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Aimco Brakes Pulse Tool ULT Series Repair Manual

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    							PO Box 16460, Portland, OR  97292-0460  503-254-6600  Fax 503-255-2615 
     
     
     
     
     
    ULT Series Repair Manual 
     
     
     
     
     
     
     
     
     
     
     
     
     
      
     
     
      ISO 9001: 2015 Certified  
    						
    							– 2 – 
    Contents 
     Page 
     Number 
     
    1. Recommended Tools 2 
    2. Special Repair Fixtures 3-5 
    3. Disassembly and Reassembly of the Pulse Unit 6-10 
    4. Disassembly and Reassembly of the Air Motor 11-13 
    5. Disassembly and Reassembly of the Shut-off Valve Section 14-15 
    6. Fill & Draw Sheet 16 
    7. Troubleshooting 17 
    8. Preventative Maintenance 18 
     
     
     
    Recommend 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 
      
    						
    							Special Repair Fixtures for Repair of ULT Series Tools 
    – 3 – 
    Part Number  Tool Model 
    Disassembly and Reassembly of Valve Cover 
    145-019-6-5 ULT-30D, 40, 50 & 60 
    147-019-6-5 ULT-70 & 80 
    147-019-8-5 ULT-90 & 100 
    130-019-2-5 ULT-130 & 150 
    128-019-2-5 ULT-180 
    Disassembly and Reassembly of Casing Connector 
    144-036-0-5 ULT-30D 
    147-036-2-5 ULT-40, 50 & 60 
    143-036-8-5 ULT-70 
    115-036-3-5 ULT-80 
    147-036-8-5 ULT-90 
    148-036-2-5 ULT-100 
    130-036-2-5 ULT-130 
    130-036-4-5 ULT-150 
    Insert of the Driving Blades 
    144-440-0-0 
    144-440-0-1 ULT-30D 
    190-440-6-0 
    190-440-6-1 ULT-40, 50 & 60 
    194-440-2-0 
    194-440-2-1 ULT-70 
    115-440-3-0 
    115-440-3-1 ULT-80 
    194-440-3-0 
    194-440-3-1 ULT-90 
    194-440-6-0 
    194-440-6-1 ULT-100 
    130-440-2-0 
    130-440-2-1 ULT-130 
    130-440-4-0 
    130-440-4-1 ULT-150 
    128-440-2-0 
    128-440-2-1 ULT-180 
     
       
    						
    							Special Repair Fixtures for Repair of ULT Series Tools 
    – 4 – 
    Part Number  Tool Model 
    Anvil Sleeve for Installation of SU-Ring 
    178-319-8-1 ULT-40, 50, 60 & 70 
    194-319-3-1 ULT-90 
    178-350-9-1 ULT-40D, 50D & 60D 
     
    TM-Type Tools 
    Part Number  Tool Model 
    Disassembly and Reassembly of Valve Cover 
    851-017-1-5 ULT-30D, 40, 50 & 60 
    851-007-1-5 ULT-70 
    851-011-1-5 ULT-90 
     
    Repairing with the PTRF 
    Part Number  Tool Model 
    Disassembly and Reassembly of Liner Casing Setter 
    PTRF-039 ULT-40, 50, 60 & 70 
    PTRF-040 used with the PTRF-039  ULT-90 
    PTRF-041 used with the PTRF-039  ULT-100 
    PTRF-042 used with the PTRF-039   ULT-30D 
    PTRF-044 used with the PTRF-039   ULT-130 
    PTRF-045 used with the PTRF-039   ULT-150 
    PTRF-046, PTRF-047 used with the PTRF-039 ULT-180 
       
    						
    							Special Repair Fixtures for Repair of ULT Series Tools 
    – 5 – 
    Repairing Without the PTRF 
    Part Number  Tool Model 
    Stand to Hold the Pulse Unit 
    144-905-0-3 ULT-30D 
    145-905-6-3 ULT-40, 50 & 60 
    194-905-0-3 ULT-70 
    194-905-3-3 ULT-80 
    147-905-8-3 ULT-90 
    148-905-2-3 ULT-100 
    194-905-4-3 ULT-130 
    130-905-4-3 ULT-150 
    128-905-2-3 ULT-180 
    Disassembly and Reassembly of Liner Casing Setter 
    144-906-0-5 ULT-30D 
    147-906-2-5 ULT-40, 50 & 60 
    147-906-6-5 ULT-70 
    147-906-3-5 ULT-80 
    147-906-8-5 ULT-90 
    148-906-2-5 ULT-100 
    130-906-2-5 ULT-130 
    130-906-4-5 ULT-150 
    128-906-2-5 ULT-180 
    Press Bar for Rear Liner Plate 
    197-901-7-9 ULT-30D 
    196-901-4-9 ULT-40, 50 & 60 
    190-901-6-9 ULT-70 
    143-901-9-9 ULT-80 & 90 
    194-901-2-9 ULT-100 
    194-901-6-9 ULT-130 & 150 
    195-901-9-9 ULT-180 
      
    						
    							Disassembly and Reassembly of Pulse Unit 
    – 6 – 
    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.  Be 
    sure  not  to  lose  the  Adjustment 
    Spacer,  Spring,  and/or  Oper-
    ating  Rod  that  are  between  the 
    Handle and Pulse Unit. 
    3. Remove  the  Oil  Fill  Plug  and 
    extract  all  of  the  oil  with  the 
    VCE-1-1  from  the  Pulse  Unit. 
    Note: The  Oil  Fill  Plug  on  the 
    ULT-30D  is  in  the  Rear  Liner 
    Plate. 
    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-
    041,  PTRF-042  or  Disassembly 
    and  Assembly  of  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,  Driving 
    Blade  Rollers,  Relief  Valve 
    Spring, Relief Valve Ball, Check 
    Valve  Spring,  and  Check  Valve 
    Ball.  Now  remove  the  Piston 
    from the Rear Liner Plate. 
    6. Remove  the  Front  Liner  Plate 
    and Liner from the Liner Casing. 
    You can use the Anvil with a set 
    of V-Blocks 
    on  the  Arbor  Press  by  placing 
    the Anvil driver end-first through 
    the  Front  Liner  Plate  and 
    pressing on the back of the Anvil 
    to  push  the  Front  Liner  Plate 
    and  Liner  out  of  the  Liner 
    Casing. Note: Always  make 
    sure  that  the  Front  Liner Plate 
    and Liner come out of the Liner 
    Casing as one piece or you may 
    cause  serious  damage  to  the 
    Liner  Casing.  Never  push  too 
    hard on the Arbor Press. Always 
    push  the  Front  Liner  Plate  and 
    Liner back and forth in the Liner 
    Casing  until  the  Front  Liner 
    Plate  and  Liner  move  freely 
    from the Liner Casing.  
    7. Separate  the  Front  Liner  Plate 
    and  Liner. Note: On  the  ULT-
    30D,  40,  50  &  60  series  tools, 
    the Front Liner Plate is made up 
    of  two  pieces:  the  Front  Liner 
    Plate  and  the  Liner  Casing 
    Spacer.  
    8. Remove the Relief Valve Spindle 
    (left-hand  thread),  Relief  Valve 
    Pin,  Relief  Valve,  Accumulator, 
    Accumulator Spring, and Locator 
    Pins from the Liner.  
    9. Remove  all  O-rings  and  Sup-
    porter 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.  
    Disassembly of Pulse Unit  
    						
    							Disassembly and Reassembly of Pulse Unit 
    – 7 – 
    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  tool  plus  dash  PRK  (i.e., 
    ULT-70-PRK). 
    2. Lubricate  all  O-rings  with 
    Pulstar Oil. 
    3. Install  the  O-ring  on  the  Relief 
    Valve  using  the  O-ring  Install 
    Fixture  and  install  the  Relief 
    Valve into the Liner lining up the 
    slot in the Relief Valve with the 
    hole in the Liner and install the 
    Relief  Valve  Pin. Note: Be 
    careful  not  to  cut  the  O-ring  on 
    the Relief Valve. 
    4. Install  the  Accumulator  O-ring 
    and  Supporter  Ring  onto  the 
    Accumulator  using  an  O-ring 
    Install  Fixture  and  install  the 
    Accumulator  Spring  and 
    Accumulator into the Liner. 
    5. Install  the  Relief  Valve  Spindle 
    into the Relief Valve and install 
    the  O-ring  on  the  Relief  Valve 
    Spindle  (left-hand  thread)  and 
    Supporter  Ring  into  the  Front 
    Liner  Plate. Note: The  Sup-
    porter  Ring  is  not  used  on  the 
    ULT-40, 50 & 60.  
    6. Install two Locator Pins into the 
    front of the Liner. 
    7. Install  the  Anvil  SU-ring  and 
    Supporter  Ring  into  the  Front 
    Liner Plate and install the Front 
    Liner  Plate  onto  the  Liner. 
    Note: Make sure that you work 
    the Relief Valve  Spindle O-ring 
    up into the Front Liner Plate by 
    turning the Relief Valve Spindle 
    back  and  forth. Note: On  the 
    ULT-30D,  40,  50  &  60  series, 
    you  install  the  Liner  Casing 
    Spacer  onto  the  Liner.  Install 
    the  Front  Liner Plate  after  the 
    Anvil  and  Driving  Blades  have 
    been installed into the Liner. 
    8. Install  the  Driving  Blade 
    Springs,  Driving  Blades,  and 
    Driving  Blade  Rollers  into  the 
    Anvil and into the Driving Blade 
    Install Fixture.  
    9. Put  the  proper  Anvil  Sleeve 
    Fixture over the drive end of the 
    Anvil  and  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. 
    10. Install two Locator Pins into the 
    rear  of  the  Liner,  the  Check 
    Valve  Spring  and  Check  Valve 
    Ball  into  the  back  of  the  Anvil 
    and  the  Relief  Valve  Ball  and 
    Relief  Valve  Spring  into  the 
    back  of  the  Relief  Valve  in  the 
    Liner. 
     
    Assembly of Pulse Unit  
    						
    							Disassembly and Reassembly of Pulse Unit 
    – 8 – 
    11. Install the O-ring onto the Rear 
    Liner Plate and install the Rear 
    Liner  Plate  onto  the  Liner. 
    Note: If the Check Valve Cover 
    was  removed  from  the  Rear 
    Liner  Plate  when  reinstalling 
    the  Check  Valve  Cover  back 
    into the Rear Liner Plate, make 
    sure that the hole in the side of 
    the  Check  Valve  Cover  is  180 
    degrees  out  from  the  hole 
    inside  of  the  Rear  Liner  Plate, 
    90 degrees out on the ULT-150 
    and ULT-180 only, and apply a 
    light  coat  of  Loctite  603  to  the 
    Check  Valve  Cover  before 
    installing. 
    12. Holding the hex end of the Rear 
    Liner  Plate  in  a  vise,  install  the 
    Front  Liner  Plate  O-ring  and 
    now  install  the  Liner  Casing 
    over  the  Anvil  and  onto  the 
    assembly. 
    13. 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  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. 
    14. Now,  using  the  PTRF-1-1  and 
    following  the  Fill  and  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. 
    15. 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,  fill  the  Rear  Liner 
    Plate with Pulstar oil, and insert 
    the  Piston  stepped-end  down 
    into  the  Rear  Liner  Plate.  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. Note: 
    The  ULT-30D  goes  into  the 
    Tank Anvil-side down. 
    16. Now,  cycle  the  Vacuum  Fill 
    Tank. Note: The  gauge  on  the 
    tank  should  read  29  in.Hg.  or 
    above. 
    17. 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. 
    18. Install  the  Purple  Cushion  onto 
    the  front  of  the  Pulse  Unit.  
    						
    							Disassembly and Reassembly of Pulse Unit 
    – 9 – 
    Make  sure  that  the  Adjusting 
    Spacer,  Spring,  and  Operating 
    Rod are back in the Handle and 
    install  the  Pulse  Unit  and 
    Casing  onto  the  Handle. Note: 
    The torque for the Front Casing 
    is 16-24 Nm for the ULT-30D ~ 
    ULT-80, 25-38 Nm for the ULT-
    90 ~ ULT-150 and 13-19 Nm for 
    the ULT-180. Apply Loctite 222 
    to  threads  on  the  Casing 
    Connector. 
    19. You  are  now  ready  to  test  the 
    tool. 
      
    						
    							Disassembly and Reassembly of Pulse Unit 
    – 10 – 
    ULT-Pulse Unit 
     
    Part 
    Number Description Part 
    Number Description 
    1 Liner Casing 19 Locator Pin 
    2 Front Liner Plate O-Ring 20 Anvil Supporter Ring 
    3 Front Liner Plate 21 Anvil SU-Ring 
    3A Liner Casing Spacer 22 Accumulator 
    4 Torque Adjuster O-Ring 23 Accumulator O-Ring 
    5 Torque Adjuster Supporter 
    Ring 
    24 Accumulator Supporter Ring 
    6 Torque Adjuster 25 Accumulator Spring 
    7 Relief Valve Pin 26 Liner 
    8 Relief Valve 27 Anvil 
    9 Relief Valve O-Ring 28 Accumulator Cover 
    10 Relief Valve Ball 29 Driving Blade Spring 
    11 Relief Valve Spring 30 Check Valve Spring 
    12 Locator Pins 31 Check Valve Ball 
    13 Anvil 32 Check Valve Cover 
    14 Driving Blade 33 Rear Liner Plate 
    15 Driving Blade Roller 34 Rear Liner Plate O-Ring 
    16 Oil Plug 35 Piston 
    17 Oil Plug Supporter Ring 36 Piston O-Ring 
    18 Oil Plug O-Ring 37 Liner Casing Setter  
    						
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