Group 4 Disassembly and Assembly: 1. Brake Pump

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GROUP 4 DISASSEMBLY AND ASSEMBLY

1. BRAKE PUMP
1) STRUCTURE

Fan pump

0
16

17
8

10
12
5

15

21
5
23

15

12
11

19

18
22
11 4

Brake pump
7407ABS19

3
4
5
8
10

Rear cover
Plate
Plate
Screw bolt
Washer

11
12
15
16
17

Seal
Seal
Back up ring
Flange
Shaft

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18
19
21
22
23

Spring
Dowel pin
Drive gear
Driven gear
Body

2) DISASSEMBLY

Fan pump

0
16

17
8

10
12
5

15

21
5
23

15

12
11

19

18
22
11 4

Brake pump

7407ABS19

Before disassembling ensure that the unit itself, bench and tools are thoroughly clean.
(1) Lightly mark the rear cover(3), body(23) and flange(16) to ensure reassembly in the correct
position.
(2) Remove the bolts(8) and separate the brake pump unit from the fan pump using a soft faced
hammer.
(3) Remove splined shaft(17).
(4) Remove the flange(16) from the body(23), free from flange using a soft faced hammer.
(5) Remove the back up ring(15), the seal element(11) and the body seal(12).
(6) Remove the rear cover(3) from the body(23).
(7) Remove the back up ring(15), the seal element(11) and the body seal(12).
Before removing the internal components each plate(4,5) must be marked to denote its location
within the body. On the plain area of the bush away from the seal location, lightly mark.
(8) With the unit laying on its side grasp hold of the drive gear(21) and pull it squarely out of the
body(23) bringing the plate(4,5) with it.
(9) Remove the driven gear(22) and the remaining plate(4,5).
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3) INSPECTION AND REPAIR


(1) Assessment
Each components should be thoroughly cleaned, carefully examined and assessed for suitability
re-use. Below is a guide for inspecting the various components.
(2) Body
Inspect the body bore cut-in where both gears wipe into the body.
The body can only be re-used if the cut-in is bright and polished in appearance and the depth
does not exceed 0.15mm(0.006").
The body should be replaced if the surface is scored, has a matt appearance or shows signs that
the tip of the gears have dug in and torn away the surface material.
The body should be inspected to ensure that there is no superficial damage which may adversely
effect performance or sealing. Pay particular attention to the port threads and body seal
recesses.
(3) Plate and cover
The inner surfaces should be inspected to ensure that there is no unusual wear or scoring in the
regions where the body seals and back up rings contact, which result in external leakage.
Check the shaft seal recess for scoring or damage that could result in oil leakage around the
outer diameter of the shaft seal. Replacement shaft seals can be refitted with Loctite hydraulic
sealant to overcome slight damage in this area.
(4) Bushes
The side faces which abut the gears should be perfectly flat showing no sign of scoring.
Characteristically there are bright polished areas on this surface caused by loading against the
gear side faces, which is often more pronounced on the low pressure side. The bush should be
replaced if there is any general scoring or fine scoring with a matt appearance or tearing of the
surface material. Often there is a witness where the tips of the opposing gears have wiped an
overlap reassembling a half moon shape. There must be no noticeable wear step as it is critical
that the bush side face is completely flat to the gear side face.
The bearing liners are acceptable providing that they are not scored or show other damage.
The general outside area of the bush should not show any prominent signs of wear.
(5) Gears
The gear side faces should be examined for bruising or scoring. Often operation on
contaminated fluid shows scoring between the root of the gear and the journal undercut, which
leaves a wear step. If a wear step can be felt, coincidental with the root diameter, by drawing a
sharp pointed tool across the surface from the undercut outwards towards the tip of the gear,
then the gear is unserviceable.
The gear teeth should then be carefully examined to ensure that there are no signs of bruising or
pitting.
The journal bearing surfaces should be completely free from scoring or bruising. The surface
should appear highly polished and smooth to touch.
Examine the area where the shaft seal lips run on the drive shaft, this shows up as a polished
ring or rings. If a noticeable groove can be felt or there is scoring the shaft should be replaced.
Provided the drive shaft is not damaged from the drive-coupling and the gears have not been
harmed as described above, then the gears can be re-used. If, however, the gears are
damaged they must be replaced as a matched pair.
As a matter of good practice, when pumps have been disassembled, all the seals should be
replaced. It is most important that only the genuine seals are used.
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4) ASSEMBLY

Fan pump

0
16

17
8

10
12
5

15

21
5
23

15

12
11

19

18
22
11 4

Brake pump

7407ABS19

Ensure that all parts are perfectly clean and lightly lubricate the bushes and gears with hydraulic
oil(Ensure body seal recess and end faces remain free from oil). This will assist with their
assembly when they are later fitted into the body.
(1) Refit the plate(4,5) into the undowelled end of the body(23) from where they were removed.
(2) Place the rear cover(3) against the body(23) and then stand the assembly on the cover so that the
hollow dowels are uppermost, i.e. the plate should be at the bottom with the plates against the
cover.
(3) Fit the drive shaft(21) and driven gear(22) back into their original positions in the body(23).
(4) Refit the plate bushing(4,5) into their original bores.
(5) Fit the new body seal(12).
(6) Fit the new seal element(11) and back up ring(15) to the plate.
(7) Carefully refit the flange(16) to the body(23). If the flange(16) is not fitted squarely the seal(11)
may become misplaced and trapped, resulting in internal damage if the unit is run in this
condition.

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ASSEMBLY

Fan pump

0
16

17
8

10
12
5

15

21
5
23

15

12
11

19

18
22
11 4

Brake pump

7407ABS19

(8) Fit shaft(17) to the flange(16).


(9) Holding the whole unit together carefully turn it over, making sure it is supported on the spacer
flange(16) not the shaft.
(10) Slide off the rear over and fit seals as in(5) and (6) above.
(11) Fit the rear cover(3), taking care not to dislodge the seal(11) and bolt(8) the unit together.
Tightening torque : 7.1kgfm(51lbfft)
Pour a small amount of oil into a port and check that the shaft can be rotated without undue force
using a smooth jawed hand wrench hooked around the shaft or a suitable half coupling locked
against the key.

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5) RUNNING-IN

Pressure gauge

Test unit

Microbic
filter

Variable
restrictor

Flow
meter
Relief valve
Strainer
Tank

(730TM-3C) 4-48

(1) A unit which has been re-assembled with either new gears, bushes or body, must be carefully runin before it is subjected to full working conditions.
(2) Ideally this should be done on a test rig(See figure) where pressure can be gradually applied and
any wipings from the body cut-in arrested by filters.
(3) It is recommended that the unit is run-in at 1500rpm, initially, at zero pressure for one minute then
in stages with the pressure increased by 500psi every minute, until maximum rated pressure has
been attained. Frequently check the system temperature, ensuring that it does not exceed the
maximum permissible figure of 80
C. If the temperature exceeds the system or unit specification
the test must be delayed and operated off-load until acceptable temperatures are obtained.

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