NLB 1012D Operation Maintenance & Parts Manual Download Page 1

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Summary of Contents for 1012D

Page 1: ...12D 312D 1060D 860D 760D Diesel Engine Driven High Pressure Water Jetting Units OPERATION MAINTENANCE PARTS MANUAL NLB Cor 29830 BECK ROAD WIXOM Ml 48393 2824 248 624 5555 FAX 248 624 0538 PARTS 1 800 227 7652 Copyright October 2005 NLB Corporation ...

Page 2: ... THIS MANUAL AND THE INFORMATION CONTAINED IN THIS MANUAL SHOULD ONLY BE USED BY PERSONS WHO ARE KNOWLEDGEABLE AND HAVE BEEN TRAINED IN THE OPERATION AND OR MAINTENANCE OF EQUIPMENT OF THE TYPE DESCRIBED HEREIN THE EQUIPMENT OWNER AND OR USER SHOULD INSPECT THE EQUIPMENT PRIOR TO ITS USE OR SERVICE IN ORDER TO MAKE CERTAIN THAT IT IS IN GOOD WORKING ORDER AND FREE FROM DEFECT ALL APPLICABLE OPERAT...

Page 3: ... of Manually Operated High Pressure Water Jetting Equipment 2 12 Section 3 PRODUCT OVERVIEW I II Table of Contents 3 1 General Description 3 2 Water Condition 3 2 III Specifications 3 3 IV Bill of Materials Assembly Drawings 3 7 Section 4 OPERATION CONTROL Table of Contents 4 1 I Machine Control 4 2 II Pre Operating Procedure 4 11 III Operating Procedures 4 14 Section 5 PREVENTIVE MAINTENANCE Tabl...

Page 4: ...ectrical System 8 80 Section 9 PARTS Table of Contents 9 1 I Model Serial Numbers 9 2 II Assembly Drawings Parts Lists 9 3 Section 10 CUSTOMER SUPPORT Table of Contents 10 1 I NLB Corp Customer Service Department 10 2 II Ordering Parts 10 3 HJ Warranty Policy 10 4 IV Parts Return Authorization RA Process 10 5 V How To Package Parts To Be Returned 10 10 VI Return Authorization Form 10 11 MANUFACTUR...

Page 5: ...Revision 11 MASTER TABLE OF CONTENTS Cont MANUFACTURERS LITERATURE Cont Water Inlet Bag Filter Assembly Optional FSP85 FSI Copyright June 2005 NLB Corporation 0 4 ...

Page 6: ... Proposition 65 Warning 29830 BECK ROAD WIXOM Ml 48393 2824 248 624 5555 FAX 248 624 0538 Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Copyright June 2005 NLB Corporation 0 5 ...

Page 7: ...TENTS SECTION 1 INTRODUCTION DESCRIPTION PAGE NUMBER I Purpose Objectives of Manual 1 2 II Manual Organization 1 3 A Terminology 1 3 B Illustrations Photographs 1 4 C Revisions 1 4 Copyright September 1999 NLB Corporation 1 1 ...

Page 8: ...ices may also apply to the operation and service of the equipment If an information conflict is found to exist between NLB s instructions and other regulations or practices NLB must be contacted for clarification prior to operation or service of the equipment Insure that all persons involved with the operation and service of the equipment have thorough knowledge of that equipment and are familiar ...

Page 9: ...e NLB parts The use of any other parts could create a hazardous situation Also the use of any other parts will void all warranties on this equipment To order replacement parts call toll free 1 800 227 7652 II Manual Organization A standard section arrangement has been adopted for the instructional sections of this manual Each section has at least one page in each of the following categories a Tabl...

Page 10: ...order to provide clarity to illustrations and photographs some illustrations and photographs show parts removed that are not related to the specific parts given in the text C Revisions This manual is a living document It is revised whenever there are changes to the high pressure water jetting equipment embodied in this manual In the upper left hand corner of each page is a revision record listing ...

Page 11: ...nal Procedures D Operational Procedures E Training III Recommended Practices For The Use of Manually Operated High Pressure Water Jetting Equipment A Introduction B Scope C Definition of Terms D Equipment Definition and Standards E Care and Maintenance of Equipment F Protective Clothing and Personnel Protection G Pre Operating Procedures H Operational Procedures I Use of Lances and Nozzles J Opera...

Page 12: ...quipment have safety signs strategically placed on the equipment If any become marred painted over or in any manner unreadable contact NLB for free replacements These signs are furnished as an aid to training employees and as a reminder to operators and their fellow employees The safety signs are not intended to be used as a substitute for a specific company training program covering the operation...

Page 13: ...Revision 2 TURTLESKIN1 t WATERARMORTM Copyright April 2003 NLB Corporation 2 3 ...

Page 14: ...it becomes marred painted over or in any manner unreadable contact NLB for a free replacement Identical printed forms are available from NLB In addition to checking off the information on the unit decal the job foreman should also fill out and sign one 1 of the printed forms to be maintained in the company Copyright January 2001 NLB Corporation 2 4 ...

Page 15: ...20 PSIG FRESH CLEAN WATER SUPPLY AT PUMP SUCTION 12 HAVE PRECAUTIONS BEEN TAKEN AGAINST FREEZING 13 DO ALL PERSONNEL HAVE THE PROPER SAFETY EQUIPMENT FOR THIS JOB 14 DO ALL PERSONNEL HAVE THE PROPER SAFETY TRAINING FOR THIS JOB 15 ARE ALL MEN QUALIFIED TO PERFORM THIS WORK 16 ARE EXPLOSIVE OR FLAMMABLE VAPORS POSSIBLE AND ARE MONITORING PROVISIONS ESTABLISHED 17 IF ANSWER TO 16 IS YES DO NOT USE D...

Page 16: ...l The recommended Safety Procedures Decal Figure 2 2 is attached to all NLB high pressure water jetting units If it becomes marred painted over or in any manner unreadable contact NLB for a free replacement Copyright January 2001 NLB Corporation 2 6 ...

Page 17: ... MUST MAINTAIN GOOD FOOTING 4 NON OPERATORS MUST REMAIN A SAFE DISTANCE FROM THE OPERATOR THE DISTANCE SHOULD BE A MINIMUM OF 25 FEET 5 NON OPERATORS SHOULD NEVER APPROACH THE OPERATOR WITHOUT FIRST TURNING THE SAFETY ELECTRICAL SWITCH OFF AT THE UNIT 6 THE OPERATING PRESSURE SHOULD NEVER EXCEED THAT WHICH IS NECESSARY TO ACCOMPl ISH THE JOB 7 NO UNAUTHORIZED ATTACHMENTS OR MODIFICATIONS SHOULD BE...

Page 18: ...s not exceeded by more than 3 Pressure Gauge The system shall be equipped with a gauge to indicate the pressure being developed Filter or Strainer The water system shall be equipped with a filter or strainer to prevent particles from entering the high pressure pump and damaging the plungers Dump System The system shall be equipped with a device which will by pass the flow or dump the discharge pre...

Page 19: ...teel toed boots Hand Protection NLB safety gloves Ear Protection Ear plugs or other suitable protection shall be worn when noise level exceeds OSHA recommended levels Recommendation The safety engineer or someone thoroughly familiar with the potential hazards to be found at the location where the work is being performed should be consulted prior to starting work to determine potential environmenta...

Page 20: ...s etc as long as an effective visible barrier is provided Hook Up Inspect all hoses and fittings for evidence of excessive wear and damage prior to installing Hoses should be laid out in a safe and orderly manner Hoses pipes and fittings shall be supported to prevent excessive sway vibration or stress on end connections Hoses should be protected to prevent kinking or excessive wear Nozzles Before ...

Page 21: ...otective Equipment Explain the minimum personal protective equipment required Instruct when and how specific limb guards special clothing and other types of devices should be worn per type of work performed locations etc System Operation Explain the operation of the system pointing out potential problems and proper corrective action Safety Devices Explain the reason for and operation of safety dev...

Page 22: ...ents occurring For this reason these practices are dated and the association shall bi annually review these practices for any required changes B Scope 1 The recommended practices are intended to provide guidance on the proper operation of high pressure water jet cleaning and cutting equipment 2 In this document the word shall indicates a requirement that is to be adopted in order to comply with th...

Page 23: ...olid particles to penetrate into the surface of a material for the purpose of cutting that material and where the pressure of the liquid jet exceeds 1 000 psi 69 bar 4 Lancing An application whereby a lance and nozzle combination is inserted into and retracted from the interior of a pipe or tubular product 5 Dump system An operator controlled manually operated device or system that rapidly reduces...

Page 24: ...ion Product and supplier Production model and serial number or year of production Maximum performance in terms of flow measured in gpm lpm and pressure measured in psi bar An outline of recommended safety procedures 2 Relief system The system shall be equipped with an automatic relief device on the discharge side of the high pressure pump 3 Automatic pressure relief devices These may take the form...

Page 25: ...ielded to preclude inadvertent operation This device should immediately shut off the high pressure water stream if the operator loses control a Dump control valve This operator controlled valve normally hand controlled automatically terminates significant flow to the lance and or nozzle assembly when released by the operator thus relieving the operating pressure within the whole system by divertin...

Page 26: ...l area of the workpiece by minimizing the spread A typical application is for cutting or for general cleaning of matter with higher shear and or bond strength b Fan jet Spreads the stream of water in one 1 plane so giving a wide band coverage of the work piece A typical application is for cleaning larger areas requiring less energy to remove unwanted matter 13 Jetting hand manifold and spray bars ...

Page 27: ...els b High pressure pump Lubricating oil and gear box oil levels c Hydraulic hose reel Lubricating oil and fluid levels d Condition of guards and shields Wear and or damage 2 Filters and strainers All water filters should be checked at regular intervals dependent upon the supply water conditions and in accordance with NLB s recommendations Extreme care should be taken to filter the water source th...

Page 28: ...n the water supply valve until water is seen trickling from each cartridge flange The cartridge flanges have been provided with fittings which deposit water directly onto the plungers as the high pressure pump runs Packing and plunger lives are directly extended by this lubrication The lubricator was factory adjusted for l 3 gallon 1 2 l of water per plunger per minute Pressure is limited to inlet...

Page 29: ...from the ingress of water Correct direction of rotation of the electric motor should be checked on initial installation and after every re connection 8 Trailers Mounted high pressure water jetting units shall be checked daily examining tires braking systems jacking points towing hitch lights safety chains structural damage and general cleanliness The units should only be towed by vehicles fit for ...

Page 30: ...or a full hood shield 4 Body protection All operators should be supplied with suitable waterproof clothing having regard to the type of work being undertaken Garments should provide full cover to the operator including the arms Liquid or chemical resistant suits shall be worn when there is a reasonable probability of injury that can be prevented by such equipment 5 Hand protection Adequate hand pr...

Page 31: ...us area The perimeter should be outside the effective range of the water jet wherever possible Barriers may be of rope safety tape barrels etc as long as they give an effective warning and are highly visible 5 Hook up a Hose Hose shall be arranged so a tripping hazard does not occur Hoses pipes and fittings shall be supported to prevent excessive sway and or wear created by vibration or stress of ...

Page 32: ...oose items and debris to prevent tripping and slipping hazards d Access Access by unauthorized persons into the area where high pressure water jetting is taking place shall be prevented The area shall be cordoned off and warning notices displayed in prominent positions The perimeter should be outside the effective range of the water jet wherever possible e Approaching the operator The occupier sha...

Page 33: ... off the pressure rapidly as this can cause the loss of footing by the lance gun operator e Additional operators Further operators are required in the following circumstances To assist the first operator with the handling of the lance if it is too long or too heavy for one 1 man To provide communication if the lance operator is out of sight of the high pressure water jetting unit operator f Job ro...

Page 34: ...to keep the system from being activated by someone stepping on the hose or running over it 6 Moleing or Flex lancing a Control The operator inserting the nozzle shall have direct control of the dump system b Reversing A positive method shall be used to prevent the nozzle from reversing direction inside the item being cleaned such as using a pipe nipple behind the nozzle which has a length larger t...

Page 35: ...ation When under manual operation the nozzle shall be inserted into the tube prior to pressurizing Conversely the system shall be de pressurized before removal of the nozzle from the tube unless proper shielding is provided d Shields When lancing tubes with a rigid lance a guard should be installed where practicable around the lance to prevent a lance nozzle from being inadvertently withdrawn and ...

Page 36: ...se should not be used for water jetting unless specifically designed for this purpose g Operator positioning The team members shall be safely positioned while operating the system and if any person should encroach into the working area high pressure water jetting shall be stopped h Work stoppage Work shall stop when the following occurs In the event that leaks or damage become apparent If any pers...

Page 37: ...r combination of lances shall be such that the lance operator can maintain control at all times 5 Jet pressure The nozzle and minimum operating pressure shall be selected by the lance operators to allow effective and efficient high pressure water jetting 6 Improper use Should a lance operator enter a manhole or access port for any purpose preferably with the high pressure water jetting unit turned...

Page 38: ...potential problems pointed out and proper corrective action 6 Control devices The operation of all control devices shall be explained The importance of not tampering with any control devices as well as the importance of keeping them in proper working order shall be stressed a Equipment maintenance It should be pointed out that valves and seating surfaces in pressure regulating devices encounter hi...

Page 39: ...ing the periods where there is a risk of freezing follow NLB s recommendations or take the following precautions on shutting down a Remove gun or nozzle from delivery hose b Pump water from supply tank until level of water is just above the filter c Add recommended quantity of anti freeze into water tank d Place delivery hose into water tank and secure e Run the pump until the anti freeze works th...

Page 40: ...ment 3 Immediate first aid Where medical examination is not immediately possible in remote situations first aid measures should be confined to dressing the wound and observing the patient closely until medical examination has been arranged 4 Reporting If any person or equipment is accidentally struck by the water jet this fact must be immediately reported to a responsible party N Responsibility 1 ...

Page 41: ... oil level etc Fit gun or lances and or control valves Visually check that correct size and type of nozzle is fitted for the application Increase pressure slowly until operating conditions are reached Re check hose couplings and joints for leaks Rectify all leaks ensuring that the unit is shut down and line pressure is released before making adjustments Ensure all operators are wearing suitable pr...

Page 42: ... satisfaction Upon completion ensure that customer has signed the necessary paperwork satisfaction notes work sheets etc Copyright January 2001 NLB Corporation DO NOT DO NOT leave equipment unattended on site DO NOT store unserviceable equipment notify supervisor DO NOT leave the site in a dangerous or untidy condition DO NOT leave site without notifying all parties engineers site agents occupiers...

Page 43: ...etting Units 1 Physical 2 Mechanical 3 Performance B CUMMINS Diesel Engine C JOHN DEERE Diesel Engine D Outdoor Site Requirements E Indoor Site Requirements Bills of Materials Assembly Drawings A 1012DB TRA High Pressure Water Jetting Unit B 1012DB SKID High Pressure Water Jetting Unit Copyright June 2005 NLB Corporation 3 1 3 1 3 2 3 2 3 3 3 3 3 4 3 4 3 5 3 5 3 5 3 6 3 6 3 7 3 7 3 9 ...

Page 44: ...ailer or skid for mobility The standard models all incorporate a V belt drive Optional water lubrication and direct drive gear pac are also available The trailer mounting unit contains the following features Rugged Steel Trailer Heavy Duty Dual Axle Design Heavy Duty Fenders 16 5 4 2 cm Wheels Lights and Electric Brakes II Water Condition To extend the lives of system components such as nozzle ori...

Page 45: ...g Unit Standard V belt drive model shown The high pressure pump can be furnished with several sizes of plungers each providing a different performance rating A CYLINDERS MODEL PLUNGER MAXIMUM GPM MAXIMUM BY PASS SIZE MM LPM PSI BAR VALVE 1312D 7 8 22 2 12 0 45 4 13 000 BV20 260 896 5 1012D l 25 4 16 0 60 6 10 000 BVl0 400 689 6 812D 1 1 8 28 6 20 0 75 7 8 000 550 BVl0 400 612D 1 1 4 31 75 25 0 94 ...

Page 46: ...Water Connection Water Supply Inlet Water Supply Pressure Range Inlet Water Supply Temperature Range Water pH Value Water Turbidity NTU Filter Cartridge Filter Cartridge Optional Copyright September 2003 NLB Corporation MAXIMUM GPM MAXIMUM BY PASS LPM PSI BAR VALVE 30 0 113 6 5 000 344 BVl0 400 35 8 135 5 4 000 280 BVl0 400 41 9 158 6 3 500 BVl0 650 245 8 48 6 184 3 000 210 BVl0 650 Trailer Mounti...

Page 47: ...lacement Copyright June 2005 NLB Corporation 35 to 110 F 2 to 43 C Up to 95 at 120 F 49 C Non condensing 36 94 1 cm Clearance on all sides for operation and service access Not to exceed an incline of5 from horizontal CUMMINS diesel 6B5 9 six cylinder 4 02 102 mm 4 72 120 mm 359 C I 5 9 l Dry 880 lbs 399 kg 115 or 80 1 5 3 6 2 4 All seasons 10 to 110 F 12 to 20 C 15W40 Winter conditions 10 to 68 F ...

Page 48: ... AIR INTAKE SYSTEM AND CAUSE ENGINE ACCELERATION AND OVER SPEEDING WHICH CAN RESULT IN A FIRE AN EXPLOSION AND OR EXTENSIVE PROPERTY DAMAGE INHALATION OF EXHAUST GASES CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH DO NOT SITUATE THE HIGH PRESSURE WATER JETTING UNIT IN A CONFINED AREA KEEP THE UNIT AWAY FROM ANY WINDOW OR DOOR OPENING E Indoor Site Requirements WARNING THE HIGH PRESSURE JETTING UN...

Page 49: ...LE6008 58 Piping Discharge l Ea l3 DM15998 Piping Water Tank l Ea 14 CLE6005 13S Piping Rupture Disk To Water Tank 1 Ea 15 CLE6005 l8S Hose Fittings By Pass l Ea 16 NLE7290 l Tags Sub BOM l Ea 17 PM7540 Decal NLB Logo l Ea 18 PM7541 Decal NLB Logo 1 Ea 19 N 1000 Cover Inspection 1 Ea 2Q S f 2092 10 Di 9pt1Jre Silver 1 J5 i ztii 1T l r t l tJ 21 BM11623 Plate Mounting Pump Base 4Ea 30 DM15999 Lubri...

Page 50: ...NG WATER LUSE 1 167 1 1 t c i HIQ Pm SSlJRE WAltR CONNCCnON G PtNTLE HITQI LOW CRANKCASE OIL SHuTOOWN LOW WATER SHUTDOWN w I o TRAILER COUP tR 84 REF TO GROUNO lllESEI ENGINE 3 TRAILER COMPONENTS lliROTTLE COMPONENTS PUii SASI MNrG F l ATE INLl T PIPING OISCHARCE PIP1NG BYPASS RUPTURE ll SC PIPING PIPING MTH RUPTURE DISC 1 F MALE MPT CONNCCTlON WATER l l 84 15 6 REf TO GRO JNO I 5 GAL LUBE Oil RES...

Page 51: ...Piping Inlet 1 Ea 12 DLE6008 58 Piping Discharge 1 Ea 13 DM15998 Piping Water Tank 1 Ea 14 CLE6005 13S Piping Rupture Disc to Watter Tank 1 Ea 15 CLE6005 18S Hose Fittings Bypass 1 Ea 16 NLE7290 1 Tags Sub BOM 1 Ea 17 PM7540 Decal NLB Logo 1 Ea 18 PM7541 Decal NLB Logo 1 Ea 19 N 1000 Cover Inspection 1 Ea 20 NSP 2002 10 Disc Rupture lOK Silver 1 21 BM11623 Plate Mounting Pump Base 4Ea 30 DM15999 L...

Page 52: ... I 0 69 1 3 16 DIESEL ENGINE i r2 JB l 101 ZDB SKID STANDARD OPTIONS 0 PuMP WITH WATER LUBE PACKING PIPING WATtR LUSE LOW CIWIKCASE OIL SHUlllOWN LOW WATER SHUTDOWN CAL LUSE RESERVOIR ...

Page 53: ...tation Layout CUMMINS Diesel Engine 4 7 D Control Panel JOHN DEERE Diesel Engine 4 8 1 Control Panel Layout JOHN DEERE Diesel Engine 4 9 2 Terminal Strip Pinout JOHN DEERE Diesel Engine 4 10 II Pre Operating Procedure 4 11 III Operating Procedures 4 14 A Start Up Shut Down 4 14 1 CUMMINS Diesel Engine Start Up 4 15 L JOHN DEbRE Diesel bngme Stan up 1 ii 3 L 55i Oil Plunger Lubricator 4 17 4 Water ...

Page 54: ...s a very important trouble shooting tool Pilot lights are equipped with a push to test feature Depressing a pilot light s lens will cause the pilot light to illuminate if the pilot light is in proper working order A pilot light can only be tested when the high pressure water jetting unit is running 3 Push Button Pilot Lights A push button pilot light is a combination of a push button and a pilot l...

Page 55: ...he engine when operating VOLTS Device Voltmeter A needle on the gauge indicates the voltage of the battery when operating measured in volts HOURS RPM Device RPM Hourmeter Digital indicator Gauges the engine RPM The hourmeter records the accumulated hours on the high pressure water jetting unit It is useful for determining or evaluating service requirements for the unit TEMPERJ TURE Device Temperat...

Page 56: ...rol panel RESET Device Tattletale TM red push button pilot light Reset Depress and hold when starting engine release after oil pressure is achieved Shuts the engine off when a problem exists with low oil pressure or high engine coolant temperature Copyright June 2005 NLB Corporation 4 4 ...

Page 57: ...Revision 11 1 Control Panel Layout CUMMINS Diesel Engine KEY START STOP PRESSURE VOLTS HOURS RPM Copyright June 2005 NLB Corporation 4 5 TEMPERATURE RESET START PUSHBUTTON FUSE ...

Page 58: ... are described from top to bottom LOW WATER LEVEL Device Pilot Light Illuminates to indicate a low water condition WARM ENGINE RUN ENGINE Device Two Position Selector Switch Color Red Allows the operator to select from WARM ENGINE position which will bypass safety switches in water protection circuit for high pressure pump to RUN ENGINE position which will protect the pump from a low water level a...

Page 59: ...ass safety switches in water protection circuit for high pressure pump RUN ENGINE will protect pump from low water pressure shut down engine if a low water condition occurs in the high pressure pump WARM RUN I ENGINE ENGINE Copyright June 2005 NLB Corporation LOW WATER LEVEL 4 7 LOWWATER I At t ...

Page 60: ...etal enclosure that contains a series of gauges which give information on the oil pressure temperature voltage RPM and other engine controls Refer to the CONTROLS INCORPO RATED Electronic Engine Controller manual located in the MANUFACTURERS LITERA TURE section of this manual for operating instructions Copyright June 2005 NLB Corporation 4 8 ...

Page 61: ...Revision 11 1 Control Panel Layout JOHN DEERE Diesel Engine 0 0 Off Run 8 Copyright June 2005 NLB Corporation RPM NLB Cor THROTTLE a 4 9 Manual Throttle 0 Automatic Throttle 0 0 ...

Page 62: ...Ooen Dlscharne Pressure Switch 24 Not Used Lube Oil level 25 Pump Fault 1 Crank Case 011 Level 26 Pump Fault 2 Low Water Level 30 Fault Reset Emeraencv Stop 31 Ground Enter 32 Throttle Down 34 CAN J1939 Hi Tl1rottle Uo 35 CAN J1939 Low Menu 36 CAN J1939 Sl1leld BOLD CONNECTIONS MUST BE GROUNDED Ir NOT USED Pin B Pin D Pin E Pin F Pin V Pin U DEUTSCH 21 PIN PLUG PINOUT Battery lo EM Plus T2 Battery...

Page 63: ... WATER JETTING UNIT UNTRAINED OPERATORS MAY CAUSE EQUIPMENT DAMAGE AND OR PERSONAL INJURY OR DEATH a Check oil level in diesel engine crankcase Figure 4 1 Figure 4 1 Check oil level in engine crankcase b Check coolant level in engine radiator c Check oil level in high pressure pump Figure 4 2 Figure 4 2 Check oil level in pump crankcase Copyright June 2005 NLB Corporation 4 11 ...

Page 64: ... the tank cover and check the water level Inspect tank condition If there is any dirt accumulated in the bottom of the tank drain the water out and clean the inside of the tank Flush the dirt out and wipe away all dirt with a lint free rag After checking the water level close the cover and secure the latches This prevents any airborne dirt from entering the tank and getting into the pump Copyright...

Page 65: ...dia is from inside to outside A minimum clearance of 15 38 1 cm above the centerline of the filter inlet is necessary for removal of the filter internals Provision should be made for relieving any residual pressure that may remain in the filter after inlet flow is shut off 1 Check oil level in gear pac if so equipped j Open and drain the stuffing box drain sump located at the rear of the unit Figu...

Page 66: ...JETTING UNIT PASSED ALL LEAK TESTS BEFORE IT WAS SHIPPED HOWEVER YOU MUST INSPECT THE UNIT FOR ANY LEAKS OR FITTINGS WHICH MAY HAVE LOOSENED DURING SHIPMENT ALL LEAKS MUST BE FIXED BEFORE PROCEEDING WITH THE START UP A Start Up Shut Down Cat t i10n To avoid possible injury make sure that all personnel are aware of impending unit start up and clear of all moving parts Clear away materials and tools...

Page 67: ...t light and hold g Push the black starter crank pushbutton and release when engine fires If the engine does not start after three 3 attempts check the fuel supply system Lack of blue or white exhaust smoke during cranking indicates that no fuel is being delivered Caution To prevent damage to the starter and fuel shut off solenoid do not engage starting motor more than thirty seconds Wait two 2 min...

Page 68: ...ten the lock nut on the handle shaft J Engine oil pressure must be indicated on the gauge within 15 seconds after starting k When starting a cold engine slowly increase the enB ine speed rpm to provide adequate lubrication to the bearmgs and also allvw tl1e oil pressure to staDillzc by turmng me throttle control After the engine speed has been adjusted for proper pump pressure tighten the lock nut...

Page 69: ...automatic pressure relieving or limiting device must be installed to protect the filter The maximum pressure across the filter media is 50 psi 3 4 bar When filter outlet fr flnv f l1 l l1 v n or rP t 1l b 1 vP I tl1e fo1 rm ir g n11 t hr c nrnr1i hPr1 a Shut off flow to filter inlet Caution Pressure may exist relieve any residual pressure in the filter Drain the filter if desired b Loosen the lid ...

Page 70: ...er jetting accessory being used Refer to your NLB accessory manual for details WARNING BEFORE OPERATING THIS EQUIPMENT READ SECTION 2 SAFETY INSTRUCTIONS OPERATORS SHOULD RECEIVE TRAINING BEFORE USING THE HIGH PRESSURE WATER JETTING UNIT UNTRAINED OPERATORS MAY CAUSE EQUIPMENT DAMAGE AND OR PERSONAL INJURY OR DEATH 1 L 55i Oil Plunger Lubricator A belt from the high pressure pump crankshaft drives...

Page 71: ...eration B Mechanical Components 1 Daily or Approximately Every Eight 8 Hours of Operation 2 Weekly or Approximately Every 40 Hours of Operation 3 Monthly or Approximately Every 160 Hours of Operation 4 Every Three 3 Months or Approximately Every 250 Hours of Operation 5 Every Six 6 Months or Approximately Every 500 Hours of Operation 6 Every Year or Approximately Every 1000 Hours of Operation 7 Ev...

Page 72: ...ance is generally performed by maintenance personnel The desirability of preventive maintenance has always been there but often because of a pressing need for emergency repair work brought on by its very absence preventive maintenance has quite often been neglected This attitude of supposedly benign neglect is changing partly in response to an ever increasing sophistication and complexity in indus...

Page 73: ... moisture requires more frequent servicing 1 Freezing Conditions To prevent freezing of liquid in the fluid cylinder and to inhibit lubricating oil from becoming too viscous you must protect the high pressure pump from freezing temperatures If exposure to temperatures below 32 F 0 C is unavoidable provisions must be made to keep the pump s power end fluid end inlet water bag filter assembly and pl...

Page 74: ...before delving more deeply into preventive maintenance Remove any loose objects such as trash and oily rags from the work area Safety begins with you Make sure that all equipment has finished operating and has been shut down before beginning work Wear protective glasses and protective shoes when working Do not wear loose fitting or torn clothing Remove all jewelry when working Do not engage in nor...

Page 75: ... turned off Always use tools that are in good condition Make sure you understand how to use them before performing any preventive maintenance work Use ONLY genuine NLB replacement parts Do not make any unauthorized alterations to the equipment or components Do not attempt pressurization of the power end with dry gas to exclude contaminants without a special oil level indicator With a standard indi...

Page 76: ...m Service intervals specified are for operating hours with moderate temperatures unless otherwise specified It should be noted that service intervals should be adjusted accordingly for operation in abnormal environmental conditions The suggested service intervals are for the purpose of illustration only It is very important that each component be checked Special attention should be given to the hi...

Page 77: ...hed the electrical components the cause must be eliminated This could indicate an incorrect or ineffective enclosure unsealed enclosure openings conduit or other or incorrect operating procedures Dirty wet contaminated or corroded parts must be replaced unless they can be cleaned effectively by vacuuming or wiping Final Check Out After maintenance or repairs of electrical components always test th...

Page 78: ...wing a Check the oil pressure indicator warning light water temperature gauge and other gauges to make sure they are operational b Check to see if the lubricating oil level is at the proper level oil mark between L and H Add as needed Note To obtain an accurate measurement the engine must be level when checking the lubricating oil level c Check to see if the coolant is at the proper level Add as n...

Page 79: ...tside Figure 5 2 Belt inspection inside e Check to see if the fan is securely mounted Inspect the cooling fan for cracks loose rivets and bent or loose blades Replace any fan that is damaged f Drain the water from the fuel water separator Use the following procedure 1 Shut off engine 2 Open drain valve Turn valve counter clockwise four 4 complete turns until the valve drops down one 1 inch 25 4 mm...

Page 80: ...oil level is full Add oil if needed If the gasket is leaking replace the gasket d Make sure there is no water accumulation in the plunger well Plunger Lubricator Oil or Water Optional a Check to see if oil or water is being deposited on the plungers when the high pressure water jetting unit is running Check to see if oil tank is filled with oil Add if needed Refer to page 5 20 for refill intervals...

Page 81: ...aves will greatly increase the rate of wear With the high pressure water jetting unit off open the access door in the V belt guard Adjust belts to correct tension refer to Section 8 REPAIR G V belt Caution Care should be taken to insure that grease and oil do not come into contact with V belts These lubricants can not only cause belt slippage but also make the belt weak and spongy Replace worn V b...

Page 82: ...ALING FACE 1OK FILTER BAG NLB P N PM6962 FLAT GASKET NLB P N PM9144 PERFORATED FILTER SUPPORT BASKET NLB P N PM12542 Figure 5 3 Close Up ofOptional Water Inlet Bag Filter PM3350 Sealing Arrangement Copyright August 2000 NLB Corporation 5 12 ...

Page 83: ...ed hoses loose clamps or punctures which may damage the engine Tighten or replace the parts as needed to make sure that the air intake system does not leak c Visually inspect the charge air cooler for cracks holes or damage Check the tubes fins and welds for tears breaks or other damage d Check the air cleaner element for dirt Clean or replace as needed Note Follow Manufacturer s instructions when...

Page 84: ...r valves and valve seats Refinish if needed b Check for compressed or broken valve springs Replace if needed c Check plungers Replace if worn scored or otherwise damaged d Replace crosshead stub seals e Check crosshead deflectors Replace if damaged f Replace V belts if slipping excessively g Change oil in high pressure pump and optional gear pac or transmission Refer to IV Lubrication Instructions...

Page 85: ...mponent Cleaning Schedule The following are suggested cleaning instructions for components utilized in high pressure water jetting units designed and manufactured by the NLB Corporation Clean each component at the suggested service interval If any special cleaning instructions for vendor components on the unit need to be addressed the manufacturer s recommendations must be followed by referring to...

Page 86: ...ally After first oil change then annually Semi Annually Semi Annually Annually Semi Annually Semi Annually Annually Annually Semi Annually Annually Wipe clean with lint free rags Wipe clean with lint free rags Remove all sludge formation for trouble free operation Clean with mineral spirits After cleaning wipe with a cloth moistened with a light machine oil SAE 10 Clean with a cloth dampened with ...

Page 87: ... s nameplate data take precedent over the following suggestions Drain lubricating oil only when it is hot and the contaminants are in suspension Diesel Engine Crankcase If the high pressure water jetting equipment is in service under no circumstances can the lubricating oil drain interval extend beyond three 3 months or 250 hours LUBRICANT AMBIENT QUANTITY SERVICE TYPE TEMPERATURE REQUIRED INTERVA...

Page 88: ... s nameplate data take precedent over the following suggestions Drain lubricating oil only when it is hot and the contaminants are in suspension Diesel Engine Crankcase If the high pressure water jetting equipment is in service under no circumstances can the lubricating oil drain interval extend beyond three 3 months or 250 hours LUBRICANT AMBIENT QUANTITY SERVICE TYPE TEMPERATURE REQUIRED INTERVA...

Page 89: ...maintained near the upper mark on the oil gauge with the pump stopped If there is excessive water contamination oil appears milky in color then change the oil more frequently than indicated below LUBRICANT TYPE QUANTITY REQUIRED SERVICE INTERVAL SAE 15W40 9 0 qts 8 5 l Initial at 125 hrs then every six 6 months or 500 hours thereafter Make an attempt during each oil change to thoroughly clean the ...

Page 90: ...s air infringement causes the oil level in the sight glass to diminish Diminishing oil level is a condition that is caused by air that gets trapped in the sight glass This air will eventually enter into the valve system in the pump and cause pump air lock The condition is associated with the use of crankcase oils Some success in dealing with this condition can be obtained by the use of settling ta...

Page 91: ...er Lubricator Reservoir Refill Intervals The standard lubricator reservoir holds four 4 qts 3 8 l Based on 10 drops per minute 48 hours Based on 20 drops per minute 24 hours Based on 30 drops per minute 16 hours Estimated L 55i Oil Plunger Lubricator Reservoir Refill Intervals The optional lubricator reservoir holds 20 0 qts 18 91 Based on 10 drops per minute 240 hours Based on 20 drops per minute...

Page 92: ...ratures below 32 F 0 C provisions must be made to keep the high pressure pump from freezing If conditions will allow water in the unit to freeze during shut down periods the entire system must be drained to prevent damage to the pump and piping Antifreeze solution liquid must then be forced from the suction line into the pumping chambers to force the fluid out of the pumping chambers The recommend...

Page 93: ...olor of the discharge from the pump matches the color of the new coolant This indicates that the coolant is in the high pressure pump and piping f The high pressure water jetting unit is now safe to store indefinitely where temperatures reach 0 F 18 C g The coolant solution in the diesel engine s radiator should be checked at regular intervals to assure that the engine does not freeze up Add coola...

Page 94: ...MAINTENANCE RECORD EQUIPMENT DATE OF HOURS RESULT OF INSPECTION PARTS REPLACED OR COMMENTS TECHNICIAN S SERIAL NO INSPECTION REPAIRED INITIALS ...

Page 95: ... Process III Trouble Shooting Guide A Symptoms 1 Excessive Pulsation in High Pressure Pump Discharge 2 Excessive Unit Vibration 3 High Pressure Pump Discharge Pressure High Above Unit Rating 4 High Pressure Pump Discharge Pressure Low 5 Excessive High Pressure Pump Noise 6 Excessive V belt Slippage or Wear B Diesel Engine Copyright June 1999 NLB Corporation 6 1 6 1 6 2 6 2 6 3 6 3 6 4 6 5 6 5 6 5 ...

Page 96: ...e maintenance Remove any loose objects such as trash and oily rags from the work area Safety begins with you Make sure that all equipment has finished operating and has been shut down before beginning work Wear protective glasses and protective shoes when working Do not wear loose fitting or torn clothing Remove all jewelry when working Do not engage in nor tolerate horseplay in the work area Revi...

Page 97: ... to exclude contaminants without a special oil level indicator With a standard indicator all oil will be lost through the vent hole in the top of the indicator Adhere to the preventive maintenance intervals to ensure proper operation of high pressure water jetting unit II Trouble Shooting Procedures The NLB Corporation Models 1312D 1012D 812D 612D 512D 412D 3 512D 312D 1060D 860D 760D high pressur...

Page 98: ...e action is a condensed step by step summary of the repair procedure required to remedy the problem Use the following trouble shooting diagnostic procedure when a high pressure water jetting system malfunction occurs a Precisely define the symptom of the problem This is the most important step in identifying the probable cause b Locate the symptom that most closely resembles your appraisal of the ...

Page 99: ... scored f Belts slipping 1 Open by pass on accessory cleaning lance Engage clutch and throttle engine upwards for one 1 minute or until you observe smooth discharge at by pass Repeat several times if needed If unsuccessful proceed to step 2 2 Bleed pump at valve intake cover by loosening caps and engaging clutch This condition is caused by a piece of dirt or an object stuck between the valve and s...

Page 100: ...h proper size nozzle Replace with proper size hose Replace 4 High Pressure Pump Discharge Pressure Low Probable Cause Corrective Action a Insufficient engine speed Adjust speed control by adjusting throttle b Too large of nozzle Replace with proper size nozzle c Belts slipping Adjust d Leaking valves Rework or replace e Leaking by pass valve Repair or replace f Clutch slipping Adjust or repair g I...

Page 101: ...ply some blue LOCTITE between faces of plunger and crosshead then tighten firmly If plungers are tight proceed to Probable Cause c c Worn crankshaft bearings Check for bearing clearance Refer to Section 8 d Worn crosshead or crosshead pins e Pump cavitation REPAIR Check crosshead clearances with cylinder wall and crosshead pin Refer to Section 8 REPAIR See Symptom 1 Excessive Pulsation in High Pre...

Page 102: ...Revision 2 B Diesel Engine Refer to the MANUFACTURERS LITERATURE section in this manual Copyright December 1999 NLB Corporation 6 8 ...

Page 103: ...Revision 0 TABLE OF CONTENTS SECTION 7 SPECIAL TOOLS DESCRIPTION PAGE NUMBER Table of Contents 7 1 I Special Tool Identification 7 2 Copyright June 1999 NLB Corporation 7 1 ...

Page 104: ...Caution Use the proper tools for the specific job The use of improper tools may result in personal injury or costly damage to the high pressure water jetting unit STl 5 8 Socket Adapter For Use on Suction Manifold and Stuffing Box Bolts STl 3 4 Socket Adapter For Use on Discharge Manifold Bolts PD 33A Packing Drift or PD 34B For Pushing Packing Elements From Stuffing Box 0 ST4 1012 Wrench Adapter ...

Page 105: ...Revision 2 m 1 s 2 PM12969 Belt Tensioning Gauge For Use on V belts Copyright December 1999 NLB Corporation 7 3 ...

Page 106: ......

Page 107: ...charge Manifolds and Valve Assemblies 8 18 c Fluid Cylinder 8 25 2 Power End 8 28 B BVl0 650 By Pass Valve 8 38 C BVl0 400 By Pass Valve 8 49 D BV20 260 By Pass Valve 8 57 E NSP 2000 Rupture Disc Valve Assembly 8 65 F NSP 3000 Rupture Disc Valve Assembly 8 67 G L 5Si v1l Plunger Lubricator 8 69 H V belt 8 73 I 4071 10 Throttle Contol 8 76 1 Seal and Piston Replacement 8 76 J 4071 20 Throttle Conto...

Page 108: ... of the high pressure water jetting unit Here is a brief review of some of the general safety precautions before delving more deeply into repair All service personnel who will perform any repair work shall take notice of all safety signs affixed to the high pressure water jetting unit Copies of each sign are found in Section 2 SAFETY The work area shall be clean and free of all debris Oil spillage...

Page 109: ...ection slowly loosen the fitting nut to allow any stored pressure to escape through the fitting weep hole Never stand directly in line with the fitting weep hole when performing such procedures Do not remove high pressure tubing protective shields If the protective shields are removed for service make sure that they are put back on before starting the unit Torque all fittings being serviced to des...

Page 110: ...ssembly Do not force parts together If mating parts bind then separate them and try again until properly aligned Caution It should never be necessary to force an assembly together Plungers are made using strong but brittle material Avoid dropping sharp blows or heavy loads when working with these expensive parts Inspect threaded areas of components that are removed for service If damaged then repa...

Page 111: ...T for procedure 2 Repair Tips The following repair tips are offered to assist the service technician in making timely repairs Make a routine daily inspection of the entire unit before operating Section 5 PREVENTIVE MAINTENANCE Inspect all parts of the unit for abnormal conditions If a malfunction has occurred then identify the cause Section 6 TROUBLE SHOOTING document the information and correct t...

Page 112: ...operating the unit Make sure all of the operating parts of the unit are clean Maintain records of the repair performed on the unit These records will provide valuable information for ordering specific parts and for maintenance in general Handle critical parts with care Avoid scratching or denting the high pressure water system components Copyright December 1999 NLB Corporation 8 6 ...

Page 113: ...res a Plunger Packing and Stuffing Boxes Service People Required 1 Recommended Tools Pliers 1 1 2 combination wrench 36 pipe wrench medium flat blade screwdriver Special Tool ST 1 5 8 Socket Adapter 3 4 socket and ratchet wrench small pry bar Special Tool PD 33A Packing Drift A Cylinders or PD 34B Packing Drift B Cylinders medium size ball peen hammer feeler gauge 0 ring pick 3 4 drive torque wren...

Page 114: ... 3 hoses Lay the plastic cover and the hoses back out of the way 2 Turn the pump crankshaft until the crosshead stub plunger reaches the correct position for repair procedure Figure 8 1 The crankshaft can be turned by moving the V belts which can be reached through the inspection port in the belt guard Figure 8 2 Figure 8 1 Turning crosshead stub plunger Figure 8 2 Accessing the V belts Copyright ...

Page 115: ...tially loosen the the plungers from the crosshead stub Push the plunger into the stuffing box Figure 8 3 Figure 8 3 Pushing plunger into stuffing box 4 Place the Special Tool ST 1 5 8 Socket Adapter into the Allen bolt socket Figure 8 4 Use a 3 4 socket and ratchet wrench to completely unscrew all four 4 bolts in the corners of the stuffing box flange Figure 8 4 Placing the special tool into the A...

Page 116: ...he pump Figure 8 5 Figure 8 5 Removing the stuffing box from the pump Removal and Replacement of Plunger Packing 6 The stuffing box should be disassembled and overhauled in a clean workbench area Remove the packing spring from the end of the plunger Pull the plunger out of the stuffing box Figure 8 6 Figure 8 6 Pushing the plunger out ofthe stuffing box Copyright October 2001 NLB Corporation 8 1 0...

Page 117: ...ut Figure 8 8 Figure 8 8 Driving out old packing 9 Clean and inspect the surface of all parts Replace damaged or worn parts Do not reuse worn plungers bushings or stuffing boxes Plungers and bushings must be within recommended maximum clearances it is of critical importance that a close tolerance must be maintained between the backup ring and the plunger The diametral clearance for a new Backup Ri...

Page 118: ...that way Figure 8 9 The first third and fifth elements are wax impregnated flax The second and fourth are made from lead Stagger the splits as shown during installation Figure 8 10 Figure 8 9 Keeping the new parts in order 4 3 Figure 8 10 Laying out the packing set Copyright October 2001 NLB Corporation 8 12 ...

Page 119: ...Ring Item 15 then the Packing Item 14 then the Throat Bushing Item 13 Figure 8 11 Assembling packing and bushings 12 Lubricate by dipping the individual pieces of the packing set and bushings into a cup of SAE 15W40 oil Figure 8 12 Figure 8 12 Lubricating the parts Copyright October 2001 NLB Corporation 8 13 ...

Page 120: ... PD 33A or PD 34B Packing Drift to seat each piece into its final position Figure 8 14 Figure 8 13 Inserting each piece Figure 8 14 Seating each piece Caution Offset the splits in the packing during installation If the splits are lined up packing failure will result Copyright October 2001 NLB Corporation 8 14 ...

Page 121: ...tuffing box Figure 8 15 Pushing the plunger into the stuffing box 15 Use a pick to remove the 0 ring Figure 8 16 Wipe off until completely clean the groove and the seating surface Lightly grease the new 0 ring Item 11 and push it without damage into the stuffing box groove Install the Packing Spring Item 12 The assembly is now ready for installation to the high pressure pump Figure 8 16 Removing 0...

Page 122: ...der 17 Tighten down the Allen bolts in increments according to the torque sequence Figure 8 18 Keep checking for even alignment of the stuffing box to the pump not cocked sideways When the stuffing box is snug to the body make sure that the fit is even Use the torque wrench to final tighten the bolts in torque sequence to the specified 300 lb ft 406 7Nm for A Cylinders and 150 lb ft 203 4 Nm for B...

Page 123: ...ead of blue LOCTITE to the threads Figure 8 20 between the plunger and the crosshead stub Use a combination wrench to draw the plunger up tight to the crosshead stub since it cannot rotate in a clockwise manner Torque to 40 50 lb ft 54 6 to 68 Nm Figure 8 20 Applying LOCTITE to threads 20 Replace the lubricator hoses and clamps Install the plastic cover Copyright October 2001 NLB Corporation 8 17 ...

Page 124: ...IRST BLEED DOWN ALL HIGH PRESSURE LINES PUT A DO NOT OPERATE TAG ON THE CONTROLS FAILURE TO DO SO MAY RESULT IN DAMAGE TO EQUIPMENT AND OR PERSONAL INJURY Removal of Suction and Discharge Manifolds 1 Remove sufficient piping or accessories from the manifold so that it can be completely separated from the pump and placed on a clean workbench 2 Insert Special Tool Figure 8 21 and socket with ratchet...

Page 125: ...ople one 1 person on each end grasp and carefully lift up the manifold Figure 8 23 If only one 1 person is available fasten two 2 each 1 2 13 eye bolts to the manifold and use a chain fall or hoist to lift off Figure 8 23 Lifting the discharge manifold Copyright December 1999 NLB Corporation 8 1 9 ...

Page 126: ...lve Assemblies Note To simplify maintenance and to avoid the possibility of seat bypass causing fluid to washout the unitized wing type valve assemblies are designed to be clamped between the fluid cylinder and the manifolds All of the components are designed together so that a valve unit cannot be installed backwards Furthermore the suction and discharge valve assemblies are interchangeable The s...

Page 127: ...ect all valve assembly parts for wear or damage Figure 8 26 Check all 0 rings on valves for any nicks or cuts Use 0 rings that are in perfect condition but replace any which are not The valve assembly is made up of from left to right 0 ring Item 3 Valve Seat Item 4 Valve Item 5 Valve Spring Item 6 0 ring Item 3 Suction Valve Stop Item 7 and 0 ring Item 3 Figure 8 26 Valve assembly Copyright Decemb...

Page 128: ...e valve from the valve seat Figure 8 28 Wash and dry the parts Clean the surfaces with a lint free rag Inspect the 0 rings and seating surfaces If a scratch groove or eroded area extends across the seating surface you must refinish the surfaces before assembling or operating the unit Figure 8 28 Removing the valve from the valve seat Copyright December 1999 NLB Corporation 8 22 ...

Page 129: ...apping the valve surfaces Note For optimum sealing the surfaces of the valve and valve seat should have an eight 8 micro inch or smoother RMS finish After the valve and seat have been refinished several times they may become too thin to perform their function effectively Replace excessively worn parts with new 11 Remove all traces of grinding compound and carefully wash and dry all parts Assemble ...

Page 130: ...ading and to evenly tighten the manifolds to the fluid cylinder apply torque to all bolts in sequence Figures 8 31 and 8 32 Tighten the suction manifold bolts in 50 lb ft increments per bolt up to the final torque of 300 lb ft 406 7 Nm Tighten the discharge manifold bolts in 50 lb ft 68 Nm increments per bolt up to the final torque of 450 lb ft 612 Nm 7 5 6 8 Figure 8 31 Tightening discharge manif...

Page 131: ...te Refer to Section 9 PARTS for breakdowns and parts lists for the following procedures The main fluid cylinder may be removed from the power end as an assembly or disassembled prior to removal If you have already removed the plungers stuffing boxes manifolds and valves or you are removing the cylinder as an assembly disregard steps 1 5 below Removal of Fluid Cylinder from Power Frame 1 Disconnect...

Page 132: ...ure 8 34 to loosen and remove the cylinder tie stud nuts Figure 8 33 Using special tool to remove tie stud nuts Figure 8 34 Using torque wrench with the special tool 8 Attach hoist or chain fall and remove slack in lifting chains Copyright October 2001 NLB Corporation 8 26 ...

Page 133: ...ding alignment holes on the fluid cylinder 10 Clean and inspect the fluid cylinder and the power frame mating surfaces Use plastic scraper to remove paint dirt or burrs Look for cracks or deep scratches Replace damaged parts with new Assembly of Fluid Cylinder to Power Frame Note The fluid cylinder may be installed with the discharge manifold assembled to the main fluid cylinder 11 With chain fall...

Page 134: ...aces are smooth Use plastic scraper to remove paint dirt or burrs Wipe surfaces clean with lint free rags on valve assemblies manifolds and fluid cylinder 14 Coat the 0 rings with light grease to hold them in position for proper seating 15 Install valve assemblies and manifolds 16 Install stuffing boxes to the fluid cylinder 17 Connect plungers to the crosshead stubs 18 Install piping hoses and ac...

Page 135: ... and Crosshead Stub Seal Item 35 If needed to facilitate removal screw two 2 3 8 9 5 mm eye bolts into the tapped holes in the cap 5 Remove each Crosshead Stub Item 31 by unscrewing it from crosshead A moderate amount of resistance will be experienced when unscrewing the stub because a medium strength anaerobic adhesive is used on the threads during assembly to minimize the chance of this joint lo...

Page 136: ...om either side by tapping gently with a wooden block Figure 8 36 Two 2 each l 25 4 mm rods each threaded on one 1 end may be screwed into the ends of the crankshaft to facilitate removal Figure 8 37 V 1000 13 LOC K Figure 8 36 Tapping with wood block Figure 8 37 Inserting threaded rods to facilitate removal Copyright October 2001 NLB Corporation 8 30 ...

Page 137: ... assembled in the same location Figure 8 38 Removing rods and crosshead assemblies 10 The Bushing Wrist Pins Item 29 are held in position in the crosshead assemblies with set screws Figure 8 39 Remove the set screws and push the wrist pins out of the rods Figure 8 39 Removing set screws and bushing wrist pins Copyright October 2001 NLB Corporation 8 31 ...

Page 138: ...nkshaft by overheating 13 Heat the new main bearing assembly as a unit to a temperature that is no hotter than 300 F 150 C Slip the hot parts into position to install on the crankshaft Removal Replacement of Connecting Rod Bearings and Wrist Pin Bushings The connecting rod and the matching cap assembly are bolted together and clamp the connecting rod bearings into position around the crankshaft Fi...

Page 139: ...es or burrs where the new wrist pin bushing will be positioned Wipe the parts clean with lint free rags Use a suitable arbor to press the new bronze wrist pin bushing into place so that it extends 1 8 3 2 mm beyond each side of the rod After the bushings are pressed into the rods ream the bushings to 2 3765 to 2 377 60 363 to 60 376 mm 17 Clean the connecting rod and bearing surfaces before instal...

Page 140: ...n bearing does this end play need to be reset to these limits Measure end play by mounting a dial indicator on the power frame and placing the indicator button on any vertical surface of the crankshaft Pry the crankshaft to one side Figure 8 41 and then to the other noting the total travel of the dial indicator To change end play add or remove shims at the crankshaft frame caps Figure 8 41 Checkin...

Page 141: ...any pin bearing rubs on the inside of any crosshead transfer shims from one side of the pump to the other side to shift the crankshaft Connecting Rod Crosshead Crosshead Pin Note J Crosshead Pin Bearing Provide gap on both sides of crosshead so bearing does not rub Figure 8 42 Shimming frame caps Copyright October 2001 NLB Corporation 8 35 ...

Page 142: ...tub Thread 40 54 6 Inspection Cover Top Bolt 35 47 2 Use blue LOCTITE on threads Clearances When Parts Are New Part Inches Millimeters Crosshead in Power Frame 006 to 008 15 to 20 Crosshead Pin Bearing over Crosshead 0020 to 0027 05 to 07 Pin Connecting Rod Bearing over Crankshaft 005 to 007 12 to 18 Crankshaft End Play 001 to 005 02 to 12 Plunger Back Up Ring 002 to 004 051 to 102 Replace Parts O...

Page 143: ...075 to 12 Plunger Back Up Ring 007 178 If high pressure pump suction pressure is high enough to keep crosshead pin bearing loaded on the suction stroke the pump will not knock as the bearing wears and the unit will operate satisfactorily with wear up to about 050 1 27 mm Copyright October 2001 NLB Corporation 8 37 ...

Page 144: ...ired 1 Recommended Tools Bench vise medium adjustable wrench 0 ring pick a clean metal rod about 24 60 9 cm long by 1 2 or smaller diameter 1000 lb ft 1360 Nm torque wrench with multiplier and a pair of needle nose pliers Parts Subject to inspection Pin Item 2 Seat Item 3 0 rings Item 14 Backup Rings Item 13 and Deflector Item 17 Supplies Medium size pan 1 4 20 cap screw emery cloth quart 94 l of ...

Page 145: ... in a bench vise Figure 8 44 Figure 8 44 Clamping seatframe 2 Unscrew the Jam Nut Handle Item 21 3 Loosen the Adjuster Screw Item 9 until there is no spring force on the screw and remove Splash Deflector Item 12 Figure 8 45 Figure 8 45 Loosening adjuster screw 4 Unscrew the Cap Nut Item 8 from the Body Item 1 Copyright October 2001 NLB Corporation 8 39 ...

Page 146: ...Item 1 and dump all internal parts into a drain pan oil will drain from the upper portion of the body If desired a 1 4 20 cap screw can be threaded into the Spring Guide Item 5 to assist in extracting the stack of Disc Springs Item 11 from the Body Item 1 Figure 8 47 Figure 8 47 Extracting disc springs Copyright October 2001 NLB Corporation 8 40 ...

Page 147: ...o push the Pin Item 2 and the Seat Item 3 out of the body oil will drain from the cavity Figure 8 48 Figure 8 48 Pushing seat and pin out ofthe body ASSEMBLY 8 Carefully wash all parts with mineral spirits Wipe dry with lint free towels 9 If the bore in the Body Item 1 is rough smooth it with emery cloth Copyright October 2001 NLB Corporation 8 41 ...

Page 148: ... to the opposite end of the pin Figure 8 49 If the Deflector Item 17 is significantly worn by water impingement then replace it Look for Deflector wear out after 100 hours of operation with continuous throttling at 25 gpm 94 5 lpm Figure 8 49 Moving Deflector to opposite end ofthe pin Caution Failure to replace a worn Deflector Item 17 will result in damage to the Body Item 1 11 Apply blue LOCTITE...

Page 149: ...m 2 Figure 8 50 Coat the 0 rings with Dexron automatic transmission fluid ATF Figure 8 50 Installing a new 0 ring and backup rings 13 Slide the Pin Item 2 into the Body Item 1 until it bottoms Figure 8 51 Figure 8 51 Sliding the pin into the body Copyright October 2001 NLB Corporation 8 43 ...

Page 150: ...into a bench vise and apply a coating of light grease to the 0 ring Item 14 and to the face of the seat frame Figure 8 53 Figure 8 53 Greasing the 0 ring andface ofthe seatframe 17 Apply anti seize compound to the threads of the Seat Frame Item 4 and to the matching threads in the Body Item 1 18 Thread the Seat Frame Item 4 into the Body Item 1 and tighten finger tight Copyright October 2001 NLB C...

Page 151: ... about 24 long by 1 2 or smaller diameter to push the Pin Item 2 onto the Seat Item 3 Nudge the pin about 1 4 6 3 mm back up onto the seat again Figure 8 55 This procedure is necessary to expel air from the cavity above the pin and to keep the valve from squealing Figure 8 55 Pushing the pin onto the seat 21 Place the first Disc Spring Item 11 face up onto the Spring Guide Item 5 Figure 8 56 Copyr...

Page 152: ... Item 11 face down onto the Spring guide Item 5 Figure 8 56 Continue to stack the remaining springs face up and face down until the last spring is placed face up 23 Slide the Guide Bushing Item 6 onto the top of the Disc Springs Item 11 Copyright October 2001 NLB Corporation 8 46 ...

Page 153: ...to the top of the Guide Bushing Item 6 26 Apply anti seize compound to the bolt threads on the Cap Nut Item 8 and thread it into the Body Item 8 and tighten 27 Unscrew the Seat Frame Item 4 about 1 4 turn tighten the seat frame to 800 lb ft 1088 Nm 28 Loosen the Adjuster Screw Item 9 29 Re install Rubber Bumper Item 19 and Rubber Bumper Item 20 Copyright October 2001 NLB Corporation 8 47 ...

Page 154: ... Nut Item 8 vent hole Figure 8 58 Performing this task will prevent oil leakage if the BV10 650 By Pass Valve is shipped or stored in the horizontal position The 0 ring can be left in while the valve is in operation Figure 8 58 Plugging the vent hole Copyright October 2001 NLB Corporation 8 48 ...

Page 155: ... nose pliers 0 to 50 lb ft 0 to 68 Nm adjustable torque wrench 50 to 300 lb ft 68 to 137Nm adjustable torque wrench flat blade screwdriver and an 0 ring pick Parts Subject to inspection All 0 rings Supplies Fine emery cloth jar of lapping compound 1 quart 94 l of Dexron automatic transmission fluid ATF oil drain pan clean medium size pan jar of anti seize compound tube of light grease long clean r...

Page 156: ...n the screw Figure 8 60 Figure 8 60 Subassembly adjuster 4 Remove the Body Item 1 from the Seat Frame Item 4 Figure 8 61 Figure 8 61 Removing the body 5 Tighten the Subassembly Adjuster Item 9 to push the Valve Seat Item 3 from the Body Item 1 Copyright October 2001 NLB Corporation 8 50 ...

Page 157: ...e Body Item 1 9 Invert the Body Item 1 Dump all internal parts into a pan Drain the oil from the upper portion of the body ASSEMBLY 10 Carefully wash and dry all parts 11 Replace any parts that are worn beyond their useful life Replace the three 3 0 rings Items 12 13 and Backup 0 ring Item 14 12 If the bore in the Body Item 1 is rough smooth it with emery cloth 13 If the seating surface of the Pin...

Page 158: ... on the pin 15 Slide the Pin Item 2 onto the Body Item 1 until it bottoms 16 With the Seat Frame Item 4 clamped in a vise Figure 8 64 install a new 0 ring Item 13 Figure 8 64 Installing new 0 ring in face 17 Coat the 0 ring Item 13 with grease and the threads of the Seat Frame Item 4 with anti seize compound Copyright October 2001 NLB Corporation 8 52 ...

Page 159: ... the frame 19 Thread the Body Item 1 onto the Seat Frame Item 4 until finger tight 20 With the Adjuster Item 9 end up pour about one 1 ounce 29 5 ml of Dexron or equal automatic transmission fluid ATF into the Body Item 1 Figure 8 66 Figure 8 66 Pouring ATF into body Copyright October 2001 NLB Corporation 8 53 ...

Page 160: ...pin and to keep the valve from squealing Figure 8 67 Expelling airfrom cavity 22 Slide the Spring Guide Item 5 into the Body Item 1 23 Pour ATF into the Body Item 1 until the cavity is about half full 24 Place the first Disc Spring Item 11 face up onto the Spring Guide Item 5 Figure 8 68 Figure 8 68 Placing first disc spring 25 Place the second Disc Spring Item 11 face down onto the Spring Guide I...

Page 161: ...e Bushing Item 6 and tighten 29 Coat the Cap Nut Item 8 with anti seize compound Thread the nut into the Body Item 1 and tighten 30 Tighten the Subassembly Adjuster Item 9 until it touches the Disc Item 7 then tighten it about three 3 more turns Figure 8 69 to push the Pin Item 2 into the Seat Item 3 and center the seat Figure 8 69 Centering the seat 31 Tighten the Seat Frame Item 4 and torque to ...

Page 162: ...Revision 6 32 Loosen the Subassembly Adjuster Item 9 Copyright October 2001 NLB Corporation 8 56 ...

Page 163: ...e nose pliers 0 to 50 lb ft 0 to 68 Nm adjustable torque wrench 50 to 300 lb ft 68to137 Nm adjustable torque wrench flat blade screwdriver and an 0 ring pick Parts Subject to inspection All 0 rings Supplies Fine emery cloth jar of lapping compound 1 quart 94 l of Dexron automatic transmission fluid ATF oil drain pan clean medium size pan jar of anti seize compound tube of light grease long clean r...

Page 164: ...n the screw Figure 8 72 Figure 8 72 Subassembly adjuster 4 Remove the Body Item 1 from the Seat Frame Item 4 Figure 8 73 Figure 8 73 Removing the body 5 Tighten the Subassembly Adjuster Item 9 to push the Valve Seat Item 3 from the Body Item 1 Copyright October 2001 NLB Corporation 8 58 ...

Page 165: ...e Body Item 1 9 Invert the Body Item 1 Dump all internal parts into a pan Drain the oil from the upper portion of the body ASSEMBLY 10 Carefully wash and dry all parts 11 Replace any parts that are worn beyond their useful life Replace the three 3 0 rings Items 12 13 and Backup 0 ring Item 17 12 If the bore in the Body Item 1 is rough smooth it with emery cloth 13 If the seating surface of the Pin...

Page 166: ...on the pin 15 Slide the Pin Item 2 onto the Body Item 1 until it bottoms 16 With the Seat Frame Item 4 clamped in a vise Figure 8 76 install a new 0 ring Item 13 Figure 8 76 Installing new 0 ring in face 17 Coat the 0 ring Item 13 with grease and the threads of the Seat Frame Item 4 with anti seize compound Copyright October 2001 NLB Corporation 8 60 ...

Page 167: ... the frame 19 Thread the Body Item 1 onto the Seat Frame Item 4 until finger tight 20 With the Adjuster Item 9 end up pour about one 1 ounce 29 5 ml of Dexron or equal automatic transmission fluid ATF into the Body Item 1 Figure 8 78 Figure 8 78 Pouring ATF into body Copyright October 2001 NLB Corporation 8 61 ...

Page 168: ...pin and to keep the valve from squealing Figure 8 79 Expelling airfrom cavity 22 Slide the Spring Guide Item 5 into the Body Item 1 23 Pour ATP into the Body Item 1 until the cavity is about half full 24 Place the first Disc Spring Item 11 face up onto the Spring Guide Item 5 Figure 8 80 Figure 8 80 Placing first disc spring 25 Place the second Disc Spring Item 11 face down onto the Spring Guide I...

Page 169: ...e Bushing Item 6 and tighten 29 Coat the Cap Nut Item 8 with anti seize compound Thread the nut into the Body Item 1 and tighten 30 Tighten the Subassembly Adjuster Item 9 until it touches the Disc Item 7 then tighten it about three 3 more turns Figure 8 81 to push the Pin Item 2 into the Seat Item 3 and center the seat Figure 8 81 Centering the seat 31 Tighten the Seat Frame Item 4 and torque to ...

Page 170: ...Revision 6 32 Loosen the Subassembly Adjuster Item 9 Copyright October 2001 NLB Corporation 8 64 ...

Page 171: ...Tape 1 Relieve system pressure Remove hose and fittings that are connected to the Rupture Disc Valve Assembly Figure 8 83 Figure 8 83 Accessing the rupture disc 2 First place a 1 1 4 open end wrench on the Body Item 1 to keep it from turning Then position a 1 1 8 open end wrench on the Pop Off Valve Item 4 and remove it from the Body Item 1 3 With a small screwdriver or 1 8 3 2 mm rod reach into t...

Page 172: ... r t l NSP 2001 1 Valve Body NSP 2002 10 Rupture Disc CM 3556 Pop Off Valve Figure 8 84 Rupture disc valve assembly Caution The bevel is only on the inside diameter of the washer It is very important that the beveled side of the washer only be placed against the dome side of the rupture disc 5 Screw the Pop Off Valve Item 4 back on to the Body Item 1 and tighten securely Install the fittings and h...

Page 173: ...Assembly Figure 8 85 Figure 8 85 Accessing the rupture disc 2 To replace the Rupture Disc Item 3 place a 1 1 4 open end wrench on the Body Item 4 to keep it from turning Then place a 13 16 open end wrench on the Cap Item 1 and remove it from the Body Item 4 The Washer Item 2 and Rupture Disc Item 3 should fall out If they fail to come out use a screwdriver to fish them out 3 Uncrew and remove Body...

Page 174: ... safely directs the water away from the operator if the rupture disc bursts Failure to replace the elbow may result in injury 5 Screw the Cap Item 1 into the Body Item 4 and tighten securely 6 Attach the Body Item 4 into the discharge block so that the taper on the seat points in the proper direction Figure 8 86 The Body Item 4 and Cap Item 1 must be tightened securely Install the fittings and hos...

Page 175: ... be obtained when the adjusting sleeve is fully extended out of the top of the plunger stroke Maximium recommended oil viscosity is 8000 SUS Suction Stroke As the plunger moves downward oil is drawn through the suction check and into the plunger bore from the small reservoir in the sight glass Reducing the volume of oil in the sight glass creates a vacuum which draws oil from the lubricator reserv...

Page 176: ...are based on SAE 15W40 oil at room temperature Sight Glass The sight glass gives a visual indication of the condition of the oil flowing through the lubrication pump An increasing oil level indicates absorption of air in the sight glass by the oil passing through Over fill eliminates visual metering of drops in the sight glass but has no effect on pump operation Airlock Airlocking occurs when air ...

Page 177: ...n the sight glass as it passes through the pump This condition does not affect the operation of the pump except that the oil cannot be observed coming out of the dropper due to the sight glass being filled with oil Normal sight glass operation can be restored by momentarily loosing the dropper at the top of the sight glass to break the vacuum within the sight glass Do not leave the sight glass dro...

Page 178: ...ubbles indicates a leakage at the sight glass Damaged seating surface either on the glass itself or the glass seating area can be responsible for air leakage 5 Strainers should not be removed from the filler spout Cleaning of the reservoir should be done periodically Section 5 PREVENTIVE MAINTENANCE Suggested Component Cleaning Schedule for procedure Remember that sludge formation due to condensat...

Page 179: ...other person or chain hoist remove guard from unit 2 Loosen up retaining bolts on sheaves Pry belt out with a screwdriver 3 Do not drive sheaves on or off shafts Be sure shaft and keyway are correct size Remove burrs by pressing lightly with a finishing file Wipe shaft key and bore clean with a light oil Tighten screws carefully Recheck and retighten after eight 8 hours of operation 4 Belts should...

Page 180: ...ng 6 17 6 58 kg Gauge Recommended Recommended Power Band Static Tension Static Tension Length Multiplier New V belt Used V belt Min Max Min Max 208 2 223 0 lb 178 4 193 3 lb 1 0094 1 0117 93 69 100 35 80 28 86 98 kg kg 7 Do not install a new belt where the sheaves have worn or damaged grooves Worn sheaves should be replaced with new ones to insure a proper fit of the belt in the grooves thus elimi...

Page 181: ...Revision 6 10 Keep extra belts stored in a cool dark and dry place Copyright October 2001 NLB Corporation 8 75 ...

Page 182: ...oid all warranties on this equipment WARNING DISCONNECT THE BATTERY NEGATIVE CABLE FIRST OR TURN DISCONNECT SWITCH TO THE OFF POSITION FIRST BLEED DOWN ALL HIGH PRESSURE LINES PUT A DO NOT OPERATE TAG ON THE CONTROLS FAILURE TO DO SO MAY RESULT IN DAMAGE TO EQUIPMENT AND OR PERSONAL INJURY 1 The Seal Item 1 is installed onto the Piston Item 2 Figure 8 88 The seal is a five piece design and is pack...

Page 183: ...n assembly into adapter and pushing it flush with the adapter end Figure 8 89 Figure 8 89 Inserting seal and piston assembly into adapter bore 3 The Adjustable Stop Item 3 should be lightly coated with anti seize compound prior to assembly The stop is made out of gall resistant bronze and does not require lubrication however the use of lubrication should provide additional wear resistance under he...

Page 184: ...oid all warranties on this equipment WARNING DISCONNECT THE BATTERY NEGATIVE CABLE FIRST OR TURN DISCONNECT SWITCH TO THE OFF POSITION FIRST BLEED DOWN ALL HIGH PRESSURE LINES PUT A DO NOT OPERATE TAG ON THE CONTROLS FAILURE TO DO SO MAY RESULT IN DAMAGE TO EQUIPMENT AND OR PERSONAL INJURY 1 The Seal Item 1 is installed onto the Piston Item 2 Figure 8 90 The seal is a five piece design and is pack...

Page 185: ... assembly into adapter and pushing it flush with the adapter end Figure 8 91 Figure 8 91 Inserting seal and piston assembly into adapter bore 3 The Adjustable Stop Item 3 should be lightly coated with anti seize compound prior to assembly The stop is made out of gall resistant bronze and does not require lubrication however the use of lubrication should provide additional wear resistance under hea...

Page 186: ... W LUBE CIL LEVEL LC W INL T WATER PRESSURE AIR COMPRESSOR OVER TEMPERATURE LC W WATER LEVEL PTO ENGAGE SOLENOID PTO DISENGAGE SOLENDID FUEL GAUGE DUMP VALVE SDLENDID J RIMNG NOTES L THIS IS A GENERIC DRAVING IT IS lllT INTENllEll TD REPRESENT A SPECIF1C o ATER JETTING UNIT 2 ALL l EATURES ARE DPTICINAI IT IS THE RESPON SllllUTY EF THE USER TD IJETERMllE VHICH IJPTl l IS APPLY TD EACH o ATER JETTI...

Page 187: ...CHASSIS GROUND ENGINE TERM 24 JNST PANEL GROUND LUG INST PANEL GROUND LUG INST PANEL GROUND LUG INST PANEL GROUND LUG NST PANEL GROUND NST PANEL GROUND LUG LUG NST PANEL GROUND LUG INST PANEL GROUND LUG NOTE 4 I FAULT CONNECTION 2 WIRE 1f70 CONNECTED TO ENGINE FUEL SOLENOID ENGINE FUEL SHUT OFF SOLENOID CUMMINS OEM INTERFACE B CONNECTOR P N 35 WIRE 037 CUMMINS OEM B CONNECTOR PIN 23 NLB AIR THROTT...

Page 188: ...ET WATER PRESSURE b I NOT LOW 70 tOOLT I FUEL l EVEL I TRANSDUCER s 0 L DISOiARGE PRESSURE I IS LOW 9 111FS t t 0 PWNGER LUBE l EVEL 6 NOT LOW 1 112F S I 10 0 0 0 i CRANK CASE OIL LE JB 6 I NOT LOW 11 0 1L WATER l EVEL 0 NOT LOW U4P8 I 12 0 I _ _ _ r _ EMERGENCY STOP I 0 I PUIAP FAULT I 0 I PUIAP FAULT 12 I I I t18P9 I O Q fl l _ r _ FAULT RESET DDClllJlll TlOM I DA ft WATPtlALI inttATMENTI UN AH ...

Page 189: ... Valve 9 16 F BV20 260 By Pass Valve 9 19 G 124 11 2 Water Tank Filter 9 22 H NSP 2000 Rupture Disc Valve Assembly 9 23 I NSP 3000 Rupture Disc Valve Assembly 9 24 J L 55i Oil Plunger Lubricator 9 25 K 2180 Float Valve 1 1 2 9 29 L 4071 10 Throttle Control 9 31 M 4071 20 Throttle Control 9 33 N 1012 Gear Pac Speed Reducer 9 35 0 Discharge Piping 1012DB 9 37 P Water Inlet Bag Filter PM3350 Optional...

Page 190: ...stamped plate is permanently riveted to the unit Figure 9 1 0 ________ ________ ________________ NLB c 29830 BECK RD WIXOM MICHIGAN 48393 9902 TELEPHONE 248 624 5555 MODEL NO l_____ JI SERIAL NO _ I_ _ _ _ I JOB NO _I_ _ _ _ _ I MAXIMUM PRESSURE 0 0 0 Figure 9 1 Model serial number on high pressure pump Note It is important when ordering replacement parts for each unit in the system that model and...

Page 191: ...quickly identified These assembly drawings with their numbered balloons are linked to parts lists with their item numbers To identify a part a Find the assembly drawing Identify the balloon numbers b Move to the accompanying parts list and locate the ITEM also called Ref No that is equal to the balloon number c Verify from the verbal description that the part in the parts list agrees with what is ...

Page 192: ... 1012D High Efficiency 6 Ea 5 CP14916 Valve Discharge 13K units only 3 Ea 6 N 334 Spring Valve Suction Discharge 6Ea 7 NC 369 Stop Valve Suction Discharge 3 Ea 8 NC 300 Cylinder Bare Fluid 1 Ea 9 NC 360 Manifold Discharge 1 Ea 10 NC 643 4 Bolt Discharge Manifold 8Ea 16 N 337 Box Stuffing 3 Ea N 353 07 Plunger 7 8 3 Ea 17 N 353 10 Plunger l 3 Ea N 353 11 Plunger l 1 8 3 Ea N 353 12 Plunger l 1 4 3 ...

Page 193: ... pump spare parts kits ITEM DESCRIPTION BP2106 07 Recommended Spare Parts Kit 1012 Pump 7 8 Plungers BP2106 10 Recommended Spare Parts Kit 1012 Pump l Plungers BP2106 11 Recommended Spare Parts Kit 1012 Pump 1 1 8 Plungers BP2106 llWL Recommended Spare Parts Kit 1012 Pump 1 1 8 Plungers Water Lube BP2106 12 Recommended Spare Parts Kit 1012 Pump 1 1 4 Plungers t Additional Items used in the 1012D H...

Page 194: ...oilerfittings order part no PM12330 A Cylinders High Pressure Pump Fluid End tHorizontal Spacer D tVertical Spacer t Additional Items used in the 1012D High Efficiency unit with 1 plungers Copyright August 2004 NLB Corporation 9 6 ...

Page 195: ...Throat 1 3 4 3 Ea 1637 p c 318 3SetS 1700 Jlafk ng 1 1 2 3 Sels 14 1701 Pac 1 S 8 3sets 1636 ra ki 1 314 3Sets 1764 packfogrt 1 2 Water Lube 3 Sets N 339 13 Ri g B ckup 1 3 8 3Ea N 339 14 J1fog 3 k uP 1 1 2 3Ea N 339 15 i g Backµp 1 5 8 3 Ea N 339 16 Ring Backup 1 3 4 3Ea1 16 NCB 337 Box Stuffing 3 Ea N 353 13 Plunger 1 3 8 3 Ea 17 N 353 14 Plunger 1 1 2 3 Ea N 353 15 Plunger 1 5 8 3 Ea N 353 16 P...

Page 196: ...t 1012 Pump 1 1 2 Plungers BP2106 15 Recommended Spare Parts Kit 1012 Pump 1 5 8 Plungers BP2106 16 Recommended Spare Parts Kit 1012 Pump 1 3 4 Plungers 4K BP2107 16 Recommended Spare Parts Kit 1012 Pump 1 3 4 Plungers 3K Copyright December 2000 NLB Corporation 9 8 ...

Page 197: ...Revision 4 For stuffing box oilerfittings order part no PM12330 B Cylinders High Pressure Pump Fluid End Copyright December 2000 NLB Corporation 9 9 ...

Page 198: ...14 N 175 Guage Oil Level Sight 1 Ea 15 04 PLG 6T S Plug 1 Ea 16 04 03 RT 40 Tee Reducer 1 Ea 17 04 CL NIP 40 Nipple 1 Ea 18 3 8 16xl 2HHP Bolt Crankshaft Cover Plate 14 Ea 19 N 113 Bolt Connecting Rod Cap 6 Ea 20 1 2LWHC SS Washer High Helical 6 Ea 21 N 112 Rod Connecting 3 Ea 22 N 116 Bearing Connecting Rod 3 Sets 23 N 133 Retainer Crankshaft Roller Bearing Open End 1 Ea 24 AA 8890 Seal t ran shl...

Page 199: ...ad Cover Plate 1 Ea N 620 Plate Crosshead Inspection 1 Ea Shaded Area Recommended for spare parts Items included in high pressure pump spare parts kit contact the NLB Customer Service Department to order the particular spare parts kit number for your unit Sold as as a set t Items included in Extreme Service Kit DX21365 Copyright October 2005 NLB Corporation 9 11 ...

Page 200: ...Revision 4 High Pressure Pump Power End Copyright December 2000 NLB Corporation 9 12 ...

Page 201: ... Disc 13 AA 179 1 R ing Backup i 14 AA 1250 O ring 15 BV12629 Handle Adjuster 16 PM12632 Pin Spring Slotted 17 BV12630 Deflector 18 10 32xl 4SS Screw Set 19 PM15934 Bumper Rubber 20 PM15935 Bumper Rubber 21 BM16267 2 Handle Jam Nut Shaded Recommended for spare parts Items included in spare parts kit BV12635 Copyright April 2002 NLB Corporation 9 13 QTY 1 Ea 1 Ea 1 Ea 1 Ea 1 Ea 1 Ea 1 Ea 1 Ea 1 Ea ...

Page 202: ...i o I _ l l U 2 N T Rtt Rd D 3651 l I RH I RH I RH TH 00 HOT SCALE ORA WING ...

Page 203: ......

Page 204: ... BV8169 Guide Spring 6 BV8170 Bushing Guide 7 BV8196 Disc 8 BM6957 Nut Cap 9 BV10943 Adjuster 11 15 BM16267 3 Handle Jam Nut Shaded Recommended for spare parts Items included in Spare Parts Kit BV11316 Copyright October 2005 NLB Corporation 9 16 QTY 1 Ea 1 Ea 1 Ea 1 Ea 1 Ea 1 Ea 1 Ea 19 Ea 1 Ea ...

Page 205: ...ER TO SOM 8V10 400 STANDARD TOLERANCES UNLESS OTHERWISE SPECIFIED 00 i 010 MACHINED SUWACES 113J 000 005 0000 ooos OTlf 1I SIJWAC S 12V F1IAC110NS 1 32 ANClES REMOV ALL BURRS ANO SHARP EDGES OR RUSHO I0 195 NR DATE I BY TREATMENT DO NOT SCALE DRAWING NLB Cor c1 H E SHAW I s lfgs nu tu sm SCALE I SHEET trul HOll 2 1124 5555 FULL 1 Of 2 INFORMATION SHOWN ON THIS DOCUMENT IS TITLE PROPRIETARY AND llA...

Page 206: ... O I co 7 l 6 ...

Page 207: ... 1 Ea 7 BV8196 Disc 1 Ea 8 BM6957 Nut Cap 1 Ea 9 BM6958 Adjuster 1 Ea 11 BM8583 Spring Disc 17 Ea 12 AA l660 ring 13 A_A 4033 g fing 14 DM6023 90 Gland 15 DM6023 95 Collar 1 Ea A J 1790 ring Back tip lEa 18 BM16267 3 Handle Jam Nut 1 Ea Shaded Recommended for spare parts Items included in Spare Parts Kit BV11317 Copyright October 2005 NLB Corporation 9 19 ...

Page 208: ... t010 MACHINED SURFACES 000 00 5 0000 0005 OTHER SURFACES 1 zv FRACTIONS 1 32 AHOl S s REMOVE ALL BURRS ANO SHARP EDGES OR BOWES I0 B 95 CK Al t UATE 12 8 95 NR DATE BY TREATMENT DO NOT SCALE DRAWING NLB Co IA 11 Cfl lllOflWrllmlllAl Ufllla am 211130 llECIC RO WIXOll lllClllC a313 SCALE SHEET lELEl llONE 2 il l24 55 FULL 1 OF 2 INFORMATION SHOWN ON THIS DOCUMENT IS TITLE PROPRIETARY ANO MAY NOT BE...

Page 209: ...HARP EDCES DR DATE RUSHO 5 10 95 OATE Cl At t DATE I BY TREATMENT DO NOT SCALE DRAWING NLB Cor IAll M lllm lllrl tTKIL Uflll IUml 2111130IECICll0 48313 SCALE SHEET TEUl HOllE 248 124 5555 1 2 1 2 OF 2 INFORMATION SHOWN ON THIS DOCUMENT IS TITLE PROPRIETARY AND MAY NOT BE DISCl OSED TO BV20 260 20k BY PASS VALVE ASSEMBLY UNAUTHORIZED PERSONS WITHOUT EXPRESS WRITTEN CONSENT or NLB CORPORATION DRAWlN...

Page 210: ... PART DESCRIPTION QTY 1 124 11 Bowl 1 Ea 2 124 12 Gasket Buna N Standard 1 Ea 3 NLB 124 1 1 2 80 Screen soMesh lEa 4 124 13 Strainer Head 1 Ea Shaded Recommended for spare parts 124 1 1 2 Water Tank Filter Copyright April 2002 NLB Corporation 9 22 ...

Page 211: ...lver lOK t Ea 2 NS g 2002r 12 Di l 1lpfore Yellow 12K lEa 3 NSP 2001 3 Washer 1 Ea 4 CM 3556 Pop Off Valve 1 Ea 5 NSP 2001 5 Deflector Safety Pop Off 1 Ea Shaded Recommended for spare parts Item included in the high pressure pump spare parts kit contact the NLB Customer Service Department to order the particular spare parts kit number for your unit Not shown NSP 2000 Rupture Disc Valve Assembly Co...

Page 212: ...3001 03 Washer 3 NSP 3002 15 Disc Rupture lSK Brown 3 NSP 3002 20 Di c Rupture 20 K Gold 4 NSP 3001 01 Body 5 NSP 3001 02 Seat Body 6 03 ST ELB 40 SS Deflector Safety Pop Off Shaded Recommended for spare parts Not shown Copyright April 2002 NLB Corporation 9 24 QTY 1 Ea 1 Ea lEa lEa 1 Ea 1 Ea 2Ea ...

Page 213: ...l 880560 318 Pump 4 Backup Ring Outlet Body 1 Ea 5 0 ring Outlet Body 1 Ea 16 0 ring Suction Tube 1 Ea 18 Ball Suction Tube 1 Ea 20 Sight Glass Seal 1 Ea 21 Ball Inlet Check 1 Ea 23 0 ring Dropper 1 Ea 250148 OutletUnionAssembly t x 1 1 Union Nut Outlet 1 Ea 2 Sleeve Assembly Outlet 1 Ea 250 166 OutletCheck KitforModet880560 3 8 Pump ii 3 Adapter Assembly with Check Balls 1 Ea 4 Backup Ring 1 Ea 5...

Page 214: ...1 Ea 21 Ball Inlet Check 1 Ea 23 0 ring Dropper 1 Ea 250173 OutletCheckKitforModel 880550 1 4 Pump 26 Backup Ring 1 Ea 27 0 ring 1 Ea 28 Adapter Assembly with Check Balls 1 Ea 250225 RockerArm Kit Series B orNewer 14 Rocker Arm 1 Ea 29 Grooved Pin 1 Ea 12 Screen Assembly 1 Ea 13 Spring Retainer 1 Ea Note Service parts for Models 880550 and 880560 are available only in the recommended NLB spare par...

Page 215: ...m w ITEM 9 PIVOT PIN 0 ITEM4 BACKUP RING WHITE 0 ITEM 5 0 RING BLACK Copyright April 2002 NLB Corporation 0 0 ITEM 11 PUMP MOUNTING GASKET ITEM 6 MOUNTING SCREW 9 27 0 ITEM 21 STEEL BALL 0 ITEM 18 STEEL BALL ITEMS COTTER PIN c i ITEM 29 GROOVED PIN ITEM 20 SEAL BLACK 0 ITEM 27 0 RING BLACK 0 ITEM 26 BACKUP RING WHITE ...

Page 216: ... TO Ill l llESSED cur A Nil CllJCAA l F f V WITH l IVOl POI 111 9 1 loll tO SECV 11 Wfflt corrtl PHI DTf Mftl Indicate Change RQCKER ARM f IVOT DE fAIL SERIES a NOTE tu l ACltiG MCKEii TH tXJsfliilO PIVOT PIN IS ro RE ll 11SID OUT AIOID v1SCAl l l t Pt AC WITH GOOOV l l tll UT fM 12 Copyright April 2002 NLB Corporation 9 28 11 17 I I 1 101 E HO TCHW ENC Of 1 ICTIOlll TUBE fl l M 191 lll TO a ASS M...

Page 217: ... Consisting of 1 2180 11 Lever Valve Plunger Connection 1 2180 8 1 2180 9 PM9601 Adapter Rod 3 8 NPTM x 3 8 16 S S 1 Ea 4 2180 7 Adaptor Rod 1 2 NPTM x 3 8 16 S S Old Style Brass 1 Ea Ball 5 2180 8 Arm Rod to Lower Arm 1 Ea 6 2180 9 Arm Lower 1 Ea 7 2180 11 Lever Valve Plunger Connection Upper Arm 1 Ea 8 2180 13 Pin Cotter 4 Ea 9 2180 14 Link Brass 2Ea 10 2180 15 Screw Thumb 1 Ea 11 PM9529 Pipe Dr...

Page 218: ...Revision 7 Wl w _J _J Z Copyright April 2002 NLB Corporation I Wl w _J _J I 0 9 30 I I I 1 w _JI BJ I I 5 I 2180 Float Valve ...

Page 219: ...Ea 4 CM15090 Body 1 Ea 5 BM15087 Spring Compression 1 Ea 6 CM12717 Nut 1 Ea 8 CM12716 Handle T 1 Ea 9 l 4 20xl 2FHSCS Screw Flat Head Socket Cap 4Ea 10 BM15083 Bracket 1 Ea 11 BM15089 Tab Operating 1 Ea 12 BM15084 Adapter 1 Ea 13 BM16267 1 Handle Jam Nut 1 Ea Shaded Recommended for spare parts Copyright April 2002 NLB Corporation 9 31 ...

Page 220: ...a 40 000 PSI THROTltE CONTRa REn R TO B 11 f4071 10 REFER TO B 11 f4071 40 H Sp a AA r l A C ht J I t I nfV f 1ttu nt s uft J Till nTY 1 l JMAn ss __j I l BMl _ TY I J 1 _ 20 000 PSI THROTltE CONTRa 24 000 PSI THROTltE CONIRa REn R TO B 11 f4071 20 REFER TO B M f4071 24 OM15091 IC ...

Page 221: ... 4 CM15090 Body 1 Ea 5 BM15087 Spring Compression 1 Ea 6 CM12717 Nut 1 Ea 8 CM12716 Handle T 1 Ea 9 l 4 20xl 2FHSCS Screw Flat Head Socket Cap 4 Ea 10 BM15083 Bracket 1 Ea 11 BM15089 Tab Operating 1 Ea 12 BM15084 Adapter 1 Ea 13 BM16267 1 Handle Jam Nut 1 Ea Shaded Recommended for spare parts Copyright April 2002 NLB Corporation 9 33 ...

Page 222: ...LQJ I I e I 10 000 PSI THROTll E CONlRQ REFER TO B 1 1 f4071 10 I SI 20 000 PSI M OTll E CONlRQ REFER TO B 1 1 f4Q71 20 illZl iD 40 000 PSI THROTll E CONlRQ REFER TO B 1 1 f4071 40 24 000 PSI THROTll E CONlRQ REFER TO B 1 1 f4071 24 ...

Page 223: ...r 1 Ea 136 Pinion Shafts Shims 2Ea 137 Pinion Shafts Inner 2Ea 140 Crankshaft End Cap 1 Ea 149 Pinion Shaft Bearings 2Ea 154 Crankcase Cover 1 Ea 156 Gear Housing Cover 1 Ea 170 Gear Housing Cover 1 Ea 171 Gear Housing Bolting Washer 2Ea 620 Crankcase Cover Gasket 1 Ea 624 Gear Housing 1 Ea 630 Crankshaft Oil Seal 1 Ea 631 Pinion Shaft Oil Seal 1 Ea 652 Crankshaft Frame Cap Gasket Inner 1 Ea Copyr...

Page 224: ...Revision 7 0 O Copyright April 2002 NLB Corporation N O 9 36 0 1012 Gear Pac Speed Reducer Ol 0 0 0 ...

Page 225: ... g 11 PM9001 Filter Snubber 12 BM9186 Washer Brass 13 BM9210 Nut Jam 14 10 CL NIP XXS S Elbow Street 15 10 04 RB 6T S Bushing Reducer Threaded 16 NQC 22 Coupler Quick Set 19 CM10063 Bracket Manifold 20 04 14 NIP 160 S Nipple Shaded Recommended for spare parts Note For the information on the discharge piping of other units contact the NLB Customer Service Department Copyright April 2002 NLB Corpora...

Page 226: ...c o I CX NOTE WHEN I 5 NOTE DETAIL A muc PIPING DISCHARGE 10120 E WITH MANIFOLD ...

Page 227: ...Water Inlet Bag Filter PM3350 Optional ITEM PART DESCRIPTION QTY 1 PM9143 0 ring Lid lEa 2 PM9144 Gasket Flat 1 Ea 3 PM6962 Bag Filter 1Ea Shaded Recommended for spare parts Copyright April 2002 NLB Corporation 9 39 ...

Page 228: ...Lube Manifold 13 PM4136 Valve Flow Control Air 14 14 TEE 40 SS Tee 15 14 CL NIP 40 SS Nipple 16 14 06 RB 6T S Bushing Reducer 17 02 PLG 40 S Plug Square Head Threaded 18 LO ST ELB 40 SS Elbow Street 19 10 04 RB 6T S Bushing Reducer 21 PM11995 Hose 22 PM7329 Fitting Hose 23 PM7328 Adapter Hose 25 04 ELB 90 40 S Elbow 26 04 60 NIP 40 Nipple Copyright April 2002 NLB Corporation 9 40 QTY 2Ea 1 Ea 5 Ft...

Page 229: ...D SURFACES 83 T 000 oos oooo oooe OlllER SURFACES 1zv FRACTIONS 1 1 n I JI REMOVE ALL BURRS AND SHARP EDGES DR SPRAGUE I I DATE BY TREATMENT DO NOT SCALE DRAWING NLB Cor CK APP IDATE SCALE I SHEET IDDllDIE 248 l2A 5ll55 1 8 1 1 OF 1 INFORMATION SHOWN ON 11115 DOCUMENT IS I TITLE PROPRIETARY AND MAY NOT BE DISCl OSED TO UNAUTHORIZED PERSONS WITHOUT EXPRESS WRITTEN CONSENT OF NLB CORPORATION PIPING ...

Page 230: ......

Page 231: ...arts Return Authorization RA Number 1 How To Acquire An RA Number C Parts Return Directives D Parts Return Authorization Procedures 1 Parts Ordered In Error By Customer Returned For Credit 2 Unused Parts Less Than One Year Old Returned For Credit 3 Parts Shipped In Error By NLB Corp Returned For Credit 4 Parts Returned For Repair 5 Parts Returned For Warranty Repair Or Replacement How To Package P...

Page 232: ...ledgeable representatives who are dedicated to customer support Representatives can provide information such as parts availability price information technical support warranty evaluation and the parts Return Authorization RA process NLB Corp maintains an inventory of thousands of spare parts readily available for shipment within three business days A Business Hours Customer service personnel are c...

Page 233: ...n highlighted on the parts list A Ordering Procedure You must have the following information available when ordering parts 1 Part name 2 Part number 3 Quantity ordered 4 Date required 5 Shipping information 6 Purchase order number If the ordered part is in stock it will be shipped within three 3 working days from the time the order is placed If the part is not in stock the customer will be given a...

Page 234: ...t of the original manufacturer s warranty and are subject to their allowance to the seller Charges for labor and or parts incidental to the removal and remounting of defective parts or accessories are the responsibility of the buyer and are not covered by this warranty This warranty does not apply to and the company assumes no responsibility for any equipment or parts that have been improperly ins...

Page 235: ...customer all possible assistance to secure satisfactory adjustment of damage claims B Parts Return Authorization RA Number Customers returning parts to NLB for any reason must obtain a Return Authorization RA Number Each RA Number issued by NLB Customer Service is unique and is used to track customer returned parts through the return process Note All parts returned to NLB Corp for any purpose requ...

Page 236: ...n resolving your request C Parts Return Directives A All returns must be pre authorized by a Customer Service representative and will not be accepted without an RA Number Unauthorized returns will be re shipped at the customer s expense B Parts built to a customer s specification parts unique to custom engineered systems or parts that have been modified by the customer cannot be returned for credi...

Page 237: ...nused in new condition and free of handling damage If parts are determined to be new the customer will receive full credit for the amount charged minus a 20 restocking fee Collect shipments will not be accepted by NLB Corp A copy of the credit memorandum will be forwarded to the customer and the credit can be used on future orders C If the returned parts are not in new condition NLB will notify th...

Page 238: ...cost effective to repair or not approved for repair they will be returned to the customer at his expense or scrapped at NLB upon receipt of written customer request 5 Parts Returned For Warranty Repair Or Replacement A Acquire an RA Number B Warranty replacement and or repair will be handled according to NLB Corp s standard warranty If you have questions answers can be obtained by writing calling ...

Page 239: ...e parts will be sent as soon as possible D If the warranty claim is approved NLB Corp will either repair replace or issue a credit memorandum for the parts A copy of the credit memorandum will be sent to the customer and the credit can be used on future orders Parts Found Not To Be Defective Under Terms Of This Warranty A If the parts are found not to be defective under the terms of this warranty ...

Page 240: ...tative Confirmation of purchase is required before warranty service is rendered B Except for parts sent for warranty or repair all parts must be clean and in re sellable condition and must be returned in their original packaging or other suitable protective container C Parts returned must be carefully packed so as to reach NLB Corp without damage Note Each RA Number is unique This number must appe...

Page 241: ...ckage I NLBCorp 29830 Beck Road D Wixom Ml 48393 248 624 5555 D Fax 248 624 0538 Customer Service 800 227 7652 Ship To __________________ Phone Fax Hours NLB Serial Customer PO Warranty Consideration Please review NLB warranty policy NLB Model Purchase Date ________ NLB Serial Failure Date Hours Customer PO __________ Customer Invoice Customer description of failure and operating conditions at fai...

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Page 243: ...RE MANUFACTURERS LITERATURE Electronic Engine Controller JOHN DEERE Diesel Engine CONTROLS INCORPORATED Power Take Off TWIN DISC Transmission Optional SPICER Water Inlet Bag Filter Assembly Optional FSP85 FSI Copyright June 2005 NLB Corporation ...

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Summary of Contents for 1012D

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NLB 1012D, Operation Maintenance & Parts Manual, Page: 1 / 244

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Summary of Contents for 1012D

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