Aimco Brakes Pulse Tool UX UXT Air Motor Repair Manual
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PO Box 16460, Portland, OR 97292-0460 503-2 54-6600 Fax 503-255-2615 UX, UX - T Series Air Motor Repair Manual UX - 450 ~ 612 and Larger UX & UX - T Air Motor, Shut - off Section, and Angle Head www.aimco-global.com
Contents Page Number 1. Recommended Tools Needed for Repair 1 2. Air Motor Repair Fixtures 2 - 3 3. Disassembly and Reassembly of the Air Motor Section 4 UX & UX - T 4. Exploded View of the Air Motor UX - Straight & Small “C” Series 5 UX - 450 ~ 612 6 5. Disassembly and Reassembly of the Air Motor Section UX & UX - T Pistol Grip Handles and Larger “S” & “C” Models 7 6. Exploded View of the Air M otor UX Series 8 UX - T Series 9 7. Disassembly and Reassembly of the Shut - off Section UX - T 10 8. Exploded View of the Shut - off Valve Section UX - T700 ~ T1820 11 9. Repair and Adjustment of Angle Head Pulse Tool 12 - 13 10. Exploded View of the Angle Head Section UX - C Series 14 11. Preventative Maintenance 15
Recommended Tools Needed for Repair 1. One Set T - H andle Metric Allen Wrenches 2. Flat - Bladed Screwdrivers 3. 10 oz. Ball Pee n Hammer 4. One Set Pin Punches 5. One Set O - Ring Picks 6. 6 ” Adjustable End Wrench 7. 12 ” Adju stable 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 - Tite #242 13. CFC Free Degreaser - Cleanser 14. Loc - Tite Accelerator 15. Arbor Press 16. O - Ring Installation Tools 17. Removal of Air Moto r Connector (UX - 450 through UX - 612) 18. Auditor Series Monitor and Transducers with the UFT Joint Simulators 19. Needle 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 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 Fixtures Set in O - Rings 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 - 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 Fixtures f or Removal o f Ball Bearing f or Cylin der Rear Plate Part Number Tools Used With 982 - 033 - 0 - 2 U - 310SD U - 350D U - 350SD 982 - 100 - 0 - 2 U - 410D U - 410S U - 410SD 982 - 401 - 0 - 2 UX - 500 UX - 602 UX - 612 982 - 402 - 0 - 2 UX - 620 UX - 622 UX - 700 982 - 403 - 0 - 2 UX - 800 UX - T800 UXR - T3000S UX - 900 UX - T900 UX - 1000 UX - T1 000 UX - T700 UXR - 3000S 982 - 404 - 0 - 2 UX - 1300 UX - T1300 982 - 951 - 0 - 2 UX - 1400 UXR - 2000S UXR - T2000 UX - 1620 UX - T1400 UXR - 1820 UX - T1620 UXR - 2000 UXR - T1820 982 - 104 - 0 - 2 UXR - 2400S UXR - T2400S
Air Motor Repair Fixtures (cont.) Fixtures for Removal of Ball Bearing for Cylinder Front Plate Part Number Tools Used With 982 - 015 - 0 - 2 U - 310SD U - 350D U - 350SD 982 - 401 - 0 - 2 U - 410 U - 410D U - 410S U - 410SD 982 - 402 - 0 - 2 UX - 500 UX - 602 UX - 612 982 - 403 - 0 - 2 US - 620 UX - 622 982 - 903 - 0 - 2 UX - 700 UX - T800 UX - 800 UX - T900 UX - 900 UX - T700 982 - 951 - 0 - 2 UX - 1000 UX - T1000 982 - 104 - 0 - 2 UX - 1300 UX - T1300 982 - 205 - 0 - 2 UX - 1400 UX - T1620 UX - 1620 UXR - T1820 UXR - 1820 UX - T1400 982 - 960 - 0 - 2 UXR - 2000 UXR - 2000S UXR - T2000 982 - 206 - 0 - 2 UXR - 3000S UXR - T3000S Fixtures for Pressing in of Ball Bear ing for Cylinder Rear Plate Part Number Tools Used With 982 - 033 - 0 - 1 U - 310SD U - 350D U - 350SD 982 - 100 - 0 - 1 U - 410 U - 410D U - 410S U - 410SD 982 - 401 - 0 - 1 UX - 500 UX - 602 UX - 612 982 - 402 - 0 - 1 UX - 622 UX - 620 UX - 700 UX - T700 982 - 403 - 0 - 1 UX - 800 UX - T900 UX - 900 UX - T100 0 UX - 1000 UX - T800 982 - 404 - 0 - 1 UX - 1300 UX - T1300 982 - 103 - 0 - 1 UX - 1400 UXR - 2000S UXR - T2000 UX - 1620 UX - T1400 UXR - 1820 UX - T1620 UXR - 2000 UXR - T1820 982 - 204 - 0 - 1 UXR - 2400S UXR - T2400S 982 - 205 - 0 - 1 UXR - 3000S UXR - T3000S 982 - 033 - 0 - 1 U - 310SD U - 350D U - 350SD Fixtures for Pressing in o f Ball Bearing for Cylinder Front Plate Part Number Tools Used With 982 - 035 - 0 - 1 U - 310SD U - 350D U - 350SD 982 - 401 - 0 - 1 U - 410 U - 410D U - 410S U - 410SD 982 - 402 - 0 - 1 UX - 500 UX - 602 UX - 612 982 - 403 - 0 - 1 UX - 622 UX - 620 982 - 102 - 0 - 1 UX - 7 00 UX - T700 982 - 950 - 0 - 1 UX - 800 UX - T900 UX - 900 UX - T1300 UX - 1300 UX - T800 982 - 103 - 0 - 1 UX - 1000 UX - T1000 982 - 906 - 0 - 1 UX - 1400 UX - T1620 UX - 1620 UXR - T1820 UXR - 1820 UX - T1400 982 - 205 - 0 - 1 UXR - 2000 UXR - 2000S UXR - T2000 982 - 206 - 0 - 1 UXR - 2400S UXR - 3000S UXR - T240 0S UXR - T3000S
Disassembly and Reassembly of the Air Motor Section UX & UX - T A. Straight Handles - UX - 450 ~ UX - 612 Pistol Grip and Smaller C Models Disassembly 1. Remove Front Casing and Pulse Unit. 2. Remove Casing Connector if on the model you are wor king on. 3. Taking a hold of the Rotor and pull the whole Air Motor from the Handle. 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. Inspection of Parts for Wear 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 Rotor for sharp edges in Blade Slots and pitting and grooving on Plate Surface. Light marks can be stoned with a medium oil stone. If d eep markings exist, replace. 6. Inspect the O - rings in the Handle for splitting or chipping, replace if necessary. 7. Thoroughly clean all parts and blow dry. Reassembly 1. Grease Rear Plate Bearing. Pres s into Rear Plate and over the rear of the Rotor at the same time. 2. There should be a small amount of drag between the Rear Plate and the Rotor. Some adjusting may be necessary. 3. Grease Front Plate Bearing and press into Front Plate. 4. Oil Blades and insta ll into 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 the Front Plate down over the Rotor and onto the Cylinder. 7. Holding the Rotor, slide the Air Motor into the Handle. 8. Thread the Ca sing Connector into the Handle. This should be torqued to 25 ft. lbs. 9. Reassemble Pulse Unit and Front Casing onto tool.
Exploded View of the Air Motor UX - Straight & Small “C” Series Part Number Description Par t Number Description 1 2 3 4 5 6 7 8 Casing Connector Front Plate Bearing Front Plate Blades Rotor Roll Pin 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
Exploded View of t he Air Motor (cont.) UX - 450 ~ 612 Part Number Description Part Number Description 1 2 3 4 5 6 7 8 Casing Connector Front Plate Bearing Front Plate Blades Rotor Roll Pin 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.) B. UX & UX - T Pistol Grip Handles and Larger “S” & “C” Models Disassembly 1. Remove the Front Casing and Pulse Unit. In the T - Series, remove the Spacer and P iston R od. 2. Remove the Head Cover and Head Cover Pa cking. In the “C” model, remove the Handle and Handle Packing. 3. Press the Rear Plate and Rotor out the back of the Handle. 4. Remove the Front Plate Bearing. 5. Press the Rotor out of the Rear Plate Bearing and away from the Rear Plate. 6. If s carring on the Front Plate or excessive wear on the Cylinder is present, press t he Front Plate and Cylinder out the rear of the Handl e at the same time by using a Hydraulic Pr ess. Inspection 1. Same as in the UX - 450 through UX - 612 A ir M otor S ection. Reassembly 1. Grease Rear Plate Bearing and press into Rear Plate and onto rear of Rotor at the same time. 2. There should be a small amount of drag between the Rear Plate and Rotor. Some adjustment may be necessary. 3. Grease the Front Plate Bearing and press into the Front Plate. 4. Oil blade and install into Rotor. 5. If the Front Plate and Cylinder were removed from the Handle, then slide the Cylinder down over the Rotor and onto the R ear Plate lining up the Port Holes and Roll Pin. Install the Front Plate bearing sid e - up, down over Rotor and onto the Cylinder. 6. For installation of the Rear Plate and Rotor only, hold the Handle in the vise with the Air Motor Section up. Heat the rear of the Handle for approximately one minute with a Propane Torch , and install the Rear Plate Rotor combination into the Handle, lining up the Roll Pin on the side of the Rear Plate with the Notch in the Handle. 7. When installing the Air Motor as an assembly, heat the Handle about two to three minutes with a Propane Torch. Now install the complete Air Motor into the Handle. Line up the Roll Pin in the side of the Rear Plate with the Notch in the Handle. 8. Install the Head Cover Gasket, Head Cover and the Alle n head bolts. Loc - Tite all bolts with service removable Loc - Tite. Cross - tighten the bolts while rotating the Rotor with the Pulse Unit. 9. On the T - S eries, install the Piston Rod and Spacer. 10. Install Front Casing and Pulse Unit.