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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. 
    						
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