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Aimco Brakes Pulse Tool UL Series Repair Manual

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     PO Box 16460, Portland, OR  97292-0460  503-254-6600  Fax 503-255-2615  
      
     
     
     
     
     
     
     
    UL Series 
    Repair Manual 
     
     
     
     
     
     
     
     
     
     
     
    ISO 9001: 2015 Certified  
    						
    							 
     
     
    Contents 
     
     
     Page 
     Number 
     
    1. Tools Needed to Repair the UL Series Tools 4 
     
    2. Special Repair Fixtures for Repair of UL Series Tools 5 
     
    3. Disassembly and Reassembly of the Pulse Unit 6-8 
     
    4. Disassembly and Reassembly of the Air Motor 9-10 
     
    5. Fill & Draw Sheet 11 
     
    6. Troubleshooting and Preventative Maintenance 11 
     
     
     
      
    						
    							 
     - 4 -  
    Tools Needed to Repair the UL Series Tools 
     
     
    1. Set of Picks 
     
    2. Standard Pliers 
     
    3. 6” Open-End Adjustable Wrench 
     
    4. 20” Open-End Adjustable Wrench 
     
    5. Hog Ring Pliers (250G Proto) 
     
    6. Set of Screwdrivers 
     
    7. Set of Punches 
     
    8. Dead Blow Hammer 
     
    9. 13 oz. Ball Peen Hammer 
     
    10. Three Ton Arbor Press 
     
    11. Set of V-Blocks 
     
    12. Three Ton Hydraulic Press (only needed if you are not using the PTRF-1-1) 
     
    13. Lap Plate 
     
    14. Parts Cleaning Tank 
     
    15. Wire Wheel 
     
    16. Service Removable Thread Locker (242 Blue Loctite) 
     
    17. PTRF-1-1 Universal Pulse Unit Repair Fixture 
     
    18. VC-101-2A Vacuum Tank 
     
    19. VCE-1-1 Vacuum Extractor 
     
    20. 1cc Glass Syringe and 0.5cc Glass Syringe 
     
    21. Pulstar Oil 
      
    						
    							 
     - 5 -  
     
    Special Repair Fixtures for Repair of UL Series Tools 
     
     
    Description Part Number  Tool Model 
    Disassembly and Reassembly of Casing Connector 143-036-0-5 UL-30 & 40 
    Disassembly and Reassembly of Casing Connector 147-036-2-5 UL-50 & 60 
    Disassembly and Reassembly of Casing Connector 143-036-8-5 UL-70 
    Disassembly and Reassembly of Casing Connector 115-036-3-5 UL-80 
    Disassembly and Reassembly of Casing Connector 147-036-8-5 UL-90 
    Disassembly and Reassembly of Casing Connector 148-036-2-5 UL-100 
    Disassembly and Reassembly of Casing Connector 130-036-2-5 UL-130 
    Disassembly and Reassembly of Casing Connector 130-036-4-5 UL-150 
    Insert of the Driving Blades 142-440-8-1, 143-440-0-0  UL-30 
    Insert of the Driving Blades 143-440-0-1, 143-440-0-0  UL-40 
    Insert of the Driving Blades 143-440-3-1, 194-440-2-0  UL-50 & 60 
    Insert of the Driving Blades 194-440-2-1, 194-440-2-0  UL-70 
    Insert of the Driving Blades 115-440-3-1, 115-440-3-0  UL-80 
    Insert of the Driving Blades 143-440-9-1, 143-440-9-0  UL-90 
    Insert of the Driving Blades 155-440-0-1, 130-440-2-0 UL-100 
    Insert of the Driving Blades 141-440-0-1, 141-440-0-0 UL-130 
    Insert of the Driving Blades 114-440-8-1, 114-440-8-0 UL-150 
    Anvil Sleeve for Installation of SU-Ring 143-319-0-1 UL-30, 40 & 50 
    Anvil Sleeve for Installation of SU-Ring 178-319-8-1 UL-60 & 70 
    Anvil Sleeve for Installation of SU-Ring 178-350-9-1 UL-50D & 60D 
    Anvil Sleeve for Installation of SU-Ring 194-319-3-1 UL-90 
     Repairing with the PTRF  
    Disassembly and Assembly of Liner Casing Setter PTRF-039 UL-50, 60 & 70 
    Disassembly and Assembly of Liner Casing Setter PTRF-040 used with the  
    PTRF-039  UL-80 & 90 
    Disassembly and Assembly of Liner Casing Setter PTRF-041 used with the 
    PTRF-039 UL-100 
    Disassembly and Assembly of Liner Casing Setter PTRF-043 used with the 
     PTRF-039  UL-30 & 40  
    Disassembly and Assembly of Liner Casing Setter PTRF-044 used with the 
     PTRF-039  UL-130  
     Repairing Without the PTRF  
    Stand to Hold the Pulse Unit 143-902-0-3 UL-30 & 40 
    Stand to Hold the Pulse Unit 143-902-3-3 UL-50 
    Stand to Hold the Pulse Unit 136-905-7-3 UL-60 & 70 
    Stand to Hold the Pulse Unit 117-902-2-3 UL-80 
    Stand to Hold the Pulse Unit 143-902-9-3 UL-90 
    Stand to Hold the Pulse Unit 148-905-2-3 UL-100 
    Stand to Hold the Pulse Unit 141-902-0-3 UL-130 
    Stand to Hold the Pulse Unit 114-902-8-3 UL-150 
    Press Bar for Rear Liner Plate 196-901-4-9 UL-70 
    Press Bar for Rear Liner Plate 143-901-9-9 UL-80 &90 
    Press Bar for Rear Liner Plate 194-901-2-9 UL-100 
    Press Bar for Rear Liner Plate 194-901-6-9 UL-130 &150 
    Disassembly and Reassembly of Liner Casing Setter 143-906-0-5 UL-30 & 40 
    Disassembly and Reassembly of Liner Casing Setter 147-906-2-5 UL-50, 60 & 70 
    Disassembly and Reassembly of Liner Casing Setter 115-906-3-5 UL-80 
    Disassembly and Reassembly of Liner Casing Setter 143-906-9-5 UL-90 
    Disassembly and Reassembly of Liner Casing Setter 148-906-2-5 UL-100 
    Disassembly and Reassembly of Liner Casing Setter 130-906-2-5 UL-130 
    Disassembly and Reassembly of Liner Casing Setter 130-906-4-5 UL-150  
    						
    							 
     - 6 -  
     
    Disassembly and Reassembly of the Pulse Unit 
     
     
    Disassembly 
     
    1. Remove the Front Casing (left-hand thread) from the tool. 
     
    2. Remove the Purple Cushion from the Pulse Unit and the Pulse Unit from the Handle. 
     
    3. Remove the Oil Fill Plug and extract all of the oil with the VCE-1-1 from the Pulse Unit. 
     
    4. Place the Pulse Unit in the PTRF-1-1 or the Stand for Holding Pulse Unit and remove the Liner Casing Setter 
    using the PTRF-039, PTRF-040, PTRF-043, PTRF-044 or Disassembly and Assembly of the Liner Casing 
    Setter (right-hand thread). 
     
    5. While holding the Pulse Unit with the Anvil up, tap on the Anvil with a Dead Blow Hammer to remove the 
    Rear Liner Plate, Anvil, Driving Blades, and Driving Blade Rollers. 
     
    6. Remove the Relief Valve and Locator Pin from the Liner on the UL-60 and up. On the UL-30 ~ 50, remove 
    the Relief Valve from the end of the Anvil and the Locator Pin from the Liner.  
     
    7. Remove all O-rings and Supporter Rings. Clean and inspect all parts. Resurface only those parts having burs 
    on them. If any parts show deep grooving or surface wear, they will need to be replaced.  
     
    Assembly 
     
    1. You will find all O-rings, Supporter Rings, and Springs needed for rebuild of the Pulse Unit in a Pulse Unit 
    Repair Kit (PRK). To order a PRK, you would order the model number of the tool plus dash PRK (i.e., UL-
    70-PRK). 
     
    2. Lubricate all O-rings with Pulstar Oil. 
     
    3. Install the O-ring and Supporter Ring on the Relief Valve using the O-ring Install Fixture and install the 
    Relief Valve into the Liner on the UL-60 and up. On the UL-30 ~ 50, install the Relief Valve into the Anvil.  
    Note: Be careful not to cut the O-ring on the Relief Valve. 
     
    4. Install two Locator Pins into the Liner. 
     
    5. Install the Anvil SU-ring and Supporter Ring into the Anvil.  
     
    6. Install the Driving Blade Springs, Driving Blades, and Driving Blade Rollers into the Anvil and into the 
    Driving Blade Install Fixture. (Notes: Chamfered end of roller goes to the front line plate.) 
     
    7. Install the Anvil into the Liner and through the Front Liner Plate removing the Driving Blade Install Fixture.  
    As you do this, make sure to keep the Nylon piece of the Driving Blade Install Fixture tight against the 
    Anvil. 
     
    8. Install the O-ring onto the Rear Liner Plate and install the Rear Liner Plate onto the Liner. 
     
    9. Clean the threads on the Liner Casing and Liner Casing Setter with a degreaser or Isopropyl Alcohol. Put a 
    small amount of thread locker (i.e., Loctite 242) on the Liner Casing Setter and install into the Liner Casing.  
    Note: If you use Isopropyl Alcohol to clean the threads, it will cause the thread locker to set up in about  
    10-15 minutes. 
      
    						
    							 
     - 7 -  
     
    Disassembly and Reassembly of the Pulse Unit (cont.) 
     
     
    10. Now, using the PTRF-1-1 and following the Fill & Draw sheet, apply the proper amount, press load to the 
    Rear Liner Plate, and tighten the Liner Casing Setter to the proper torque. Note: Make sure that you use the 
    proper Press Cap when applying the press load to the Pulse Unit.  
     
    11. Once you are sure that the thread locker has set up, make sure that the Torque Adjuster is turned all the way 
    out counter-clockwise on the UL-60 and up. On the UL-30 ~ 40, the Torque Adjuster should be flush with 
    the end of the Anvil. Put the Pulse Unit into the VC-101-2A Vacuum Fill Tank, making sure that the Pulstar 
    oil is about one-half of an inch below the oil fill hole on the Pulse Unit. 
     
    12. Now, cycle the Vacuum Fill Tank. Note: The gauge on the tank should read 29 in.Hg. or above. 
     
    13. Now, pull the Pulse Unit out of the Vacuum Fill Tank. Tip the Pulse Unit on its side to remove the excess 
    oil from the top of the Pulse Unit so that it is level with the top of the oil fill hole. Following the Fill & 
    Draw sheet, remove the recommended cc’s of oil from the Pulse Unit and install the Oil Fill Plug. Note:  
    Make sure that you pull up lightly on the plunger of the syringe as you put the needle into the Pulse Unit.  
    This will keep you from displacing the oil out of the Pulse Unit when you put the needle into the Pulse Unit. 
     
    14. Install the Purple Cushion onto the front of the Pulse Unit and install the Pulse Unit and Casing onto the 
    Handle. Note: The torque for the front casing is 16-24 Nm. 
     
    15. You are now ready to test the tool. 
      
    						
    							 
     - 8 -  
     
    Disassembly and Reassembly of the Pulse Unit (cont.) 
     
     
     
    UL Pulse Unit 
     
     
      
     
     
      Part 
    Number 
     
    Description 
     Part 
    Number 
     
    Description 
     1 
    2 
    3 
    4 
    5 
    6 
    7 
    8 
    9 
     Oil Fill Plug 
    Oil Fill Plug O-Ring 
    Liner 
    Anvil Supporter Ring 
    Anvil O-Ring 
    Anvil 
    Driving Blade 
    Driving Blade Roller 
    Locator Pin 
     10 
    11 
    12 
    13 
    14 
    15 
    16 
    17 
     
     Rear Liner Plate 
    Liner Casing Setter 
    Relief Valve Supporter Ring 
    Relief Valve O-Ring 
    Relief Valve 
    Anvil Retainer Pin 
    Driving Blade Spring 
    Rear Liner Plate O-Ring  
    						
    							 
     - 9 -  
     
    Disassembly and Reassembly of the Air Motor 
     
     
    Disassembly 
     
    1. Remove the Casing (left-hand thread) and Pulse Unit from the Handle. 
     
    2. With the Casing Connector Fixture, remove the Casing Connector (left-hand thread) from the Handle. 
     
    3. Remove the Front Air Motor Plate, Rotor, Cylinder, Blades, Rear Air Motor Plate, O-ring, and Rear Plate 
    Spacer from the Handle. 
     
    4. Remove the O-rings from inside of the Handle. 
     
    5. Remove the Bearings from the Front and Rear Air Motor Plates. The Bearing is a press fit into and over the 
    Rotor on the Rear Air Motor Plate. 
     
    6. Clean and inspect all parts. Resurface only those parts having burs on them. If any parts show deep grooving 
    or surface wear, they will need to be replaced.  
     
    Assembly 
     
    1. You will find all Bearings, O-rings, Blades, and Filter needed for rebuild of the Air Motor in an Air Motor 
    Repair Kit (RK). To order an RK, you would order the model number of tool plus dash RK (i.e., ULT-70RK). 
     
    2. Coat one-third of the Bearings with a good-quality grease (i.e., Chevron Moly Grease EP NLG1 2). 
     
    3. Press the Rear Plate Bearing into the Rear Plate and over the Rotor at the same time. Note: You should not 
    be able to see any light between the Rear Plate and the Rotor and the Rotor should turn freely when you 
    have it set right. 
     
    4. Put a light coat of air motor oil on the Blades and install them in the Rotor. 
     
    5. Put the Cylinder down over the Rotor and onto the Rear Plate with exhaust holes up. 
     
    6. Press the Front Plate Bearing into the Front Plate and install the Front Plate onto the Cylinder and Rotor. 
     
    7. Install the O-ring and Rear Plate Spacer onto the Rear Air Motor Plate. 
     
    8. Lightly oil the O-rings and install them into the Handle. 
     
    9. Line up the pin on the side of the Front Plate with the cut-out on the inside of the Handle and install the Air 
    Motor into the Handle. 
     
    10. Install the Casing Connector into the Handle. The recommended torque for the UL-30-80 is 40-50 Nm, the 
    UL-90 and 100 is 45-55 Nm, the UL-130 is 55-65 Nm, and the UL-150 is 60-70 Nm. Make sure to use a 
    good service removable thread locker on the Casing Connector.  
     
    11. Install the Pulse Unit and Casing on the Handle. Make sure to use a good service removable thread locker 
    on the Casing Connector. 
     
    12. The tool is ready to test.  
    						
    							 
     - 10 -  
     
    Disassembly and Reassembly of the Air Motor (cont.) 
     
     
     
    UL Pulse Unit 
     
      
     
     
      Part 
    Number 
     
    Description 
     Part 
    Number 
     
    Description 
     1 
    2 
    3 
    4 
    5 
    6 
    7 
     Casing Connector 
    Front Plate Bearing 
    Front Plate 
    Blade 
    Roll Pin 
    Cylinder 
    Rear Plate 
     8 
    9 
    10 
    11 
    12 
    13 
    14 
     Nylon Ball 
    Rotor 
    Roll Pin 
    Nylon Ball 
    Rear Plate Bearing 
    O-Ring 
    Handle 
      
    						
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