~ T140 Part Number Description Part Number Description 1 2 3 4 5 6 7 O - Ring Front Plate Bearing Front Plate Cylinder Roll Pin Rear Plate Bearing Head Cover Packing 8 9 10 11 1 2 13 Handle Casing Rotor Blades Rear Plate Roll Pin Head Cover