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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   
    						
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