DIY pump repair nsh 100

• City: Saint Petersburg

Kasappa will not supply such a pump, a week ago I requested it out of interest caused by a message from the vehicle on another forum
this particular pump is reserved for the equipment manufacturer. as it often happens
it may be possible to find an analogue, but maybe not
When a pump is reserved by the manufacturer, then it may differ from the serial one, starting with some serious difference in iron, and ending with the fact that it is simply painted in a different color (of the type also special design). Only the manufacturer has data on the differences, or it is necessary to disassemble and watch the sample.

but here is Kasappa's answer
I have checked but unfortunately this pump is reserved for our Customer CNH INDUSTRIAL ITALIA SPA ,
so it’s not possible to offer and you should contact them directly for every replacement:

Repair kit for pump NSh-100A <>

Repair kit for gear pump NSh-100A-3, series "ANTEY"
Catalog number: 119

Repair kits for hydraulic units and tractor units, repair kits for diesel engines, sets of gaskets for car engines, combines from the manufacturer

PE "RODONIT 2008" offers a full range of repair kits, rubber goods for the repair of hydraulic units and units: tractors: MTZ, YuMZ, KhTZ, LTZ, VTZ, T-16, T-25, T-40, T-70, T-130, T -150, DT-75, K-700, K-700A, K-701, T-4A, TT-4M, TDT-55A; diesel engines: D-240, D-245, D-260, D-21, D-65, D-144, D-160, A-41, A-01, SMD-14, SMD-18, SMD-22 , SMD-60, SMD-72; trucks: ZIL, ZIL-130, GAZ, GAZ-53, SAZ, KAMAZ, MAZ, KRAZ, URAL; combines: NIVA SK-5M1, DON-1200, DON-1500, YENISEI, AKROS, SKIF, KSK-100, etc.

The complete set of the repair kit is compiled in accordance with the catalogs of parts and assembly units of tractors, excavators, loaders, combines, trucks, dump trucks, trailers, semi-trailers, tractor trailers and corresponds to the technical documentation for disassembly, assembly of units and assemblies.

Telescopic and piston hydraulic cylinders, hydraulic cylinders for tractor trailers, hydraulic cylinders for trucks and dump trucks.

PE ”RODONIT 2008” - production, repair and sale of hydraulic cylinders for trucks and dump trucks, hydraulic cylinders for tractor trailers, hydraulic cylinders for a combine, telescopic and piston hydraulic cylinders.

Hydraulic distributors, hydraulic cylinders, hydraulic motors, hydraulic pumps, turbochargers, NSh pumps, metering pumps, clutch baskets, clutch discs, starters, starting motors. Spare parts for agricultural machinery, special machinery, road-building machinery, trucks and loading machinery.

Sales department:
t. 050-985-10-96
t.068-177-76-35

Video Repair kit for pump NSh-100A of the RODONIT 2008 channel

for warranty service and technical expertise of low pressure pumps, hydraulic valves, hydraulic cylinders

The purpose of our service center – warranty repair and service of hydraulic valves, gear pumps, hydraulic cylinders.Experienced service center specialists provide advice on the operation, applicability and repair of hydraulic units - low pressure pumps, hydraulic cylinders and hydraulic valves. Having the status of the official service center "Hydrosila-MZTG" we provide an official - factory opinion for all tested products with the provision of a product inspection certificate with a detailed indication of the causes of malfunctions and the work performed to eliminate them.

R 80 3 / X-XX (all modifications)

R 80 3 / X-XXX (all modifications)

R 160 3 / X-XXX (all modifications)

* Repair price + cost of components

• Hydraulic equipment not included in the price list is repaired according to a separate estimate.
• Hydraulic equipment is being repaired according to its actual state and the list of prices may change up or down
• All products tested in our service center are labeled
• All products after repair are provided with a proprietary warranty
• After verification, an ACT is issued for all products with a conclusion

The warranty period for hydraulic valves, hydraulic cylinders, gear pumps is 12 months from the date of sale indicated in the warranty card, but not more than 18 months from the date of manufacture, subject to the conditions of transportation, storage and operation.
In case of failure of hydroelectric units during the warranty period, the claim is accepted by the organization that sold the unit.

The warranty does not apply to waterworks:
- not stamped with the date of sale in the warranty card;
- not installed on the machine within 6 months from the date of manufacture;
- installed in products for which their applicability has not been agreed;
- disassembled by the consumer (the seal is missing or damaged)

Please be informed.

Complaints about the quality of products from consumers are considered only if there are acts of complaint indicating:

• Name of the organization,
• the date and number of the document by which this product was purchased,
• product name,
• what equipment was the product installed on
• nature and reasons of product failure

For warranty repair of NSh pumps, hydraulic valves and hydraulic cylinders, as well as post-warranty service, please contact "Service Center Vostok"
Moscow region, Noginsk, st. Zakharovskaya, 2
Tel. 8 (985) 360-18-24
Fax. 8 (496) 519-18-00

Close the valve for supplying oil to the pump NSh 100A-3L on the left hydraulic tank and remove pump 4 (Fig. 17).

With light blows with a copper hammer through the mandrel on the end of the shaft, press out the shaft 13 towards the rear flange until the bearing 7 comes out of the casing hole. Press bearing 7 off the shaft with a puller without removing the shaft from the casing. Press out the shaft with bearing 4 towards the front flange, engaging the teeth of the shaft and the distribution gears. Press bearing 4 off the shaft.

If necessary, press out the oil seals 8 from the flanges, unscrew the breather 9 and the plug 11, remove the cover 10.

Press the collars 8 into the front and rear flanges until they stop in the shoulder. The lips of the collar must face the inside of the flanges. Install cover 10 with gasket, breather 9, plug 11.

Press bearing 7 onto the shaft. Install the ring 6 into the groove of the shaft.

1. Shaft diameter for bearing - 90 + 0.025mm. The allowed shaft diameter is 89.99 mm. The preload between the shaft and the bearing is 0.003… 0.045 mm, the allowable gap is 0.01 mm.

Spare parts production:

Gear pump repair

The repaired gear pumps of the NSh type have a warranty period of 6 months.

When repairing in accordance with technical requirements, troubleshooting of parts and interfaces is carried out, 100% regrinding and assembling of gears, replacement of rubber goods, if necessary, manufacturing of housings, bushings, clips - clamping and bearing.

The pumps are tested at the KI 4815 stand for pressure and efficiency of at least 90%.

In 2015, 2,505 hydraulic pumps were repaired.

There is an exchange fund at the plant, which allows our customers to hand over gear pumps for overhaul and on the same day to receive circulating units from the warehouse.

Repair of hydraulic pumps is often necessary when problems arise with this special technique. Often, such a situation does not require the intervention of qualified specialists, and if you have a little certain knowledge, you can fix it with your own hands.

It is suggested to get acquainted with the most common malfunctions and ways to eliminate them from the article.

The operation of any hydraulic pump is based on the principle of suction and discharge of liquid.

Main structural elements:

A liquid moves between them, which, when the pressure chamber is filled, begins to press on the piston, displacing it, imparting movement to the working tool.

Basic operating parameters of all types of hydraulic pumps:

• Engine speed, measured in rpm.
• Working pressure in the cylinder, in bar.
• The volume of the working fluid, in cm³ / rev, or the amount of fluid displaced by the pump during one revolution of the motor shaft.

The main types of equipment:

• Manual hydraulic hydraulic pump... This is the simplest unit operating on the principle of liquid displacement.

When the handle is pressed, the piston moves upward, which creates a suction force and, through the KO2 valve, liquid enters the chamber, which is displaced when the handle is lifted.

The advantages of such units:

1. low performance compared to drive units.

• Radial piston. They are able to develop pressure up to 100 bar, have a long period of operation. Radial piston pumps can be of two types:

1. rotary. In such devices, the piston group is placed inside the rotor, from its rotation the piston makes reciprocating movements, alternately joining the holes for draining the liquid through the spools;

Rotary radial piston pump device

1. with eccentric shaft. Its difference is the location of the piston group inside the stator; such pumps distribute liquid through the valves.

1. high reliability;
2. work is done with high pressure, which increases productivity;
3. creates a minimum noise level during operation.

1. high pulsation rate during liquid supply:
2. large mass.

• Axial piston. This is the most common type of equipment.

Depending on the location of the axis of rotation of the engine, there may be:

The advantages of such pumps:

1. high efficiency;
2. high performance.

1. high price.

• Gear pumps refer to rotary equipment... The hydraulic part of the structure consists of two rotating gears, their teeth, upon contact, displace liquid from the cylinder. Gear pumps can be:

1. with external gear;
2. with internal gearing, in which the gears are located inside the housing.

The photo shows the types of gear pumps.

Gear units are used in systems where the operating pressure does not exceed 20 MPa. They are most used in agricultural and construction equipment, lubrication systems and mobile hydraulics.

• Simple construction.
• Small size.
• Light weight.

• Low efficiency, up to 85%.
• Small turns.
• Short service life.

Advice: To increase the service life of the hydraulic pump, it is necessary to strictly follow the requirements of the operating instructions.

Almost all breakdowns that occur during the operation of hydraulic pumps are the result of such factors as:

• Failure to comply with the rules of equipment management and neglect during its maintenance:

1. untimely replacement of oil and filters;
2. elimination of leaks in the hydraulic system.

• Errors in the selection of hydraulic fluid or oil.
• The use of accessories that do not correspond to the operating mode of the pump.
• Incorrect hardware setup.

The table provides a list of the most common malfunctions and how to fix them:

Clearance in the control rod.

The bearing seat pins are broken.

The channel between the control spool and the piston is dirty.

Seizure received on the surface of the piston impedes its smooth movement

Check and repair, if necessary, the hydraulic pump

The resistance of the hydraulic line between the remote elements of the pressure compensator and the control panel has increased.

Low control pressure

Adjust equipment control pressure

The drive shaft splines are worn out.

Piston shoes or pistons themselves are worn or damaged

Bearings worn out too much

Pressure compensator incorrectly aligned.

The spool of the control mechanism has broken.

The control spool springs are damaged or broken.

Seizure has formed on the spool or bore.

The control cylinder springs are damaged or broken.

Malfunctions of elements in the circuit of the remote pressure compensator

The minimum working volume of the equipment is set too high.

The supporting surfaces of the hydraulic pump cradle and the saddle of the support bearings are worn out or damaged

Check and, if necessary, repair the hydraulic pump

The channel from the output channel to the control spool is dirty

There is a low level of working composition in the tank.

Low pressure at the inlet to the hydraulic pump.

Worn or damaged interface surfaces between the cylinder block and the distributor.

Poor heat exchanger cooling. Inspect the heat exchanger, rinse and clean the cooling surfaces.

Major malfunctions gear pump

Wear of the walls and bottom of the housing wells, the ends of the gears and the surfaces of the trunnions, bushing holes for the trunnion, chipping of the edges of the pump cover collars for the sealing gland, wear of the cover plane.

Gear pump repair

The pump is disassembled and repaired if it has a volumetric K.P.D. less than 0.6 (after replacing the seals). To properly control this indicator, it is necessary to distinguish between the designations of hydraulic pumps. In the markings NSh-10D, NSh-32 and NSh-46U, the figure corresponds to the theoretical productivity of the new pump in cubic centimeters per revolution of the gears. Letters D, U after the number mean the pump model. The direction of rotation of the drive gear is shown on the pump plate with the letter L (left) or P (right, but most often not indicated)

Dimensions of the gear pump housing, mm. Table 1

* Dimensions for crimp rebuilt hulls

When disassembling the pumps, unscrew the bolts, remove the pump cover and remove the parts by hand. The puller is used only when removing the lower pair of bushings from the socket. The bushings of the cover and sealing ring of the NSh-32 and NSh-46 pumps are interchangeable, but if the pump is assembled again from these parts, then depersonalization of the bushings and gears is not allowed.

Pumps received for the first time for repair are repaired by displacing the gears with concentric bushings. This method allows you to repair the pump at a lower cost, since the restoration of the pump body is reduced to one operation - wasting the wells to an increased size (Table 1; Fig. 1). the pump is assembled with eccentric bushings, the displacement of the gear axis should be equal to half the difference in the sizes of the gear teeth heads and the housing wells.

Fig. 1. Hydraulic pump housing

With greater wear of the pump casing surfaces (second and third repairs), the casing is subjected to plastic deformation - hot compression.

Rice. 2. Device for crimping the pump casing: 1-repaired pump casing; 2-ejector; 3-matrix; 4-mold body; 5-poison; 6-top plate.

For this, the body is placed in an electric heating furnace with automatic temperature control and held for 30 minutes. at 500 + 10 0 С. Then the body is installed in the matrix 3 (Fig. 2) of the device and compressed under a press. Compression of the body must be completed at a temperature not lower than 4300 C. The compressed body is subjected to heat treatment: heating and holding for 30 minutes. at 5200 C, quenching in water with a temperature of 60-1000 C and tempering (aging) for 4-6 hours at 170-1800 C. The crimped body is bored on a 1L62B lathe or on 6M82 and 6M12P milling machines using a device (Fig. 3).

Rice. 3. Device for boring gear pump casings: a - jig for pinless installation of the casing; b - a device for boring; in-mandrel; 1-device body; 2-pin; 3-axis housing; 4-conductor body; 5-movable cone; 6-clamp; 7-cutter mandrel; 8-clamping screw; 9-cutter; 10-pin; 11-cutter.

The ellipticity of bored wells should be no more than 0.01 mm, the taper - no more than 0.02 mm, the non-parallelism of the axes of the wells - no more than 0.03 mm, and the misalignment of the planes of the bottom of the housing wells - no more than 0.02 mm. The depth of the wells is controlled by an indicator.

To restore the pump gears, the worn surfaces of the trunnions, ends and surfaces of the gear teeth heads are ground to repair sizes on a 3B12 cylindrical grinding machine. The grinding wheel of the PP-300x40x127-Ek brand is filled for grinding the ends of the gears, as shown in Figure 4. The radius of curvature of the edges of the teeth should be 0.01 mm.

Rice. 4. Grinding of the ends of the gears: a - the position of the edge of the wheel during grinding; b-grinding of the end face; in-dressing the grinding wheel.

The runout of the ends of the gear teeth relative to the center line is allowed no more than 0.01 mm. The grinding wheel should be straightened after machining with 20-30 gears, the dimensions of the gears after grinding are shown in table 2.

Dimensions of gear pump gears after grinding. table 2

Outer diameter of the gear tooth head, mm

The depth of the carburized layer of the gear after processing must be at least 0.8 mm (hardness HRC 58-62).

Depending on the length of the tooth, the repaired gears of each repair size are sorted into groups with an interval of 0.005 mm using a lever bracket.

Pump bushings are repaired by plastic deformation by compression (Fig. 5) in a cold state.

Rice. 5. Device for crimping bushings: a-device for crimping bushings; b-sleeve; 1-rod (working tool); 2-poison; 3-sleeve; 4-matrix; 5-insert; 6-ejector; 7-matrix body.

The dimensions of the sleeve blank after swaging are shown in Table 3.

Dimensions of the sleeve blank after swaging Table 3

At the crimped sleeve, end face B is machined, an oil groove to a diameter d1 (Fig. 6), a hole for a trunnion is expanded or bored to a size d.

When machining, an eccentric collet chuck is used (Fig. 7), which allows processing bushings with an eccentric.

Rice. 7. Eccentric collet chuck: 1-collet; 2-sleeve retainer; 3-adjusting bolt; 4-cartridge case; 5-clamping screws.

To process the end planes B and C (see Fig. 6), two cutters are installed on the support using a special head (Fig. 8) so that the length of the sleeve after processing corresponds to the data in Table 4.

Rice. 8. Dimensions of the sleeve after machining (see Fig. 6), mm Table 4

* Dimensions for compression remanufactured pump casings.

The height of the bushings, processed simultaneously with two cutters, usually differs by no more than 0.005mm, and the bushings correspond to the same group. The butt planes of the bushings are milled on a milling machine using a device (Fig. 9)

Fig. 9. Milling of the butt plane of bushings: 1-bushings; 2-cutter.

Irregularities in the mating surface of the cover 1 (Fig. 10) of the pump are eliminated by milling this surface until wear marks are removed. If at the cover the collar holding the gland retaining ring is broken off, then a groove is made in place of the collar and a steel ring 2 is installed in the cover, attached with screws 3.

Rice. 10. Restoration of the retaining collar of the pump casing cover: 1-cover; 2-ring; 3-screw.

Bushings and gears, are mating parts, are selected according to size groups so that the length of each pair of lower bushings, gears and upper bushings differs by no more than 0.005 mm. The bushings installed in the housing should not protrude more than 0.005mm relative to each other. The rubber sealing rings and the cuff, which have lost their original elasticity, are replaced. The selected gears and bushings are lubricated with diesel oil before assembling the pump. When assembling the left rotation, the body is installed in a fixture or a vice with copper jaws so that the inlet is directed towards the worker. The matched pair (left and right) of the lower sleeves is inserted into the wells of the pump casing. The drive gear is installed in the right well, and the driven gear is installed in the left. When assembling a pump of right rotation, the drive gear is installed in the left well, and the driven gear is installed in the right. The stuffing box is lubricated with a thin layer of graphite grease or grease and pressed into the cover using a mandrel. The lip of the oil seal must face the inside of the cover. The assembled pump is run in and tested on the KI-4200 or KI-4815 stand (Fig. 11)

Rice. 11. Testing the gear pump: a-installation of the pump on the KI-4200 stand; b-diagram of connecting the pump to the hydraulic system; 1-fitting for connecting hydraulic units; 2-discharge hose; 3-test pump; 4-hose to the suction cavity of the pump; 5-pump mounting bracket; 6-consumable tank; 7-filter; 8-liquid flow meter; 9-radiator of the cooling system; 10- centrifugal filter; 11-overflow spool; 12-toggle switch of the revolution counter; 13-revolution counter; 14-high pressure gauge; 15-block of low pressure with a pressure gauge; 16-throttle; 17-way valve.

Run-in mode: without pressure - 4 minutes, at a pressure of 2.0 MPa - 7 minutes, at 4.0 MPa - 5 minutes, at 7.0 MPa - 4 minutes, at 10.0 MPa - 12 minutes, and at 13.5 MPa - five cycles 0.5 min. The pressure in the discharge line is controlled by a throttle.

The pumps are tested for performance at a pressure of 10 MPa and an oil temperature of 45-550C. The test results must correspond to the indicators given in table 5.

Indicators of the repaired gear pumps. Table 5

The pump should be removed from the tractor and carry out routine repairs if the following malfunctions are found: air leaks (oil foams in the hydraulic system tank), oil leaks through the seals, linkage mechanisms do not rise or rise very slowly.

Unfasten screws and lower front engine cowl. Close the hydraulic tank valves.

Disconnect the oil inlet and elbow coupling of the high pressure hose from the pump. Remove the four bolts and remove the pump from the timing gear housing flange. Close the pump casing openings with safety plugs.

Disassembling the pump

Remove the bolts 10 (Fig. 5.109) remove the cover 9 from the body 8. Remove the safety plugs 15 and 20 from the body. Remove the centering bush 21 from the housing and bearing cage 22. Remove the cages 19 and 22 with gears 4 and 6 and O-ring 23 from the casing.

Remove the gear casings without distortions and damage to the surfaces.

Remove the bearing cage from the gears and the gears from the clamping cage 19. Remove the liners 7 from the gears and remove the plates 16 from the clamping cage.

It is not allowed to uncomplete the clips, gears and plates.

Remove plates 11, safety rings 1 and 12, gaskets 17 and 25 and cuffs 18 and 24 from the plastic plates and the clamping yoke.

Remove the collar 14 with the support plate 13, the circlip 3 and the support ring 5 from the housing. Press cuffs 2 out of the body.

Checking the technical condition and flaw detection of pump parts

Rinse pump parts in diesel fuel. Scratches, scratches or significant signs of wear are not allowed on rubbing surfaces.

Replace all rubber seals with new ones.

Rice. 5.109. Pump NSh 100A-3-00

Lubricate all parts with engine oil before assembling the pump.

Insert the collar 14 with the support plate 13 into the body 8. Install the seals 18 and 24, gaskets 17 and 25, safety rings 1 and 12 and plates 11 into the plates 16 and the retainer 19.

Insert the plastic plates into the retaining clip. Put the inserts 7 on the drive and driven gears 4 and 6.Install the gears with inserts on the clamping cage with plates and the bearing cage 22 on the gears with inserts.

Insert the cages with gears into the housing and the centering sleeve 21 into the housing and the bearing cage. Install rubber ring 23 and cover 9 on the body and secure it with bolts 10 with washers. Install the pump cover so that the inscription on it EXIT is located on the side of the clamping yoke.

Put the collars 2 on the drive gear 4 and press them with the oil scraper lips inside the pump until they stop in the shoulder of the casing. Insert support ring 5 and secure with circlip 3.

Pump test

Install the pump on the KI-4815M stand. Test fluid: engine oil at a temperature of 45-55 ° C.

Check the pump for leaks. Create a cyclic load by raising the pressure with the throttle from 0 to 13.5 MPa (135 kgf / cm2) according to the pressure gauge and dropping it. Carry out at least five loading cycles. The duration of each cycle is at least 30 seconds. At the same time, oil leaks through the seals are not allowed.

Check air leakage at a pressure of 0.2-0.5 MPa (2-5 kgf / cm2) for 3 minutes. In this case, air leakage (foaming of oil in the stand tank) is not allowed.

Check pump flow. Using the throttle handle, set the pressure to 10 MPa (100 kgf / cm2) according to the pressure gauge and turn the valve to direct the oil flow through the liquid flow meter. Turn on the toggle switch of the impulse counter. After 200 liters of oil has passed through the meter, turn it off. The number of pulses must be equal to or less than 1677. The indicated value corresponds to a feed rate of 0.75. The control value of the flow must be at least 110 l / min for D-180.120 and 130 l / min for D-180.100.

Installing the pump

Video (click to play).

Place the pump on the distribution gear housing flange and secure it with bolts and washers. Connect the oil inlet and elbow coupling of the high pressure hose to the pump. Lift up the front guard and secure it to the side member with bolts and washers.

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