Aimco Brakes UFT Series Joint Simulator Operation Manual
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PO Box 16460, Portland, OR 97292-0460 800-852-1368 Fax 800 -582- 9015 www.aimco -global.com UFT Series Joint Simulator Operations Manual
Contents Page Number 1. Operations Instructions for the UFT -S10 and UFT -S16 1 2. Breakdown of the UFT -S Joint Simulator 2 3. Breakdown of the UFT -S10 Joint Simulator 3 4. Breakdown of the UFT -S16 Joint Simulator 4 5. Operations Instructions for the UFT -6, UFT -10, UFT -16 and UFT -24 5 6. Breakdown of the UFT -BC Joint Simulator (Front and Top Views) 6 7. Breakdown of the UFT -6 Joint Simulator 7 8. Breakdown of the UFT -10 Joint Simulator 8 9. Breakdown of the UFT -16 J oint Simulator 9 10. Breakdown of the UFT -24 Joint Simulator 10 11. Maintenance 11 12. Certification of the UFT Joint Simulator 12 13. List of Hexagon Head Bolts 13
- 1 - Operations Instructions UFT-S10 and UFT -S16 These testers are capable of simulating four dif ferent joints: A, B, C, and D ( hard, medium-hard, medium -soft, and soft, respectively). A Joint : C and D valves closed ( clockwise) and the A joint sleeve installed between the Plunger Bushing and the Spindle Nut. B Joint: C and D valves closed (clockwise) and remove the A joint sleeve. C Joint: Open the C valve under the side cylinder one turn (counter -clockwise). The D valve remains closed. D Joint : Open both the C and D valves ( one turn). Changing Bolt Kits To change the bolt : 1. Remove the test bolt. 2. Remove the S pacer and Plunger B ushing. 3. Remove the Allen H ead Bolt that holds the Spindle N ut. This is located on the side of the teste r by the D valve lever. 4. Remove the S pindle Nut. 5. Install the new Spindle N ut. 6. Install the Allen H ead Bolt back through the S pindle Nut. 7. Install the P lunger Bushing, S pacer, and new bolt.
- 2 - Breakdown of the UFT-S Joint Simulator Top View of UFT-S Joint Simulator Side View of UFT -S Joint Simulator
- 3 - Breakdown of the UFT-S10 Joint Simulator Index No. Code No. Description Qt y. Index No. Code No. Description Qt y. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 17 18 19 20 21 21 -1 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 839 -96 5-5 839 -718- 5 839 -285- 5 839 -286- 5 839 -600- 5 840 -318- 5 839 -604- 5 839 -674- 5 839 -546- 5 194 -742- 3 839 -100- 5 839 -359- 5 839 -562- 5 839 -567- 5 839 -560- 5 839 -289- 5 839 -017- 5 839 -545- 5 839 -016- 5 839 -082- 5 944 -003- 0 944 -005- 0 944 -015- 0 944 -316- 0 944 -025- 0 944 -044- 0 945 -005- 0 945 -3 15-0 945 -330- 0 945 -443- 0 945 -94 3-0 946 -972- 0 960 -020- 0 962 -011- 0 962 -013- 0 962 -644- 0 966 -100- 0 Base Setting Plate Rear Plate Cylinder Plunger Pilot Pin Plunger Bushing Cylinder Bushing Piston Oil Plug Valve Spindle Nut (M10) Stopper Bushing ( M10) Piston Spring Guide Front Plate Oil Casing Piston Oil Casing Cover Connecting Screw Supporter Ring (3.0 x 5.0 x 1) Back -up Ring (4.2 x 6 x 1) Back -up Ring (P7) Back -up Ring (P16) Back -up Ring (P24) Back -up Ring (P44) Allen Head Bolt (M3 x 50) Allen Head Bolt (M8 x 1 5) Allen Head Bolt (M8 x 30) Allen Head Bolt (M12 x 20) Hexagon Round Head Bolt (M4 x 8) Hexagonal Bolt (M10 x 35) (UFT) Hexagon Nut (1 -M3) Spring Washer (2- 8S) Spring Washer (2- 12S) Belleville Spring (42 x 14.3 x 2.5) Allen Head Plug (1/8) 2 2 1 1 1 4 1 2 6 2 2 1 1 1 6 1 1 1 1 1 2 2 6 1 1 1 2 4 10 2 2 1 4 14 2 17 1 38 39 39 -1 40 40 -1 41 42 43 44 45 46 47 48 49 51 52 53 54 Option M8 Type 5 8 56 57 5 9 60 61 62 M6 Type 66 64 65 67 68 69 70 966 -102- 0 973 -072- 0 975 -066- 0 975 -552- 0 975 -893- 1 976 -495- 0 976 -706- 0 990 -004- 0 990 -015- 0 990 -024- 0 990 -041- 0 990 -97 0-0 990 -007- 0 990 -908- 0 990 -91 9-0 990 -993- 0 990 -998- 0 990 -972- 0 878 -903- 1 878 -901- 1 878 -902- 1 946 -971- 0 975 -551- 0 990 -906- 0 990 -91 9-0 878 -908- 1 878 -906- 0 878 -907- 0 946 -970- 0 975 -550- 0 990 -904- 0 990 -91 9-0 Allen Head Plug (3/8) Roll Pin ( 2.5 x 12) Spacer (13 x 4.2 x1.5) Spacer (22 x 10.5 x 3) (H) Adjusting Spacer (53 x 48.2 xT) Spring (21 x 65) Spring (33 x 65) O -Ring (P6) O -Ring (P15) O -Ring (P24) O -Ring (P44) O -Ring (SNS -2 ) (NOK) O -R ing ( P9) O -Ring (SNS -10) O -Ring (SNS -2 2) O -Ring (SNS -70) O -Ring (SNS -112) O -Ring (SNS -4) (NOK) Bushing (M8) Plunger Bushing (M8) Spindle Nut (M8) Hexagonal Bolt (M8 x 32) (UFT) Spacer (18 x 8.5 x 2.5) (H) O -Ring (SNS -8) O -Ring (SNS -2 2) Bushing (M6) Pl unger Bushing (M6) Spindle Nut (M6) Hexagonal Bolt (M6 x 30) (UFT) Spacer (14 x 6.5 x 2) (H) O -Ring (SNS -6) O -Ring (SNS -2 2) 1 1 2 1 1 6 6 6 1 1 1 2 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1
- 4 - Breakdown of the UFT-S16 Joint Simulator Index No. Code No. Description Qt y. Index No. Code No. Description Qt y. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 5 1 6 1 7 1 8 19 2 0 2 1 22 23 2 4 2 5 2 6 27 28 29 30 31 32 33 34 35 36 37 839- 965-6 839- 718-6 839- 285-6 839- 286-6 839- 600-6 840- 318-6 840- 604-6 839- 674-6 839- 546-6 185- 807-1 839- 100-5 839- 359-6 839- 562-6 839- 567-6 839- 560-6 839- 289-6 839- 017-6 839- 545-6 839- 016-6 839- 082-6 944- 005-0 944- 032-0 944- 070-0 944- 312-0 944- 316-0 945- 005-0 945- 423-0 945- 429-0 945- 433-0 945- 505-0 945- 942-0 946- 975-0 960- 020-0 962- 012-0 962- 014-0 966- 100-0 966-102-0 Setting Stand Setting Plate Rear Plate Cylinder Plunger Pilot Pin Plunger Bushing (M16) Cylinder Bushing Piston Spacer Valve Spindle Nut Stopper Bushing (M16) Piston Spring Guide Front Plate Oil Casing Pi ston (large) Oil Casing Cover Connecting Screw Back -up Ring (4.2 x 6 x 1) Back -up Ring (P32) Back -up Ring (P70) Back -up Ring (P 12) Back -up Ring (P 16) Allen Head Bolt (M3 x 50) Allen Head Bolt (M10 x 20) Allen Head Bolt (M10 x 35) Allen Head Bolt (M10 x 45) Allen Head Bolt (M14 x 30) Hexagon Round Head Bolt (M4 x 6) Hexagonal Bolt (M16 x 50) (UFT) Hexagon Nut (1- M3) Spring Washer (2- 10S) Spring Washer (2- 14S) Allen Head Plug (1/8) Allen Head Plug (3/8) 2 2 1 1 1 4 1 3 9 2 2 1 1 1 6 1 1 1 1 1 2 1 1 9 1 2 4 6 4 3 2 1 4 14 3 2 1 38 39 40 41 4 2 4 3 4 4 4 5 4 6 47 4 8 4 9 50 51 5 2 5 3 5 4 5 5 5 6 Option M14 Type 57 58 59 60 6 1 6 3 6 4 M12 Type 66 6 7 68 6 9 70 73 74 973- 216-0 839- 019-5 975- 557-0 975- 907-0 976- 561-0 976- 711-0 976- 780-0 990- 010-0 990- 015-0 990- 020-0 990- 032-0 990- 055-0 990- 328-0 990- 914-0 990- 937-0 990- 971-0 990- 972-0 990- 996-0 990- 999-0 878- 777-1 878- 911-1 878- 912-1 946- 974-0 975- 556-0 990- 912-0 990- 937-0 878- 781-1 878- 916-1 878- 917-1 946- 973-0 975- 555-0 990- 911-0 990-937-0 Roll Pin (4 x 16) Spacer (13 x 4.2 x 1.5) Spacer (35 x 16.5 x 3) (H) Adjusting Spacer (68 x 30 x T) Spring (23 x 75) (4.0) Spring (37.5 x 75) (7.0) Spring (64 x 75) (12.0) O -Ring (P 11) O -Ring (P 15) O -Ring (P22 ) O -Ring (P 32) O -Ring (P 70) O -Ring (JW1530 -15 ) O -Ring (SNS -16) O -Ring (SNS -4 6) O -Ring (SNS -3) (NOK) O -Ring (SNS -4) (NOK) O -Ring (SNS -100) O -Ring (SNS -150) Plunger Bushing (M14) Spindle Nut (M14) (S16) Bushing (M14) Hexagonal Bolt (M14 x 50) (UFT) Spacer (30 x 14.5 x 3) (H) O -Ring (SNS -14) O -Ring (SNS -46) Plunger Bushing (M12) Spindle Nut (M12) (S16) Bushing (M12) Hexagonal Bolt (M12 x 45) (UFT) Spacer (26 x 12.5 x 3) (H) O -Ring (SNS -12) O-Ring (SNS-46) 1 2 1 1 9 10 9 9 1 1 1 1 3 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
- 5 - Operations Instructions UFT-6, UFT -10, UFT -16 and U FT-24 Warning 1. Always operate test bolt within specified torque range. 2. Always secure joint simulator before use. Operation Cautions 1. Never change joints without loosening the test bolt. 2. Check the test bolt every 50,000 cycles. 3. Double -ch eck all bolts after changing joints and bolt sizes. 4. Never use sloppy sockets or extensions. 5. Always use Power Driver Sockets per ANSI B107.2. Operation Instructions UFT-6, UFT -10, UFT -16 and UFT -24 There are two joints on these models: A “B” joi nt (medium-hard) and a “C” joint (medium -soft). To change these joints, simply turn the silver knob on the front of the tester clockwise until it stops for the “B” joint and counter - clockwise until it stops for the “C” joint. Changing Bolt Kits UFT-10, UFT -16 and UFT -24 1. Each bolt kit has certain springs that go with them. Please consult the chart below to match the right spring with the size of bolt that you are using. 2. To change bolts: a) Remove the test bolt and Plunger Bushing. b) On the UF T-10 and UFT -16, remove the two Allen Head Bolts from the Spindle Nut located on the back of the testers. Insert the new Spindle Nut and re -install the Allen Head Bolts. c) Install the new bolt and Plunger Bushing. d) Remove the Cylinder Liner Casing Co ver and change out the springs. Reinstall the Cylinder Liner Casing Cover. Model Bolt Size Spring Size Installed Into the Chamber and the Quantity Used UFT-10 M6 48.5 x 120 (8.5) 1 pc. M8 51 x 120 (9.5) 1 pc. M10 51 x 120 (10.0) 1 pc. UFT -16 M12 49 x 120 (9.0) 2 pcs. M14 49 x 120 (9.0) 2 pcs. M16 49 x 120 (9.5) 2 pcs. UFT -24 M18 59 x 115 (11.0) 3 pcs. M20 M20 59 x 115 35.5 x 105 (11.0) (6.6) 3 pcs. 3 pcs. M24 M24 59 x 115 35 x 105 (11.0) (7.0) 3 pcs. 3 pcs.
- 6 - Breakdown of the UFT-BC Joint Simulator Front View Top View
- 7 - Breakdown of the UFT-6 Joint Simulator Index No. Code No. Description Qt y. Index No. Code No. Description Qt y. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 20 -1 21 22 23 24 25 26 27 28 29 30 840 -965- 4 840 -286- 4 840 -600- 4 840 -318- 4 840 -049- 5 840 -604- 4 840 -359- 4 840 -676- 4 840 -546- 4 840 -164- 4 840 -175- 4 840 -107- 5 840 -100- 5 840 -133- 4 840 -166- 4 944 -005- 0 944 -011- 0 944 -027- 0 944 -028- 0 946 -96 9-0 975 -550- 0 945 -010- 0 945 -108- 0 945 -245- 0 945 -325- 0 948 -423- 0 966 -110- 0 973 -008- 0 973 -010- 0 973 -130- 0 973-210-0 Setting Stand Cylinder Plunger Pilot Pin Setting Screw for Pressure Sensor Plunger Bushing (M6) Spindle Nut (M6) Cylinder Liner Piston Retain er Retainer Bushing Valve Lever Valve Valve Wheel Nut Flange Spring Holder Spacer Support Ring (42 x 6 x 1) Back -up Ring (P9) Back -up Ring (P6) Back -up Ring (P28) Hexagon Bolt (M6 x 18) (UFT) Spacer (14 x 6.5 x 2) (H) Allen Head Bolt (M4 x 10) Allen Head B olt (M5 x 8) Allen Head Bolt (M6 x 45) Allen Head Bolt (M8 x 25) Allen Flush Head Screw (M3 x 6) Allen Head Plug (NPT1/16) Roll Pin (2 x 8) Roll Pin (2 x 10) Roll Pin (3 x 30) Roll Pin (4 x 10) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 4 1 1 1 1 1 31 32 33 34 35 36 37 38 39 40 41 42 M 5 Type 45 46 47 48 49 50 M 4 Type 51 52 53 54 55 56 976 -768- 0 990 -004- 0 990 -007- 0 990 -027- 0 990 -912- 0 990 -916- 0 990 -917- 0 990 -928- 0 990 -972- 0 966 -102- 0 878 -850- 1 975 -550- 1 878 -76 3-1 878 -764- 1 946 -968- 0 975 -549- 0 990 -912- 0 990 -917- 0 878 -766- 1 878 -767- 1 946 -967- 0 975 -548- 0 990 -912- 0 990 -917- 0 Spring (52 x 80) (9.0) O -Ring (P6) O -Ring (P9) O -Ring (P28) O -Ring (SNS -14) O -Ring (SNS -18) O -Ring (SNS -24) O -Ring (SNS -38) O -Ring (SNS -4) Allen Head Plug (3/8) Test Socket (10 x 3/8) Spacer (14 x 6.5 x 2) (H) Plunger Bushing (M5) Spindle Nut (M5) Hexagon Bolt (M5 x 17) (UFT) Spacer (12 x 5.5 x 2) (H) O -Ring (SNS -14) O -Ring (SNS -24) Plunger Bushing (M4) Spindle Nut (M4) Hexagon Bolt (M4 x 15) (UFT) Spacer (10 x 4.5 x 2) ( H) O -Ring (SNS -14) O -Ring (SNS -24) 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5 40
- 8 - Breakdown of the UFT-10 Joint Simulator Index No. Code No. Description Qt y. Index No. Code No. Description Qt y. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 28 -1 29 30 31 840 -965- 5 840 -718- 5 840 -286- 5 840 -600- 5 840 -318- 5 840 -049- 5 840 -674- 5 840 -604- 5 840 -359- 5 840 -676- 5 840 -546- 5 840 -905- 5 840 -164- 5 840 -175- 5 840 -906- 5 840 -107- 5 840 -014- 5 840 -100- 5 944 -005- 0 944 -011- 0 944 -017- 0 944 -025- 0 944 -045- 0 945 -214- 0 945 -230- 0 945 -320- 0 945 -967- 0 946 -972- 0 975 -552- 0 966 -110- 0 973 -114- 0 973 -1 26- 0 Setting Stand Setting Plate Cylinder Plunger Pilot Pin Pressure Gauge Stand Screw Cylinder Bushing Plunger Bushi ng (M10) Spindle Nut (M10) Cylinder Liner Piston Cylinder Liner Casing Spring Setter Spring Setter Bushing Cylinder Liner Casing Cover Selecting Dial Valve Body Valve Backup Ring (4.2 x 6 x 1) Backup Ring (P9) Backup Ring (P14) Backup Ring (P24) Backup Ring (P48A) Allen Head Bolt (M6 x 14) Allen Head Bolt (M6 x 30) Allen Head Bolt (M8 x 20) Hexagon Round Head Bolt (M6 x 25) Hexagonal Bolt (M10 x 35) (UFT) Spacer (22 x 10.5 x 3) (H) Allen Head Plug (NPT1/6) Roll Pin (3 x 14) Roll Pin (3 x 26) 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 3 2 2 6 1 3 1 1 1 1 32 33 34 35 36 37 38 39 40 41 42 43 44 45 M8 Type 47 48 49 49 -1 50 51 52 M6 Type 54 55 56 56 -1 57 58 59 976 -767- 0 979 -312- 0 990 -007- 0 990 -014- 0 990 -024- 0 990 -045- 0 990 -904- 0 990 -905- 0 990 -908- 0 990 -913- 0 990 -916- 0 990 -924- 0 990 -972- 0 966 -102- 0 878 -770- 1 878 -771- 1 946 -971- 0 975 -551- 0 976 -766- 0 990 -906- 0 990 -924- 0 878 -773- 1 878 -774- 1 946 -970- 0 975 -550- 0 976 -765- 0 990 -904- 0 990 -924- 0 Spring (51 x 120) (10.0) Inner Snap Ring (IRTW -12) O -Ring (P9) O -Ring (P14) O -Ring (P24) O -Ring (P48A) O -Ring (SNS -6) O -Ring (SNS -7) O -Ring (SNS -10) O -Ring (SNS -15) O -Ring (SNS -18) O -Ring (SNS -30) O -Ring (SNS -4) (NOK) Allen Head Plug (3/8) Plunger Bushing (M8) Spindle Nut (M8) Hexagonal Bolt (M8 x 32) (UFT) Spacer (18 x 8.5 x 2.5) (H) Spring (51 x 120) (9.5) O -Ring (SNS -8) O -Ring (SNS -30) Plunger Bushing (M6) Spindle Nut (M6) Hexagonal Bolt (M6 x 30) (UFT) Spacer (14 x 6.5 x 2) (H) Spring (48.5 x 120) (8.5) O -Ring (SNS -6) O -Ring (SNS -30) 1 1 2 1 1 1 1 1 3 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 45