1012 Series Pump Unit Rev12 Oct2005

Revision 12
1312D, 1012D, 812D, 612D,

512D, 412D, 3.512D, 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

Revision o
GENERAL INFORMATION
Every effort has been made to include the most up-to-date information at the time of
publication of this manual. However, the possibility exists that subsequent product changes
made by NLB Corporation may cause the information in this manual to be rendered
inaccurate. In the event that an information conflict is found to exist between this manual,
other publications or the condition and function of your equipment, NLB must be contacted
for clarification prior to operating or servicing the equipment.
Caution:
The information contained in this manual may be rendered inaccurate if the
equipment described herein is modified in any way, without the authorization
of NLB, or that said equipment is not maintained or operated in a proper
manner as instructed in this manual. NLB assumes no responsibility or
liability for equipment that has been modified, for equipment that
incorporates any non-NLB manufactured parts as components or for
equipment that has not been maintained or used in the manner set forth in
this manual. In that event, all NLB warranties, either express or implied, are
void.
WARNING:
THE EQUIPMENT DESCRIBED IN 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
OPERATION, USE AND SERVICE MANUALS DESCRIBING THE FORESEEABLE
USES OF THE EQUIPMENT MUST BE READ AND UNDERSTOOD. THE
EQUIPMENT MUST ONLY BE USED IN THE MANNER SET FORTH IN THIS
MANUAL, AS SUPPLEMENTED BY ALL APPLICABLE FEDERAL, STATE AND
LOCAL LAWS, ORDERS AND REGULATIONS THAT PERTAIN TO THE
OPERATION AND USE OF THE EQUIPMENT. IF THIS EQUIPMENT JS
OPERATED BEYOND ITS INTENDED CAPACITY OR FORESEEABLE USE, IS
MISUSED, MODIFIED OR ABUSED IN ANY WAY WHATSOEVER, OR IF IT IS
NOT MAINTAINED IN ACCORDANCE WITH THE INSTRUCTIONS CONTAINED
IN THIS MANUAL, WITH NLB APPROVED PARTS; DEATH, SEVERE PERSONAL
INJURY OR EQUIPMENT DAMAGE MAY RESULT.
NLB WARRANTY WILL BE VOIDED IF NON-NLB MANUFACTURED
REPLACEMENT PARTS ARE USED. NLB'S WARRANTY IS VOID AS TO ANY
DAMAGES CAUSED TO THE EQUIPMENT OR BY THE EQUIPMENT AND TO
EXCLUDE ANY LIABILITY AS A RESULT OF INJURY, IF SUCH DAMAGE OR
INJURY CAN BE LINKED TO THE SUBSTANDARD REPLACEMENT PART.
© Copyright September, 1999 NLB Corporation 0-1

Revision 11
MASTER TABLE OF CONTENTS
1312D, 1012D, 812D, 612D, 512D, 412D, 3.512D, 312D, 1060D, 8600,
& 760D
Diesel Engine Driven,
High Pressure Water Jetting Units
DESCRIPTION PAGE NUMBER
Section 1 - INTRODUCTION
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
I. Purpose & Objectives of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
II. Manual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Section 2 - SAFETY
Table of Contents 2-1
I. Safety Precautions That Must Be Observed By User .................... 2-2
II. Safety Aspects of High Pressure Water Cleaning Systems ............... 2-8
III. Recommended Practices For The Use of Manually Operated High Pressure
Water Jetting Equipment .......................................... 2-12
Section 3 - PRODUCT OVERVIEW

Table of Contents ............................................... 3-1
I. General Description ............................................. 3-2
II. Water Condition ....................................... '. ........ 3-2
III. Specifications .................................................. 3-3
IV. Bill of Materials & Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -7
Section 4 - OPERATION CONTROL

I. Machine Control ................................................ 4-2
II. Pre-Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
III. Operating Procedures ............................................ 4-14
Section 5 - PREVENTIVE MAINTENANCE

I. Preventive Maintenance Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
II. Preventive Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
III. Suggested Component Cleaning Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
IV. Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
V. Winterizing Procedure ........................................... 5-20
VI. Sample "Maintenance Record" ..................................... 5-23
© Copyright June, 2005 NLB Corporation 0-2

Revision 11
MASTER TABLE OF CONTENTS (Cont.)
Section 6 - TROUBLE-SHOOTING
I. Trouble-Shooting Guidelines ...................................... 6-2
II. Trouble-Shooting Procedures ...................................... 6-3
III. Trouble-Shooting Guide .......................................... 6-5
Section 7 - SPECIAL TOOLS

I. Special Tool Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -2
Section 8 - REPAIR
I. Repair Overview ................................................ 8-2
II. High Pressure Water Jetting Unit Repairs ............................ 8-7
III. Electrical System ............................................... 8-80
Section 9 - PARTS
I. Model & Serial Numbers ......................................... 9-2
II. Assembly Drawings & Parts Lists .................................. 9-3
Section 10 - CUSTOMER SUPPORT

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
MANUFACTURERS' LITERATURE
Diesel Engine
CUMMINS
JOHN DEERE
Electronic Engine Controller (JOHN DEERE Diesel Engine)

CONTROLS INCORPORATED
Power Take-Off
TWIN DISC

Revision 11
MASTER TABLE OF CONTENTS (Cont.)
MANUFACTURERS' LITERATURE (Cont.)

Water Inlet Bag Filter Assembly (Optional) - FSP85
FSI

Revision 11
NLB Cor
Manufacturer of the National Liquid Blaster
29830 BECK ROAD
WIXOM, Ml 48393-2824
(248) 624-5555
FAX(248)624-0538
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects and
other reproductive harm.

Revision O
TABLE OF CONTENTS
SECTION 1
INTRODUCTION
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

Revision O
I. Purposes & Objectives of Manual
This manual is mandatory reading for all personnel who will be operating or performing
maintenance and/or repairs on the NLB high pressure water jetting equipment. The manual
must also be distributed to maintenance supervisors responsible for work planning,
scheduling, training, performance evaluating, and reporting. While some sections will be of
more interest to equipment operators, others are for the use of the maintenance personnel. It
is specifically developed to assist operating and maintenance personnel and is not intended as
a replacement or substitution for customer developed maintenance criteria. The manual
describes safety features, start-up procedures, recommended preventive maintenance
agendas, troubleshooting activities, special tool descriptions, and repair procedures. As
further assistance to maintenance personnel, there are recommended spare parts lists,
photographically reproduced drawings, bills of materials, and assembly drawings which may
list other drawings that can be consulted as reference. The information contained in this
manual supplements instructions preferred by the customer.
There is also a section on safety, located in this binder, intended to point out certain safety
precautions and procedures applicable to high pressure water jetting equipment. The safety
section contains NLB's instructions concerning safe operation and service of the equipment.
Certain governmental regulations and industry practices 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 with the location and operation of all
stopping devices. Except in cases of extreme emergency, permit only authorized personnel
to start or stop any equipment in the system. Confine operation of the equipment to
authorized operators. Leave repair functions to trained maintenance personnel.
Be alert to hazardous conditions such as sharp edges and protruding objects, and replace any
broken parts causing these conditions as soon as possible. Maintain good housekeeping
practices. Clean up all spilled lubricants and other material as promptly as possible. Report
all accidents resulting in damage to equipment and any irregularities in equipment operation
to the proper authority.
Reliability of mechanical equipment depends largely on sound maintenance procedures. All

NLB high pressure water jetting equipment should be thoroughly inspected at regular
intervals and corrective measures must be taken to prevent major breakdowns and a loss of
valuable operation time.
A well organized program should be part of any maintenance plans. If a log is maintained
with sufficient information, a multi-purpose will be accomplished: first, a record of trouble
and responsibility is available; secondly, the log can be reviewed periodically for equipment
© Copyright September, 1999 NLB Corporation "1 -2

Revision O
evaluation; and lastly, as a historical record. From the information collected, frequency of
inspection and performance change methods could be made. This would then, over a period
of time, make the maintenance program more effective. The PREVENTIVE
MAINTENANCE section includes a suggested maintenance record form to accomplish these
tasks.
Factors of significant importance that must also be considered are adjustment procedures,
lubrication instructions, troubleshooting, and replacement of parts. These factors are
thoroughly discussed in other sections of this manual.
Note:
Do not attempt to perform maintenance or make adjustments on any equipment
without first consulting this manual.
Note:
Replacement parts must be genuine 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, Table of contents
b. Body of the section
A. Terminology
The following describes the usage of Note, Caution and Warning terms in this manual:
Note:
Key Information: "Note" is used to give special emphasis to instructions or additional
information concerning a function, step, or action to be taken.
Caution:
Minor Personal Injury and/or Equipment Damage: "Caution" is used to indicate the
presence of a hazard which can or will cause minor personal injury or equipment damage if
the caution is ignored.
© Copyright September, 1999 NLB Corporation 1 -3

Revision O
WARNING:
Severe Personal Injury and/or Equipment Damage: "WARNING" is used to indicate the
presence of a hazard which can or will cause severe personal injury, death, or substantial
equipment damage if the warning is ignored.
B. Illustrations & Photographs
Use the illustrations and photographs in this manual as a guide to perform the action,
maintenance, or repair described. Many illustrations are generic and will not look exactly
like the high pressure water jetting equipment or the parts used in your unit. In 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 the number of revisions
that have occurred to that page or section from the initial establishment of this manual to the
present time. When contacting NLB for clarification of information contained in this
manual, please indicate the revision number of the page in question.

Revision 1
TABLE OF CONTENTS
SECTION 2
SAFETY
IMPORTANT:
PLEASE READ THIS SECTION COMPLETELY BEFORE OPERATING ANY OF
THE HIGH PRESSURE WATER JETTING EQUIPMENT.

I. Safety Precautions That Must Be Observed By The User ............... . 2-2
A. Operator Safety Equipment ................................... . 2-2
B. Pre-Service Safety Check List ................................. . 2-4
C. Recommended Safety Procedures Decal ......................... . 2-6
II. Safety Aspects of High Pressure Water Cleaning Systems .............. . 2-8
A. Equipment ................................................. . 2-8
B. Personal Protective Equipment ................................. . 2-9
C. Pre-Operational Procedures ................................... . 2-10
D. Operational Procedures ....................................... . 2-11
E. Training . . . . . . . . . . . . . . . . ................................... . 2-11
III. Recommended Practices For The Use of Manually Operated
High Pressure Water Jetting Equipment ............................. . 2-12
A. Introduction ................................................ . 2-12
B. Scope ..................................................... . 2-12
C. Definition of Terms .......................................... . 2-13
D. Equipment Definition and Standards ............................ . 2-14
E. Care and Maintenance of Equipment ............................ . 2-17
F. Protective Clothing and Personnel Protection ..................... . 2-19
G. Pre-Operating Procedures .................................... . 2-20
H. Operational Procedures ....................................... . 2-21
I. Use of Lances and Nozzles .................................... . 2-26
J. Operational & Training Requirements ........................... . 2-27
K. Permanent Cleaning Areas .................................... . 2-28
L. Freeze Precautions .......................................... . 2-28
M. Accidents .................................................. . 2-29
N. Responsibility .............................................. . 2-29
© Copyright January, 2001 NLB Corporation 2-1

Revision 3
WARNING:
I. Safety Precautions That Must Be Observed By User
Refer to the SAFETY section before operating any high pressure water jetting components.
Do not operate this or any high pressure water jetting component or system without first
reading and understanding the SAFETY section. If the SAFETY section is missing from this
binder, call NLB at 1-800-226-7652 for a free copy.
Safety Signs:
All NLB high pressure water jetting equipment 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 and
safety of the equipment. It is supervision's responsibility to call these signs to the attention
of all personnel.
A. Operator Safety Equipment
NLB offers complete operator safety suits for high pressure waterblasting operations and
recommends the use of all operator and jobsite safety equipment that is available. NLB also
offers operation, maintenance & parts manuals and jobsite barrier marking tape.
Caution:
The use of hearing protection is advised when operating this equipment.

Revision 2
TURTLESKIN1!t
WATERARMORTM
© Copyright April, 2003 NLB Corporation 2-3

Revision 1
B. Pre-Service Safety Check List
The Pre-Service Safety Check List (Figure 2-1) 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.
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.

Revision 1
PRE-SERVICE SAFETY CHECK LIST - HIGH PRESSURE WATER CLEANING

DATE: LOCATION:_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
EQUIPMENT BEING SERVICED: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
YES NO N/A
1 IN THE AREA, INCLUDING OTHER END OF UNIT BEING SERVICED,
CLEAN, ROPED OFF, AND PROPER SAFETY SIGNS POSTED?
2 HAVE PRECAUTIONS BEEN TAKEN TO PROTECT ELECTRICAL
EQUIPMENT FROM WATER?
3 IS THERE ANY HAZARD TO PERSONNEL FROM POSSIBLE DAMAGE TO
EQUIPMENT SUCH AS RELEASE OF CORROSIVE CHEMICALS,
FLAMMABLE LIQUIDS OR GASES, ETC.?
4 ARE ALL FITTINGS OF THE CORRECT PRESSURE RATING?
5 ARE ALL HOSES OF THE CORRECT PRESSURE RATING?
6 ARE ALL HOSES IN GOOD OPERATING CONDITION?
7 ARE ALL FITTINGS IN GOOD OPERATING CONDITION?
8 ARE ALL NOZZLES FREE FROM PLUGGING? AND IN GOOD
OPERATING CONDITION?
9 HAVE PRECAUTIONS BEEN TAKEN TO PREVENTLINEMOLE
REVERSAL?
10 IS THE FILTER ON THE PUMP SUCTION CLEAN AND IN GOOD
OPERATING CONDITION?
11 IS THERE A MINIMUM 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 DEMINERALIZED WATER OR
CONDESATE AND GROUND LANCE EQUIPMENT BEING CLEANED.
·18 IS THERE ANY DANGER FROM THE WASTE WATER OR FROM THE
REACTION OF THE SCALE AND WATER?
19 IF ANSWER TO 18 "YES", HAS PROPER PERSONAL PROTECTIVE
EQUIPMENT BEEN SUPPLIED TO PREVENT INJURY, AND HAS
PERSONNEL BEEN INFORMED OF THIS ADDITIONAL HAZARD?
20 HAS COMPLETE HOOK-UP BEEN FINISHED PRIOR TO INSTALLING
NOZZLES?
21 HAS HOOK-UP, INCLUDING PIPES, HOSES AND CONNECTIONS, BEEN
PRESSURE TESTED WITH WATER AT MAXIMUM OPERATING
PRESSURE?
22 IS DUMP SYSTEM OPERATING PROPERLY? (WILL IT DUMP WHEN
RELEASED)?
23 ARE SAFETY SYSTEMS OPERATIONAL?
Figure 2-1. Pre-Service Safety Check List.

Revision 1
C. Recommended Safety Procedures Decal
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.

Revision 1
IMPORTANT RECOMMENDED SAFETY PROCEDURES
AS WITH ALL POWER TOOLS, THE NATIONAL LIQUID BLASTER MUST BE USED IN
ACCORDANCE WITH SPECIFIED SAFETY PROCEDURES AND COMMON SAFETY SENSE. TO
AID IN INSURING THAT THIS EQUIPMENT IS OPERATED WITH A MAXIMUM AMOUNT OF
SAFETY. WE HAVE PREPARED THE FOLLOWING LIST OF RECOMMENDATIONS. THIS LIST IS
NOT INTENDED TO BE ALL INCLUSIVE AND ADDITIONAL SAFETY PRECAUTIONS SHOULD BE
FOLLOWED. AS THEY ARE DICTATED BY THE APPLICATION. PLANT SAFETY PROCEDURES
AND PARTICULAR WORKING CONDITIONS.
1. SAFETY EQUIPMENT TO BE WORN BY OPERATORS.

A. GOGGLES
B. HARD HELMET WITH EAR PROTECTION
C. STEEL TOED SHOES
D. HEAVY-DUTY RUBBER UNIFORMS AND GLOVES
2. THE LANCE MUST ALWAYS BE DIRECTLY POINTED AT THE WORK AREA.
3. THE OPERATOR 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 MADE TO THE UNIT.

THE CLEANING GUN, OR THE ACCESSORIES.
8. OPERATORS SHOULD BE CHANGED ON FREQUENT INTERVALS TO AVOID FATIGUE.
9. OPERATORS AND ALL PERSONS WITHIN THE OPERATING AREA SHOULD NOT ENGAGE IN
"GOOFING OFF" PRACTICES.
10. EQUIPMENT SHOULD BE PROPERLY MAINTAINED AS OUTLINED IN THE MAINTENANCE

MANUAL.
11. ALL OPERATORS SHOULD BE PROPERLY TRAINED AS OUTLINED IN THE MAINTENANCE

MANUAL.
12. EQUIPMENT SHOULD BE CLEANED OFTEN TO PREVENT DIRT AND OTHER BUILD-UPS.
Figure 2-2. Recommended Safety Procedures Decal.

Revision 1
II. Safety Aspects of High Pressure Water Cleaning Systems
For maximum operational safety, the following equipment and manual procedures must be
used where applicable:
A. Equipment
High Pressure Pump

The principal component of the high pressure water jetting cleaning system is usually a
positive displacement high pressure pump which discharges water into a common manifold
to which flexible hoses or lances with nozzles or other cleaningor cutting accessories are
attached. The pumps are appropriately powered and can be either mobile or permanently
mounted. They shall never be operated above NLB's recommended operating pressure.
Relief System
The system shall be equipped with an automatic relief device on the discharge side of the
pump, adjusted so that the maximum allowable working pressure of the system is 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 pressure to a safe level immediately when actuated. An operator shall control this
dump system.
Hose Assembly
Hose assemblies used on the discharge side of the pump shall have a safety factor of 3.0
based on the manufacturer's rated minimum burst pressure.
Fittings/Valves
All fittings and valves used in the discharge side of the pump shall have a safety factor of 3.0
based on the tensile strength of the materials.
Electrical Controls
All electrical controls handled by personnel shall be either fail safe, low voltage or protected
with an approved ground fault circuit interrupter.

Revision 1
B. Personal Protective Equipment
It is essential that each operator wear the appropriate protective equipment to accomplish the
job safely. The following is a list of NLB recommended safety equipment:
Body Protection
Liquid resistant suits
Head Protection
Head protection equipment - hard hats
Eye and Face Protection

Protective eye and face equipment - face shields
Foot Protection
Steel-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 environmental and/or personal problems peculiar to that specific task. If
any are determined to exist, appropriate action must be taken prior to starting the job.

Revision 1
C. Pre-Operational Procedures
Planning
Pre-job planning shall take place prior to start of any job. Personnel familiar with the
equipment to be cleaned and the environment of the work area shall meet with the personnel
who will be doing the cleaning or cutting and outline the potential hazards of the work area,
environmental problems and safety standards.
Check List
A safety and equipment check list shall be used.
Barricades
Barricades shall be erected to enclose hazardous areas. Barricades may be rope, safety tapes,
barrels, 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 installing the nozzle, the system shall be completely flushed with sufficient water to
remove air and foreign particles.
Inspect all nozzles for damage and/or plugged orifices before installing. The high pressure
water jetting unit should be shut off and disconnected before installing nozzles.

Revision 1
D. Operational Procedures
Work Area
All personnel working or entering the barricaded area while cleaning or cutting is in progress
shall wear the required protective equipment in accordance with the job conditions.
Pressuring System
Pressure shall be increased slowly on the system while being inspected for leaks and/or
faulty components. All leaks or faulty components shall be repaired or replaced. System
shall be de-pressurized to effect repairs.
Caution:
Never leave the system unattended when pressurized.
E. Training
Cutting Action
Demonstrate the cutting action and potential hazard involved through the use of audio-visual
aids or actual use of the equipment. Cut through a piece of lumber, dissect a grapefruit, etc.
Personal Protective 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 devices. Stress the importance of not
tampering with any safety devices.
Hose
Explain the proper method of connecting hoses, including laying out without kinks,
protection from excessive wear and proper tools to use on couplings and fittings.
General
The system shall be de-pressurized any time the system is not in use.
The system shall be de-pressurized any time an unauthorized person enters the barricaded
area.
The system shall be de-pressurized when any replacement or repairs are made to the system.

Revision 1
Ill. Recommended Practices For The Use Of Manually Operated

High Pressure Water Jetting Equipment
A. Introduction
These recommended practices cover the personnel requirements, operator training, operating
procedures, and recommended equipment for the proper operation of all types of high
pressure water jetting equipment as normally used by industries concerned with construction,
maintenance, repair, cleaning, and demolition work. Attention is drawn to the relevant or
proposed OSHA, ASTM and ANSI standards. It is intended that extension to this code will
be produced in due course to cover specialist applications (e.g., multiple-gun operation,
pulsed jets, cutting with the use of abrasives and high pressure intensifiers) but in the
meantime, these practices should be used as afar as practicable.
The use of high pressure water jets for cutting and cleaning is a rapidly evolving technology
with current developments 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 these recommended practices.
3. The term "high pressure water jetting" covers all water jetting, including the use of
additives or abrasives at pressures above 1000 psi (70 bar) approximately.
4. These recommended practices are also applicable at lower pressures where there is
foreseeable risk of injury. As a guideline, the recommended practices are applicable
where the product of pressure- measured in psi (bar), times flow- measured in gallons
per minute (liters per minute) exceeds 2,000 psi times gpm (560 bar times lpm).
5. Any person required to operate or maintain high pressure water jetting equipment shall
have been trained and have demonstrated the ability and knowledge to do so.

Revision 1
C. Definition of Terms
1. High pressure water jet systems - High pressure water jet systems are water delivery
systems which have nozzles or other openings whose function is to increase the speed
of liquids. Solid particles or additional chemicals may also be introduced, but the exit
in all cases will be a free stream.
In terms of these recommended practices, the "system" shall include the pumps
(pressure producing devices) and the hoses, lances, nozzles, valves, and safety devices,
as well as any heating elements or injection systems attached thereto.
2. High pressure water cleaning - The use of high pressure water, with or without the
addition of other liquids or solid particles, to remove unwanted matter from various
surfaces where the pressure of the liquid jet at the orifice exceeds 1,000 psi (69 bar).
Caution:
The lower limit of 1000 psi (69 bar) does not mean that pressures
below 1000 psi (69 bar) cannot cause injury or require any less
attention to the principles of these recommended practices.
Adequate precautions, similar to those of these recommended
practices, are required at all pressures.
3. High pressure water cutting - The use of high pressure water, with or without the
addition of other liquids or solid 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 the pressure to a level that yields a pressure flow at the nozzle that is
considerably below the risk threshold.
6. Moleing - Moleing is an application whereby a hose, fitted either with a nozzle or with
a nozzle attached to a lance, is inserted into and retracted from the interior of a tubular
product. It is a system commonly intended for cleaning the internal surfaces of pipes
or drains.
It can be self-propelled by its backward directed jets, and is manufactured in various

shapes, sizes and combinations of forward and backward directed jets.
7. Nozzle - A device with one (1) or more openings where the fluid discharges from the
system. The nozzle restricts the area of flow of the liquid, accelerating the water to the
required velocity and shaping it to the required flow pattern and distribution for a
particular application. Combinations of forward and backward nozzles are often used
to balance the thrust. Such nozzles are commonly referred to as tips, jets, orifices, etc.

Revision 1
8. Operator - A person who has been trained and has demonstrated the knowledge and
experience to perform the assigned task.
9. Operator trainee - A person not qualified due to the lack of knowledge and/or
experience to perform the assigned task without supervision.
10. Shotgunning - An application whereby a lance and nozzle combination can be
manipulated in virtually all planes of operation.
11. Hose Assembly - A hose with coupling attached in accordance with manufacturer's
specifications.
12. Lance - A rigid metal tube used to extend the nozzle from the end of the hose.
D. Equipment Definition and Standards

1. Pressurizing high pressure pump - A unit designed to deliver high pressure water or
other fluid. This is usually based on positive displacement pistons or rubber
diaphragm/hydraulic systems, and discharges water into a common manifold to which
either flexible hoses, or rigid tubing, connecting to lances and nozzles are attached.
These high pressure pumps can be either mobile or permanently mounted.
The pump should have a permanently mounted tag or tags providing the following
information:
• 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 of:
a. Pressure relief valve (by-pass valve) or bursting disc (rupture disc) in holder -
Usually mounted on the pump discharge chamber to prevent the pressure exceeding the
rated maximum pressure of the whole system.
b. Automatic pressure regulating valve (unloading valve) - Limits the pressure at
which the high pressure pump operates by releasing a preset proportion of the
generated flow back to the pump suction chamber or to waste. It may be used to
regulate the water pressure from the pump and is individually set for each operation.
This device may be integral with the pump hydraulic assembly. Where there is no
demand for pumpage, the water pressure is brought down to zero.
c. By-pass valve - A device which can be adjusted to control the flow, and thus the
pressure, of the jet stream issuing from the nozzle by by-passing the excess flow to
another circuit.

Revision 1
4. Pressure gauge - The system should be equipped with a gauge indicating the pressure
being developed. Gauges shall have a scale range of at least 50% above the
maximum working pressure of the system.
5. Filter or strainer - The water system should be equipped with a filter or strainer to
prevent particles from restricting the orifices in the nozzle. The filter or strainer should
be capable of removing particles smaller in size than the smallest orifice in the nozzle,
and usually smaller to protect high pressure pumps, etc.
6. Dry shut-off control valve - This operator-controlled valve, normally
hand-controlled, automatically shuts off flow to the lance and/or nozzle assembly when
released by the operator, but retains the operating pressure within the supply line when
so shut-off. This valve shall be used in systems with an automatic pressure regulating
valve (IIID#3b above).
Caution:
Care should be taken to release the pressure in the dry shut-off
valve and line when the pump is shut down, otherwise the valve
operating lever may remain alive.
This valve may alternatively be actuated by solenoid or pilot pressure mechanism.
7. Dump system - The system should be equipped with a device which will either shut
down the unit, idle it to a safe rpm, by-pass the flow, or reduce the discharge pressure
to a low level. The dump system actuator device should be shielded 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 diverting the flow produced by the pump to atmosphere. A valve size should be
selected that will not cause generation of or significant back pressure at the maximum
possible pumping rate of the pump. This valve may alternatively be actuated by
solenoid or pilot pressure mechanism.
b. Solenoid and electronically operated control dump systems - All electrically
controlled dump systems should be of fail safe design. Voltage of an alternating
current (AC) or direct current (DC) dump system handled by personnel should not
exceed 24 volts.
8. High pressure hose - This is a flexible hose which connects two (2) components and
which delivers the high pressure fluid to the gun or nozzle components. The hose
should have a burst rating of a minimum of two and one half (2.5) times the intended
working pressure. Operating levels below this ratio should require a protective
shielding around that hose. The hose should be marked on one (1) end with the
manufacturer's symbol, the serial number and the maximum permissible operating
pressure and test pressure. The high pressure hose should be tested at one and a half
(1.5) times the working pressure.

Revision 1
9. End fittings and couplings - High pressure hose and end fittings and couplings shall
be manufactured to be compatible with the hose and tested as a unit.
10. Jetting gun extension - This is a length or lengths of tube carrying high pressure fluid
to the nozzle. Each shall be manufactured from suitable material for the application.
End connections shall be suitable for the application. The extension is used in
conjunction with a control valve (IIID#6 and IIID#7 above). The extension shall have
a minimum burst strength of at least two and a half (2.5) times the highest actual
operating pressure being used.
11. Nozzle - The nozzle creates the water jet, or jets, at the required velocity, flow rate,
pressure, shape, and distribution for a particular application. Combinations of forward
and backward directed water jets are often used to balance the thrust. Such nozzles
may be referred to as tips, jets or orifices.
12. Water jet - A jet stream of water produced from the individual outlet orifice of a
nozzle. The shape of the jet is determined by the form of the orifice while the speed at
which it travels is determined by the orifice design, orifice area and flow. The pressure
drop at the orifice is a result of an increase in velocity. The most commonly used jet
shapes are the straight-jet and fan-shaped jet.
a. Straight jet - Concentrates the stream of water over a small 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 - These are pieces of equipment into which
individual nozzles are fitted.
14. Foot control valve - The lance/gun operator's control valve (IIID#6 and IIID#7
above) may be arranged for actuation by the operator's foot if desired, either in place
of, or in addition to the hand-control.
An adequate guard should be fitted to prevent accidental operation and the base plate
area should be sufficient to ensure stability in use. If on the dump type (llID#7 above),
the layout should ensure that the dump line, if used, is restrained from whipping when
the valve is released.
15. Jetting gun - A portable combination of operator's control valve (IIID#6 and IIID#7
above) and nozzle (#11 above) which resembles a gun in layout and outline.
The control valve is hand-operated, generally by a squeeze action of the hand of the
operator, who should always have control of this device and may be of the dry shut off
(IIID#6 above) or dump (IIID#7 above) type, the gun being named accordingly. The
hand-control normally takes the form of a trigger or lever which should be provided
with either a guard adequate to prevent accidental operation, or the means of being

Revision 1
immobilized in the "OFF" position by means of a safety catch. The gun may be fitted
with a shoulder pad or hand grips to facilitate back thrust control.
16. Retro gun - A retro safety gun is fitted with forward and backward facing jets. This
reduces the thrust experienced by the operator. This type of gun is used mainly for
underwater high pressure water jetting operations. The retro balance jet protection tube
should be sufficiently long or constructed so as to prevent the operator from directing a
retro balance jet at himself.
17. Changeover valve - An operator-controlled valve designed to properly direct high
pressure water flow from the pump (IIID#l above) to one (1) or another items of
equipment at the operator's choice. It shall be designed to withstand the maximum
pressure and can be power operated.
E. Care and Maintenance of Equipment

1. High Pressure Water Jetting Unit - The unit shall be maintained in accordance with
NLB's instructions. Where applicable, this should include daily checks on the
following items:
a. Drive - Lubricating oil, water, hydraulic fluid, and fluid levels
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 through proper micron
filtration, to prevent foreign particles from cutting changeover valves and seating
surfaces and to prevent clogging the changeover valve operating mechanism. Such
clogging can cause a loss of control, which can be dangerous to the lance/gun operator.
3. Hose assemblies - All hose assemblies shall be inspected prior to use with respect to
the following:
a. Correct pressure rating and size
b. Free from external damage - e.g., exposed or broken wires
c. All end fittings and couplings are in good order and of the correct pressure rating for
the unit operating pressure
4. Nozzles - All jetting nozzles shall be kept clean and the orifice shall be checked to
ensure that it is not obstructed or damaged before installation. Defective nozzles shall
not be used but should be replaced or repaired before installation. During the start-up,

Revision 11
2. JOHN DEERE Diesel Engine Start-Up
Refer to the CONTROLS INCORPORATED Electronic Engine Controller manual located in

the MANUFACTURERS' LITERATURE section of this manual for operating instructions.
3. L-55i Oil Plunger Lubricator
To set lubricator drip flow adjustment, refer to Section 5: PREVENTIVE MAINTENANCE -

Lubrication Instructions.
When starting, be sure that all air is purged from the high pressure water jetting unit before
connecting the oil line to the pump discharge. Before connecting the oil line to the point of
lubrication, be sure that oil flows from the end of the feed line before it enters the check
valve. If oil does not flow, refer to Section 8: REPAIR - L-55i Oil Plunger Lubricator Pump
Priming.
4. Water Plunger Lubricator (Optional)
Open 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 supply pressure.
a. Before engaging the clutch, disconnect the high pressure hose from the pump discharge,
then engage the clutch. The pump is now operating and a steady stream of water will be
discharged out the high pressure water outlet (Figure 4-8). If the water stream tends to
pulsate, it is an indication that air pockets are in the high pressure fluid cylinder, or the
valves are worn or not operating properly. For corrective action, refer to Section 6:
TROUBLE-SHOOTING - Excessive Pulsation in High Pressure Pump Discharge.

Revision 1
prior to operation, the nozzle should be removed from the lance and the system flushed
thoroughly to remove air and foreign particles.
5. Jetting guns and lances - Jetting guns and lances shall be checked daily and the
trigger mechanism and guard given a thorough visual examination to ensure correct
operation. All high pressure connections should be observed during operation of the
equipment at pressure. If a leak is observed, the high pressure water jetting unit shall
be shut down and the connection repaired or replaced before further operation.
6. Foot control valves - All foot control valves shall be checked and cleaned daily and
the foot mechanism and guard given a thorough visual examination to ensure correct
operation.
7. Electrical Equipment - All electrically operated high pressure water jetting units shall
be checked daily for external damage with special emphasis placed on connection,
junction boxes, switches, and supply cables. Care should be taken to ensure that the
electrical system is protected 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 the
purpose.
9. Engine controls - All throttle cables and engine stop devices shall be checked daily to
ensure that they are functioning properly.
10. Maintenance servicing and repair
The following operations should only be carried out by competent

personnel:
a. NLB's servicing requirements
b. The following items should be overhauled and checked for correct functioning at
manufacturer's recommended intervals:
• Pressure relief valve (by-pass valve)
• Bursting discs (rupture discs)
• Pressure control valve
• Hand or foot operated dump control valve, shut off control valve
• Dry shut off valve or dump system
• Changeover valve
11. Tools - When maintaining or assembling high pressure water jetting systems, the
correct size tools must be used. The use of adjustable tools with serrated gripping jaws,

Revision 1
(e.g., pipe wrenches) which can damage equipment, is not recommended, particularly
on the crimped portion of a hose fitting.
12. Compatibility - All component parts and fittings should be checked to ensure they are
of the correct size and rating for the unit.
F. Protective Clothing and Personnel Protection

1. OSHA compliance - All applicable OSHA regulations covering personal protective
equipment shall be followed.
2. Head protection - All operators shall be issued with suitable head protection which
shall be worn, where possible. This should also include a full face shield.
3. Eye protection - Suitable eye protection (i.e., adequate for the purpose and of
adequate fit on the person) shall be provided to all operators of high pressure water
jetting equipment, and must be worn within the working area. Additionally, several
states have regulations governing eye protection which must be conformed with.
Caution:
Where liquids liable to cause eye damage are encountered, it may be
necessary to use either a combination of visor and goggles or a full face
shield.
Where liquids liable to cause eye damage are encountered, it may be necessary to use
either a combination of visor and goggles 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 protection should be supplied to all operators and
shall be worn when there is a reasonable probability of injury that can be prevented by
such equipment.
6. Foot protection - All operators should be supplied with waterproof boots with steel or
aluminum toe-caps. A metatarsal guard should also be used by water jetting lance/gun
operators.
7. Hearing protection - Most high pressure water jetting operations produce noise levels
in excess of 90 dB (A), consequently, suitable ear protection issued in accordance with
OSHA standards must be worn and provision should be made for its regular inspection
and maintenance. All personnel and operators should receive instruction in the correct
use of ear protectors so that noise exposure lies within the limits as specified by OSHA.
8. Respiratory protection - A respiratory protection program shall be implemented
where there is a reasonable probability of injury that can be prevented by such a
program.

Revision 1
9. Equipment limitations - It should be recognized that protective equipment may not

necessarily protect the operator from injury by direct high pressure water jet impact.
G. Pre-Operating Procedures
1. Planning - Each job shall be preplanned. Personnel familiar with the equipment to be
cleaned or the material to be cut and the work environment shall meet with the
personnel that will be doing the work and outline potential hazards of the work area,
environmental problems, safety standards, and emergency aid procedures.
2. Check List - A check list shall be used to assure that the proper procedures and
proper equipment selection are followed. (See page 2-5.)
3. Dump Valve - All systems shall incorporate at least one (1) fluid shut off or dump
device. The lance operator must always be able to shut down the water jet by releasing
pressure on the trigger, switch or foot valve pedal.
4. Warning barriers - Barricades shall be erected to encompass the hazard area and
signs posted to warn personnel that they are entering a hazardous 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 the end connections when laid on the ground, over sharp objects or on
vertical runs.
b. Fittings - All fittings shall be cleaned and lubricated before installing in the system.
Be sure all fittings, hoses and nozzles are fit for the purpose.
c. Hose - All hoses shall be checked for evidence of damage, wear or imperfection. The
check shall be made periodically during the operation.
d. Pre-flushing - The system shall be completely flushed with sufficient water to remove
any contaminants before installing the nozzle.
e. Nozzle - All orifices shall be checked in all nozzles for any stoppage, damage or
imperfections.
f. Electrical equipment - Any electrical equipment in the immediate area of the
operation that presents a hazard to the operator shall be de-energized, shielded or
otherwise made safe.

Revision 1
H. Procedures
1. Work area - Where practical, work pieces to be jetted should be removed from plant
areas to a high pressure water jetting area. Where this is impractical, cutting or
cleaning in place, or adjacent to the installed position, can be done with the necessary
clearance and permission of the occupier.
a. Area limits - Area limits applicable to the cutting or cleaning operations shall be
defined and the team shall mark these limits by barriers and notices to warn against
access to other personnel. Suitable barriers shall be an approved form of hazard
warning, rope or tape, as a minimum. Alternatively, a suitable barrier shield is
acceptable at any reasonable distance. Notices should state the following (or in other
suitable wording):
"DANGER
KEEP CLEAR,
HIGH PRESSURE WATER JETTING IN OPERATION"
b. Corrosive materials - Where there is a possibility of encountering corrosive or toxic
materials, the occupier shall be requested to inform the person in charge of high
pressure water jetting of any precautions that may be necessary, including the
collection and disposal of waste materials.
c. Work surface - Operators should have good access to the work piece, a safe working
platform and secure footing. The area in which work is to proceed shall be kept clear
of loose 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 shall be requested to inform all personnel
likely to require access to the area that high pressure water jetting is in progress.
Personnel having reason to enter the water jetting area should wait until the water jet is
stopped and his presence is made known. Personnel wishing to have the jet stopped
shall approach a team member other than the lance/gun operator. The lance/gun
operator shall not be distracted until the water jet has been stopped.
f. Side protection - Target and side shields shall, where feasible, be suitably placed to
safeguard personnel and equipment against contact with grit or solids removed by
water jets.
g. Protective equipment - All personnel working or entering the barricaded area while
cleaning or cutting is in progress shall wear the required protective equipment.
2. Pressurizing the system - Pressure shall be increased slowly on the system while
being inspected for leaks and/or faulty components. All leaks or faulty components
shall be repaired or replaced. System shall be de-pressurized for repairs.

Revision 1
3. Team operations - In most water jetting operations, it is accepted practice to employ a

minimum of two (2) persons.
a. Supervision - All high pressure water jetting operations shall be controlled by a
supervisor who is trained in all aspects of the high pressure water jetting operation.
b. Number of operators - The operation of the high pressure water jetting equipment
should be by two (2) or more operators according to the equipment being used and the
nature of the job. These operators shall work as a team with one (1) member in charge.
The operator of the gun or lance (as defined below) shall take the lead role while
jetting is in progress.
c. Lance/Gun operator - One (1) operator from the team shall hold the lance/gun or
delivery hose with the nozzle mounted on it. His primary duty is to direct the water jet.
d. Second operator - The second operator of the team shall attend the high water jetting
unit, keep close watch on the first operator for signs of difficulty or fatigue and watch
the surrounding area for intrusion by other persons or unsafe situations. If required, he
will shut off the pressure until it is safe to continue. Caution should be exercised in
shutting 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 rotation - The team members should rotate their duties during any job to
minimize fatigue to the operator holding the lance/gun.
g. Team leader - The team leader is responsible for basic equipment checks (as detailed
below), the preparation of the working area for safe operation and for obtaining a
permit to work where and when required.
h. Code of signals - Before starting a high pressure water jetting operation, the team
members (one [1] of whom must be in charge) shall agree on a code of signals to be
used during the operation of the equipment.
1. Fitness - The operator and other team members shall be physically and mentally
capable of performing the required operations.
4. Single person operation - Single person operation is allowed where the pressure does
not exceed 2,000 psi (137.9 bar) and the flow is less than 20 gpm (5.2 !pm).
a. Single operator guidelines - All other recommendations pertaining to team operations
shall hold.
5. Shotgunning

Revision 1
a. Attendance - The system shall never be left unattended when pressurized.

b. Multiple operation - When more than one (1) shotgunning operation is being
performed within the same area, a physical barrier shall be installed or adequate
spacing between operators shall be maintained to prevent the possibility of injury from
the high pressure water.
c. Target holding - Objects to be cleaned shall never be held manually.
d. Connection protection - The point where the hose connects to the gun shall be
shrouded by a protective device, (e.g., heavy duty hose, shoulder guard, etc.,) so as
to prevent injury to operator should hose, pipe or fitting rupture.
e. Minimum length- Where practicable, the minimum length of the shotgun lance
extension should be four (4) feet (1.8 m) from the triggering device to the nozzle.
f. Hose protection - Steel braided hoses should be used on air operated fail safe systems
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 than the inside diameter of the item being cleaned. This pipe
nipple is known as a "stinger" (Figure 2-3).
TRAILER MOUNTED
TO PREVENT LINE MOLE REVERSAL, ALWAYS USE A "STINGER"

(A PIPE NIPPLE WITH A LENGTH GREATER THAN THE INSIDE DIAMETER OF THE PIPE)
Figure 2-3. Moleing or Flex lancing

c. Retrojets - During manual operations, the entrance to a line or pipe shall not be
cleaned with a nozzle containing back water jets without adequate shielding.
d. Clearance - The clearance between the outside diameter of the hose, lance and nozzle
assembly and the inside wall of the item being cleaned shall be sufficient to allow
adequate washout of water and debris.

Revision 1
e. Pressurization - During 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.
f. End identification - Hoses shall be conspicuously marked no closer than 24" (0.6 m)
from the nozzle to warn the operator of the nozzle location.
g. Nozzle support - Where the length of the nozzle and rigid coupling is less than the
inside diameter of the pipe, a length of rigid pipe (i.e., stinger) not less than the
diameter of the pipe being cleaned should be fitted directly behind the nozzle or a
suitable safety shield should be provided to protect the operator. This is to prevent the
nozzle turning around 180 degrees and doubling back towards the operator.
7. Rigid lancing
a. Control - The operator inserting the nozzle shall have direct control of the dump
system.
b. Clearance - The clearance between the outside diameter of the lance and nozzle and
the inside wall of the item being cleaned shall be sufficient to allow adequate washout
of water and debris.
c. Pressurization - 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 causing injury.
8. Additives
a. Additives - Any water additive (e.g., chemical, detergent or solid particle) shall be
used in accordance with the manufacturer's recommendations.
9. Proper operation
a. Start up - The high pressure water jetting unit shall not be started and brought up to
pressure unless each team member is in his designated position, the nozzle is held in, or
directed at, the work piece and the lance/gun securely held.
b. Adjustments - Apart from operational procedures, no attempt shall be made to adjust
any nut, hose connection, fitting, etc., while the system is under pressure. The high
pressure water jetting unit shall be stopped and any pressure in the line discharged prior
to making any such adjustments.
Caution:
Care should be taken to release the pressure in the dry shut off gun and the
line when the unit is switched off.

Revision 1
c. Equipment malfunction - If for any reason the water flow does not shut off when the
trigger or foot pedal is released, work shall cease until the item has been serviced,
repaired or changed by properly trained personnel.
d. Reaction force - The lance/gun operator should be allowed to experience the reaction
force of the water jet progressively until the required operating pressure is reached.
The lowest pressure should be used compatible with the work to be done. The pressure
shall not be adjusted without the lance/gun operator's awareness.
e. Effect of line impulses - Lance/gun operators should be made aware of the reactive
effect of pressure in the line which can transmit a severe jolt to the operator when the
dump valve or dry shut off valve is operated. To minimize this effect, total hose
lengths should be kept as short as possible. Damping devices can be introduced into
the system.
f. Thermo-plastic hoses - Thermo-plastic hose 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 person becomes aware of any change in conditions or any hazards be introduced
or exist.
• If plant or work alarms are sounded.
• If any of the recommended practices in this document are not followed.
i. Hose protection - All hoses should be protected from being run over and crushed by
vehicles, fork lift trucks, etc.
J. Back thrust - The back thrust from a linearly directed jet can be calculated from the
following equation:
Back thrust (lb.) = 0.052 Q (P) 05
Where: Q is the flow rate in U.S. gallons per minute

P is the jet pressure measure in psi
Caution:
It is not recommended that any one (1) person be required to
withstand a back thrust of more than one third (1/3) of their body
weight for any extended period of time.

Revision 1
I. Use of Lances and Nozzles

1. Lances - Lances which are rigid or semi-rigid having nozzles fitted to with any
combination of forward, backward or 90 degree angle jets shall be used with either a
dump system or dry shut off control valve. When a flexible lance or nozzle mounted
on a hose is in use, the jet should not be operated at pressure unless the nozzle is
properly positioned inside the work piece, or the lance operator is protected by screens
or proper shielding from rear facing jets. If necessary, the lead-in to the work piece
should be cleaned by other methods.
2. Flexible lances - Flexible lances used to clean pipes, where the inside diameter of the
pipe is not small enough to prevent the lance from turning back on itself, shall have a
piece of rigid straight tube, slightly longer than the diameter of the pipe, fitted
immediately behind the nozzle to prevent this from happening.
3. Distance indicator - When an assembly is used which allows the nozzle to enter the
work piece with restricted visibility, the lance, hose or floor should be clearly marked
in a manner which enables the lance operator to judge how far the nozzle is in the work
piece before pressure is applied and, conversely, so that pressure is released before the
apparatus is completely withdrawn from the work piece.
4. Lance length - The length of a rigid lance or 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 off), the hose shall
not be used to support his weight when climbing up or down.
7. "T" pieces - When using a "T" piece or nozzle carrier "T" (devices for producing two
(2) equal and opposite water jets at the end of the lance and at right angles to the
normal flow), it should be inserted into a tube, a vessel, or between two (2) surfaces
before the system is pressurized. This is necessary to ensure that should one (1) water
jet be larger than the other, or one (1) water jet become blocked or partially blocked,
the operator of the lance will not be spun out of control. When a "T" piece is used to
provide a balancing jet on a long lance to clean a single surface, it is not always
possible to check for equal thrust from both jets in the manner described above,
therefore these lances should be checked by progressive pressure increases. This
restraint shall also apply to any form of multi-jet nozzle, the jets issuing from which
having a radial component.
8. Confined working - Before entry into a confined work space for high pressure water
jetting, a certificate of clearance shall be obtained to ensure that access is safe.

Revision 1
J. Operational & Training Requirements

1. Qualified operators - Only trained personnel shall operate high pressure water jetting
equipment and supervise the training of new operators.
2. Training - A personnel training program shall be developed by each employer and be
presented to each employee before assignment to employee's first high pressure
cleaning or cutting job. Such training shall include, as a minimum, coverage of all
items listed in these recommended practices.
3. Cutting action - The cutting action of a high pressure water jet and the potential
hazard it poses to the human body shall be demonstrated through the use of
audio/visual aids or actual use of equipment (i.e., by cutting through a piece of lumber,
concrete block, etc.).
4. Personal protective equipment - The minimum personal protective equipment shall
be explained. Instructions shall be given as to when and how specific clothing and
other types of protective devices shall be worn according to the type of work
performed, locations, etc.
5. System operation - The operation of the system shall be explained with 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 high wear during high pressure water jetting.
These items require frequent inspections, maintenance and/or replacements in order to
provide operation.
7. Hose - The proper method of connecting hoses, including laying out without kinks,
protection from excessive wear, and proper tools to use on couplings and fittings shall
be explained.
8. Stance - The proper stance for sound footing and how to use the various devices for
lancing, shotgunning and moleing shall be demonstrated. The trainee, under close
supervision, shall use the various devices while the unit is slowly pressurized.
9. Proficiency - Personnel shall demonstrate knowledge and skill in the proper operation
of equipment through practical application.
10. General
a. System shall be de-pressurized when:

• Not in use
• An unauthorized or inadequately protected person enters the barricaded area

Revision 1
• Replacement or repairs are made to the system

• Any recommended practices are violated
11. Refresher training - Operator retraining shall be on an annual basis or more
frequently, if needed.
K. Permanent Cleaning Areas

1. Enclosure - The areas shall be suitably enclosed and warning notices prominently
displayed at the access points and perimeters.
2. Access - Access by persons other than the high pressure water jetting team shall be
strictly prohibited while work is in progress. If any unauthorized entry is made, all
work shall cease immediately.
3. Hazards -The working area shall be free from hazards likely to trip personnel and be
provided with adequate drainage and lighting fixtures.
L. Freeze Precautions
1. Freeze precautions - During 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 through the system.
f. Move selector lever to dump or recycle position until the anti-freeze shows in the
water tank.
g. If no supply tank is fitted, follow NLB's recommendations.
WARNING:
IF A HIGH PRESSURE PUMP OR HOSE APPEARS FROZEN, ON NO ACCOUNT
MUST THE PUMP BE ENGAGED OR THE ENGINE STARTED IF THERE IS
DIRECT DRIVE TO THE PUMP, UNTIL THE SYSTEM HAS BEEN THAWED OUT
AND LOW PRESSURE WATER HAS BEEN ALLOWED TO FLOW THROUGH
THE SYSTEM TO THE NOZZLE END OF THE LANCE (THE LANCE HAVING
BEEN REMOVED).

Revision 1
M. Accidents
1. Personal injuries - In the event that a person is injured by the impact of a high
pressure water jet, the injury caused may appear insignificant and give little indication
of the extent of the injury beneath the skin and damage to deeper tissues. Large
quantities of water may have punctured the skin, flesh and organs through a very small
hole that may not even bleed.
2. Operator identification - Immediate hospital attention is required and medical staff

must be informed of the cause of the injury. To ensure that this is not overlooked, all
lance/gun operators engaged in high pressure water jetting should carry an immediately
accessible waterproof card which outlines the possible nature of the injury and titled
with the following text:
"IMPORTANT MEDICAL INFORMATION!"

This card is found in the inside pocket of this binder. If the card is missing contact
NLB at 1-800-227-7652 for a replacement.
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. Purpose - These recommended practices are provided to assist persons unfamiliar with
the operator of high pressure water jetting equipment.
The responsibility of correct operation and use of the equipment is the sole
responsibility of the operator. The operator should be familiarize himself with the
identification of high pressure water jetting metal fittings, hoses, lance/guns, and
accessories. Modification of high pressure water jetting equipment or accessories is not
recommended without prior written approval by NLB.
Serious harm or injury may result from the misuse of high pressure water jetting
equipment, the use of improper fittings, hoses or improper attachments.

Revision 1
DO . ........ . DO NOT......... .
Contact site engineer, obtain necessary DO NOT commence work on site without
permits and note special precautions. necessary permission.
Erect barriers, rope off the clear area. DO NOT commence any jetting operation
Erect warning signs. until warning signs are on show and area is
roped off.
Ensure adequate water supply.
DO NOT operate without adequate personal
Check fluid levels on engine, gearbox protection for eyes, head, ears, hands, feet,
and pump (lubrication oil, fuel and water). and body.
Lay out equipment and visually inspect DO NOT run any equipment with leakage
for damage (hoses, connections, etc.). whatsoever, without rectifying.
Assemble equipment, checking all joints. DO NOT attempt to tighten any pressure
joint while equipment is under pressure.
Ensure that filters are clean.
DO NOT by-pass safety cut-outs.
Fully prime equipment and bleed where nee- DO check reasons for malfunctions (low
essary. water, blocked filters, low oil level, etc.).
Fit gun or lances and/or control valves. DO NOT operate with guns and control
Visually check that correct size and type valves not functioning correctly (leaking or
of nozzle is fitted for the application. failing to shut off).
Increase pressure slowly until operating DO NOT operate guns or control valves
conditions are reached. with the operating lever tied back, wedged
or locked in the "ON" position.
Re-check hose couplings and joints for
leaks. DO NOT operate with badly worn or
undersize nozzles.
Rectify all leaks, ensuring that the unit
is shut down and line pressure is DO NOT continue to operate if any
released before making adjustments. unauthorized personnel enter the operating
area.
Ensure all operators are wearing
suitable protective clothing and DO NOT operate equipment at power levels
are correctly positioned. which can produce a reaction force greater
than the lance/gun operator can comfortably
Regularly check operating conditions absorb.
(oil and water pressure, condition of
filters, pipe work and hoses). DO NOT leave high pressure water jetting
unit running unattended.

Revision 1
DO . ........ . DO NOT......... .
Ensure that all pressure in lines is DO NOT leave equipment unattended

released on any shut down. on site.
Upon completion, strip down DO NOT store unserviceable equipment

equipment and store in clean condition. (notify supervisor).
Clear the site of barriers, warning signs DO NOT leave the site in a dangerous or
and debris, to customer's satisfaction. untidy condition.
Upon completion, ensure that customer DO NOT leave site without notifying all
has signed the necessary paperwork parties (engineers, site agents, occupiers,
(satisfaction notes, work sheets, etc.). etc.).

Revision 11
TABLE OF CONTENTS
SECTION 3
PRODUCT OVERVIEW

I. General Description ............................................ . 3-2
II. Water Condition ............................................... . 3-2
III. Specifications ................................................. . 3-3
A. High Pressure Water Jetting Units .............................. . 3-3
1. Physical ................................................ . 3-4
2. Mechanical ............................................. . 3-4
3. Performance ............................................ . 3-5
B. CUMMINS Diesel Engine .................................... . 3-5
C. JOHN DEERE Diesel Engine .................................. . 3-5
D. Outdoor Site Requirements .................................... . 3-6
E. Indoor Site Requirements ..................................... . 3-6
IV. Bills of Materials & Assembly Drawings ............................ . 3-7
A. 1012DB-TRA High Pressure Water Jetting Unit ................... . 3-7
B. 1012DB-SKID High Pressure Water Jetting Unit .................. . 3-9

Revision 7
I. General Description
The NLB Corporation Models 1312D, 1012D, 812D, 612D, 512D, 412D, 3.512D, & 312D
high pressure water jetting units are designed for minimal maintenance and dependable
performance at full scale industrial use.
The high pressure water jetting units consist of a 1012 Triplex high pressure pump, suction
surge tank, driver motor, and various accessories which are all mounted on a trailer 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 orifices and seals, and to reduce the
accumulation of mineral deposits on the by-pass valve and other components, high pressure
water must have a low mineral content.

Revision 7
Ill. Specifications
Note:
Some specifications may differ from those of your unit. Contact NLB if you require
clarification.
A. 13120, 10120, 8120, 6120, 5120, 4120, 3.5120, 3120, 10600,
8600, & 7600 High Pressure Water Jetting Units
Figure 3-1. 1012D Trailer Mounting 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 (94.6) 6,000 (480) BVl0-400

Revision 8
"A" CYLINDERS (Cont.)

1060D 7/8" (22.2) 10.0 (37.9) 10,000 BVl0-400
(689.6)
860D l" (25.4) 12.5 (47.3) 8,000 (550) BVl0-400
760D 1-1/8" (28.6) 14.0 (53.0) 6,000 (480) BVl0-400
"B" CYLINDERS
512D 1-3/8" (34.9) 30.0 (113.6) 5,000 (344) BVl0-400
412D 1-1/2" (38.1) 35.8 (135.5) 4,000 (280) BVl0-400

3.512D 1-5/8" (41.3) 41.9 (158.6) 3,500 BVl0-650
(245.8)
312D 1-3/4" (44.5) 48.6 (184) 3,000 (210) BVl0-650
1. Physical
Weight: Trailer Mounting Unit: 5,100 lbs. (2,315 kg)
Skid Mounting Unit: 4,500 lbs. (2,045 kg)
High Pressure Pump Oil - Capacity: 9.0 qts. (8.5 l)
High Pressure Pump Oil - Viscosity: SAE 15W40
L-55i Oil Plunger Lubricator: SAE 15W40: 4.0 qts. (3.8 l)
L-55i Oil Plunger Reservoir with
Low Level Shut-down (Optional): SAE 15W40: 20.0 qts. (18.9 l)
Gear-Pac (Optional): SAE 15W40: 2.5 qts. (2.4 l)
2. Mechanical
Polypropylene Water Tank Capacity: 66.0 gal. (250.8 l)
Inlet Water Connection: 1" (25.4 mm)
Water Supply: Total hardness: Less than 10 ppm (10 mg/l)
Inlet Water Supply Pressure Range: Minimum: 40 psi (2.8 bar)
Maximum: 140 psi (9. 7 bar)
Inlet Water Supply Temperature Range: Minimum: 34°F (1 °C)
Maximum: 140°F (60 °C)
Water pH Value: 6.5 to 8.5
Water Turbidity (NTU): Maximum: 5
Filter Cartridge: One (1 ), Disposable, 80 mesh screen
Filter Cartridge (Optional): FSP85

Revision 11
Filter Cartridge (Optional): PM3350 - Inlet Water Bag Filter

Maximum Differential Pressure Across Filter
Media:
50 psi (3.4 bar)
3. Performance
Volumetric Efficiency at Maximum Pressure: 90%
Ambient Temperature Range: 35° to 110° F (2 ° to 43 °C)
Relative Humidity: Up to 95% at 120°F (49 °C)
(Non -condensing)
Space Requirements: 36" (94.1 cm) Clearance on all sides for
operation and service access
Site Elevation: Not to exceed an incline of 5 ° from horizontal
B. CUMMINS Diesel Engine
Make: CUMMINS diesel 6B5.9 six-cylinder

Bore: 4.02" (102 mm)
Stroke: 4.72" (120 mm)
Displacement: 359 C.I. (5.9 l)
Weight: Dry: 880 lbs. (399 kg)
Horsepower (continuous): 115 or 80
Firing Order: 1-5-3-6-2-4
Oil Viscosity: All seasons:
10° to 110°F (-12 ° to 20 °C) 15W40
Winter conditions:
-10° to 68°F (-23 ° to 20 °C) 10W30
Oil Capacity: 17.2 qts. (16.3 l)
Oil pressure at Idle: 10 psi (. 69 bm)
Coolant: 50% Concentration of ethylene glycol or
propylene glycol low silicate antifreezes
Coolant Capacity: Engine: 9.0 qts. (9.5 l)
Total: 27.0 qts. (25.5 l)
Fuel Tank Capacity: 32.0 gal. (121.6 l) with gauges
Fuel Type: Diesel fuel oil No.2-D
Fuel Filters: Dual system
Fuel Consumption: 3.5 gal./ hr. (13.3 l./hr.) at 25% duty cycle
C. JOHN DEERE Diesel Engine

Make: JOHN DEERE diesel Model 4045
Bore: 4.19" (106.0 mm)
Stroke: 5.00" (127.0 mm)
Displacement: 276.0 C.I. (4.5 l)

Revision 11
Weight: Dry: 853.0 lbs. (387.0 kg)

Firing Order: 1-3-4-2
Oil Viscosity: All seasons:
10° to 110°F (-12 ° to 20 °C) 15W40
Winter conditions:
-10° to 68°F (-23 ° to 20 °C) 10W30
Oil Pan Capacity: Refer to JOHN DEERE manual
Oil pressure at Idle: 50 psi (345 kPa)
Coolant: 50% Concentration of ethylene glycol or
propylene glycol low silicate antifreezes
Coolant Capacity: Engine: 9.0 qts (8.5l)
D. Outdoor Site Requirements

WARNING:
DO NOT OPERATE THE HIGH PRESSURE WATER JETTING UNIT WHERE
THERE ARE OR CAN BE COMBUSTIBLE VAPORS. THESE VAPORS CAN BE
DRAWN THROUGH THE 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 UNIT'S EXHAUST SYSTEM IS DESIGNED TO
DISCHARGE GASES TO THE OUTSIDE ATMOSPHERE. DO NOT OPERATE
THE HIGH PRESSURE JETTING UNIT INDOORS. INHALATION OF EXHAUST
GASES CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH. ANY
MODIFICATIONS TO THE EXHAUST SYSTEM MUST BE APPROVED BY NLB
OR ALL WARRANTIES WILL BE VOIDED.

Revision 11
IV. Bill of Materials & Assembly Drawings

A. 101208-TRA High Pressure Water Jetting Unit
ITEM
PART# DESCRIPTION QTY.
#
.1 1012A-10 Pump, Complete . .; with l" Plungers ·1Ea.
2 DM10711 Skid, Trailer 1 Ea.
3 6B-5.9P Engine, Diesel, CUMMINS 1 Ea.
4 MFB4311-7 Base, Pump 7" l Ea.
5 MFG4305 Guard, Belt 1 Ea.
6 DM11924 Trailer, Components l Ea.
7 DM15994 Drive, Components l Ea.
8 DM15995 Throttle, Components 1 Ea.
9 DM15996 Battery, Components l Ea.
10 DM15997 Piping, Fuel Tank 1 Ea.
11 NLE6007-5S Piping, Inlet l Kt.
12 DLE6008-58 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 Lubricator, Components, Oil 1 Ea.
31 PM15499 Eye, 3" Lunette, Adjustable Type l Ea.
Shaded Area: Listed are the part numbers for the 1012DB-TRA High Pressure Water Jetting
Unit, contact the NLB Customer Service Department for the particular part listing for your
unit.

F"UEL TANK
NU!PIPING
LOGO '""'
CECAi.
NPT
TANK
48
®A
OPTIONAL PINTLE EYE
1/8
I NLB P/N 'f>M15499'
3' ADJUSTABLE EYl.
20.000 LBS CAPACITY
& 1012DB-TRA STANDARD OPTIONS

COUPLER 1
12 0 PuMP 'MTH WATER LUBE PACKJNC
I © PIPING. WATER LUSE
~~~~~~~~~~~~~~~~~~-:::1~~~167 ~~·~~~~~--1~~~~~~-:;1--~~-:t-:---~~-'<c::::--i I /2• l'tMALE OU!CK couPl.l:R

HIQ< Pm:SSlJRE WA ltR CONNCCnON
G PtNTLE HITQI
@ LOW CRANKCASE: OIL SHuTOOWN

w TRAILER lliROTTLE INLl:T OISCHARCE BYPASS RUPTURE ll!SC
@ LOW WATER SHUTDOWN
I COMPONENTS COMPONENTS PIPING PIP1NG PIPING PIPING 'MTH
RUPTURE DISC
o:> @ 5 GAL LUBE Oil RESl:RVOIR
lllESEI.
ENGINE
.,....
3
'~~·
l
84
REF TO
GROUNO 1" F'!:MALE MPT
! WATER
CONNCCTlON
TRAILER
COUP!.tR 84 15~6
l
REf' TO
GRO<.JNO
I MJA
,.,
DO NOT SCALt OIAweNG
PUii?
SASI:
MNrG
F'l..ATE &
Revision 11
8. 101208-SKID High Pressure Water Jetting Unit
ITEM
#
1 1012A-10 Pump, Complete - with 1'' Plungers lEa.·.·
2 DM13050 Skid 1 Ea.
3 6B-5.9P Engine, Diesel, CUMMINS 1 Ea.
4 MFB4311-7 Base, Pump 7" 1 Ea.
5 MFG4305 Guard, Belt 1 Ea.
6 CLE6004-23 Piping, Remote Oil Drain For CUMMINS Engine 1 Ea.
7 DM15994 Drive, Components 1 Ea.
8 DM15995 Throttle, Components 1 Ea.
9 DM15996 Battery, Components 1 Ea.
10 DM15997 Piping, Fuel Tank 1 Ea.
11 NLE6007-5S 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.
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 Lubricator, Components, Oil 1 Ea.
Shaded Area: Listed are the part numbers for the 1012DB-SKID High Pressure Water Jetting
Unit, contact the NLB Customer Service Department for the particular part listing for your
unit.

;.~~~
i
r2 •JB
& 101 ZDB-SKID STANDARD OPTIONS
(,,) 0 PuMP WITH WATER LUBE PACKING
......I @ PIPING, WA TtR LUSE

0 DIESEL
ENGINE
® LOW CIWIKCASE OIL SHUlllOWN
@ LOW WATER SHUTDOWN
@ ~ CAL LUSE RESERVOIR
69 1.3/16
""'
l .,
'
Revision 11
TABLE OF CONTENTS
SECTION 4
OPERATION CONTROL

I. Machine Control ................................................ 4-2
A. Control Devices ............................................. 4-2
1. Push Buttons ............................................. 4-2
2. Pilot Lights .............................................. 4-2
3. Push Button Pilot Lights .................................... 4-2
4. Selector Switch ........................................... 4-2
5. Float Switch ............................................. 4-2
B. Control Panel - CUMMINS Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . 4-3
1. Control Panel Layout - CUMMINS Diesel Engine ............... 4-5
C. Low Water Level Push Button Station (Optional) - CUMMINS
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
1. Push Button Station 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 ........................ +-ii. 1
3. L-55i Oil Plunger Lubricator ................................ 4-17

4. Water Plunger Lubricator (Optional) .......................... 4-17
5. High Pressure Pump ....................................... 4-17
6. Water Inlet Bag Filter - PM3350 (Optional) .................... 4-18
7. Diesel Engine Shutdown .................................... 4-19
B. Operation Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
1. L-55i Oil Plunger Lubricator ................................ 4-19

Revision 1
I. Machine Control
A. Control Devices
Control devices found on the Control Panel have a fundamental impact on safety, because at
least a portion of them are able to initiate machine motion. For this reason, it is essential that
every person who comes into contact with this equipment must have a basic grasp of their
functions.
The following are brief descriptions of the push buttons, pilot lights, selector switch, and
float switch that will be encountered on this equipment:
1. Push Buttons
Push buttons are a type of electrical switch used to provide interface between operator and
high pressure water jetting unit controls.
2. Pilot Lights
Pilot lights give a quick visual indication of equipment status. Because of this function, they
often serve as 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 light which
illuminates for a fault condition.
4. Selector Switch
A selector switch provides mode selection capability, e.g., "Warm Engine I Run Engine".
This is a maintained contact device.
5. Float Switch
A float switch is a device designed for automatic control of a liquid in an open or closed
reservoir. A float attached to an arm extending off the switch activates the switch when the
liquid level raises or lowers. The float switch on the high pressure water jetting unit is used
to indicate a low water condition.
© Copyright November, 1999 NLB Corporation 4-2

Revision 11
B. Control Panel - CUMMINS Diesel Engine
The Control Panel features a simple design for operation ease. The panel is housed in a met-
al enclosure that contains a series of gauges which give information on the oil pressure, tem-
perature, voltage, and engine RPM.
For a detail drawing of the panel, refer to "Control Panel Layout", included in this section.
Devices on the Control Panel are described from top to bottom:
"PRESSURE"
Device: Oil pressure gauge

The oil pressure gauge indicates the oil pressure of the 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: Temperature gauge

The temperature gauge shows the operating temperature of the engine.
"KEY START/STOP"
Device: Key start switch

A two-position on/off switch used for starting and stopping the engine.
"START PUSH BUTTON"
Device: Engine start push button

Depress to engage the starter.

Revision 11
"FUSE"
Device: 30 amp fuse

Protects the electrical circuit of engine and control panel.
"RESET"
Device: Tattletale red push button pilot light (Reset)

TM
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.

Revision 11
1. Control Panel Layout - CUMMINS Diesel Engine
PRESSURE TEMPERATURE
\ \
KEY START
START/ STOP PUSHBUTTON
\ FUSE
VOLTS RESET
HOURS
RPM

Revision 11
C. Low Water Level Push Button Station (Optional) - CUMMINS

Diesel Engine
NLB high pressure water jetting units can be supplied with an optional Low Water Level
Push Button Station. The station is housed in a metal enclosure that contains a pilot light,
push button, and a two-position selector switch.
Refer to the "Low Water Level Push Button Station Layout" for a detail drawing of the
station.
Devices on the push button station are described from top to bottom.
"LOW WATER LEVEL"
Device: Pilot Light Color: Red
Illuminates to indicate a low water condition.
"WARM ENGINE/ RUN ENGINE"

Device: Two-Position Selector Switch
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 and shut down the engine if a low water
condition occurs in the water tank.
"LOW WATER RESET"

Device: Push Button Color: Black
Depress to reset a low water condition after the fault has been corrected.

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1. Push Button Station Layout - CUMMINS Diesel Engine
Caution:
WARM UP ENGINE will bypass 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.
LOW WATER
LEVEL
(WARM RUN I ( LOWWATER I

ENGINE ENGINE At.:.::>t::; ·

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D. Control Panel - JOHN DEERE Diesel Engine
The Control Panel features a simple design for operation ease. The panel is housed in a
metal 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.

Revision 11
1. Control Panel Layout - JOHN DEERE Diesel Engine
0 0
RPM
0 NLB Cor • 0
THROTTLE
Off Manual
8 ...
Run Throttle
a 0
Automatic
Throttle

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2. Terminal Strip Pinout - JOHN DEERE Diesel Engine
TERMINAL STRIP PINOUT

{Location on Circuit Board)
j 30 I 31 I 32 J 30 I 31 I 32 j
( ) ( ) ( )\( ) ( ) ( )
(Terminal Strip Definitions)
Terrn # Connection Terrn # Connection

1 Batterv Positive 17 Batterv Positive Common Contact
2 Batterv Neaative 18 Switched Power to ECU
3 Not Used 19 Switched Power to Crank Solenoid
4 Ground 20 Pre Alarm Common
5 Air Compressor Ternp 21 Pre Alarm Normally Open
6 Inlet Water Pressure 22 Fault Common
7 Analoa Fuel Level 23 Fault Normallv Ooen
8 Dlscharne Pressure Switch 24 Not Used
9 Lube Oil level 25 Pump Fault #1
10 Crank Case 011 Level 26 Pump Fault #2
11 Low Water Level 30 Fault Reset
12 Emeraencv Stop 31 Ground
13 Enter 32
14 Throttle Down 34 CAN J1939 Hi
15 Tl1rottle Uo 35 CAN J1939 Low
16 Menu 36 CAN J1939 Sl1leld
-· -
BOLD CONNECTIONS MUST BE GROUNDED Ir NOT USED
DEUTSCH 21 PIN PLUG PINOUT

Pin B Battery+ lo EM Plus T2 PlnJ Battery + to Alt
Pin D Battery + to Start Slave Relay Pin G Battery + to ECM
Pin E Battery- Pin L Deere Analog Throttle Emulator
Pin F CAN Shield Pin M Deere Analog Throttle Emulator
Pin V CAN High Pin C Deere Analog Throttle Emulator
Pin U CAN Low Pin R Deere Digital Throttle Emulator
Pin S Deere Digital Throttle Emulator

Revision 11
II. Pre-Operating Procedure
WARNING:
READ SECTION 2; SAFETY INSTRUCTIONS BEFORE OPERATING THIS
EQUIPMENT. OPERATORS SHOULD RECEIVE TRAINING BEFORE USING THE
HIGH PRESSURE 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.

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d. Check oil level in plunger lubricator (Figure 4-3).
Figure 4-3. Check oil level in oil plunger lubricator.
e. Check fuel level in fuel tank (Figure 4-4).
Figure 4-4. Check level in fuel tank.
f. Undo the water tank latches, open 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.

Revision 11
g. Check the inlet filter on the water tank by unscrewing the plastic bowl (Figure 4-5).
Flush out the bowl and rinse the screen before re-installing the screen and bowl.
Tighten the bowl finger tight.
Figure 4-5. Check water inlet filter.
h. If the unit is equipped with the optional Water Inlet Bag Filter (PM3350), connect the
inlet and outlet piping to filter, connections are 1-1/2" female NPT. (Flow through the
filter media 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 (Figure 4-6).
The dram sump preven1s the, water and 011 mixture packmg weepage from rnn~mg onto
the surface where the high pressure water jetting unit is located.
Figure 4-6. Drain stuffing box.

Revision 11
k. Grease all fittings on the engine power take-off clutch. Fitting locations will vary on
different engines.
1. Check that the high pressure water jetting unit is level on the location surface. Use the
tongue jack for adjustment on the trailer model.
rn. Check that the water supply hose is hooked up and that the water is turned on.
Caution:
Inlet water supply pressure must be a minmum of 40 psi (2.8 bar) to avoid
starving the high pressure pump of water.
n. After all pre-operating checks have been completed, verify and record the completion
of all safety checks listed in Section 2: SAFETY. Make copies of the provided safety
check list so that you can use a new list for start up of each job.
Ill. Operating Procedures
WARNING:
THIS HIGH PRESSURE WATER 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
from the unit work area. To further ensure accident prevention, the operator
should call out a "Start up!" warning.
WARNING:
DO NOT OPERATE THE DIESEL ENGINE WHERE THERE ARE, OR CAN BE,
COMBUSTIBLE VAPORS. THESE VAPORS CAN BE DRAWN THROUGH THE
AIR INTAKE SYSTEM AND CAN CAUSE ENGINE ACCELERATION AND
OVER-SPEEDING WHICH CAN RESULT IN A FIRE, AN EXPLOSION, SEVERE
PERSONAL INJURY, OR DEATH, AND EXTENSIVE EQUIPMENT DAMAGE.
WHEN THE DIESEL ENGINE JS OPERATING DURING WARM UP OR NORMAL
OPERATION, HIGH PRESSURE WATER WILL BE CREATED.

Revision 11
1. CUMMINS Diesel Engine Start-Up
After all pre-operating and safety checks have been performed, the engine is ready to be
started. Refer to recommended engine start-up procedures in the engine manual located in
the MANUFACTURERS' LITERATURE section of this manual.
a. Follow the daily maintenance instructions listed in Section 5: PREVENTIVE

MAINTENANCE - Daily or Approximately Every 8 Hours of Operation.
b. Disengage the clutch.
c. Turn the fuel shut-off control to the "RUN" position.
d. Reset the Warning push button pilot light by depressing it.
e. Turn the key-operated two-position ignition switch to the "START" position.
f. Depress the Tattletale TM (Reset) pushbutton pilot 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) minutes between each
Rttempt to start
h. Continue to hold Tattletale (Reset) pushbutton pilot light until engine oil pressure
TM
gauge needle moves off resting stop.
L This unit is equipped with an Automatic Throttle Control (ATC) (Figure 4-7). The ATC
uses system pressure to control engine speed. When system pressure is low, the ATC
keeps the engine at idle speed. When system pressure is high, engine speed is held at the
preset (loaded) value.

Revision 11
Figure 4-7. Automatic Throttle Control (ATC).
The ATC may be adjusted for any desired loaded engine speed, and locked in that
position so that each time the water jetting accessory is actuated, the engine speed will
increase to that preset value.
Set the ATC at the idle position at the start of each job, or when the water jet nozzle has
been changed. After the clutch is engaged, and the water jetting accessory valve trigger
is squeezed, adjust the ATC to produce the desired system pressure.
Engine speed is increased by turning the handle counterclockwise and decreased by

turning it clockwise. After the engine speed has been set to produce the desired
pressure, tighten 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 on the handle shaft.
Caution:
Do not idle the engine for excessively long periods of time. Idling more than
10 minutes can cause combustion chamber temperatures to drop so low that
fuel cannot burn completely. This will allow carbon to clog the injector spray
holes and piston rings and can cause the valves to stick.
The throttle control should be adjusted to idle speed at the start of each job
or when a nozzle size has been changed.

Revision 11
Figure 4-8. High pressure water outlet.
b. If the pump discharge is proper, allow the pump to run at idle speed for approximately
one (1) to two (2) minutes to insure proper oil circulation.
c. After warm up-period, disengage the clutch, connect the high pressure hose to the pump
discharge. The unit is now ready for operation. If you are using accessories, refer to
your NLB high pressure water jetting accessory manual for details.
6. Water Inlet Bag Filter - PM3350 (Optional)
The maximum pressure/temperature rating of the filter is 300 psi (20. 7 bar) at 100°F
(38 °C). If operating pressure can exceed 300 psi (20. 7 bar) an 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 hold-down nuts and remove the lid.
c. Remove the filter media. Clean or replace as necessary and reinstall in the filter. If it
was necessary to remove the perforated support basket, be sure to reinstall the flat
gasket. Contaminated by-pass may result if the flat gasket is not in place. Make sure
all flat gasket and sealing surfaces are clean.
d. Reinstall the lid hold-down nuts.

Revision 11
e. Turn on flow to inlet bag filter.
7. Diesel Engine Shutdown
a. Disengage the high pressure pump.
b. Allow engine to cool (approximately five [5] minutes).
c. Turn key-operated two-position ignition switch to the "OFF" position.
B. Operation Description
The operation description for each application varies with the type of high pressure water
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 the lubricator. Inside the lubricator, a
body. Oil is then pumped onto the high pressure pump plungers.

Revision 3
TABLE OF CONTENTS
SECTION 5
PREVENTIVE MAINTENANCE

I. Preventive Maintenance Overview ................................. . 5-2
A. Preventive Maintenance Program ............................... . 5-3
B. Maintenance Record Form .................................... . 5-3
C. Abnormal Environmental Conditions ............................ . 5-3
1. Freezing Conditions ...................................... . 5-3
2. Dusty Conditions ........................................ . 5-3
3. Corrosive Vapors ......................................... . 5-4
4. High Humidity .......................................... . 5-4
D. Safety .................................................... . 5-4
II. Preventive Maintenance Intervals .................................. . 5-6
A. Electrical Components, Control Panel & Push Button Station ........ . 5-7
1. Daily or Approximately Every Eight (8) Hours of Operation ...... . 5-7
2. Weekly or Approximately Every 40 Hours of Operation .......... . 5-8
B. Mechanical Components ...................................... . 5-8
1. Daily or Approximately Every Eight (8) Hours of Operation ...... . 5-8
2. Weekly or Approximately Every 40 Hours of Operation .......... . 5-10
3. Monthly or Approximately Every 160 Hours of Operation ........ . 5-13
4. Every Three (3) Months or Approximately Every 250 Hours
of Operation . . . . . . . . . . .................................. . 5-13
5. Every Six (6) Months or Approximately Every 500 Hours
of Operation ............................................ . 5-14
6. Every Year or Approximately Every 1000 Hours of Operation ..... . 5-14
7. Every Two (2) Years or Approximately Every 2000 Hours
of Operation ............................................ . 5-15
III. Suggested Component Cleaning Schedule ........................... . 5-15
IV. Lubrication Instructions ......................................... . 5-17
v. Winterizing Procedure .......................................... . 5-21
VI. Sample "Maintenance Record" .................................... . 5-23
© Copyright August, 2000 NLB Corporation 5-1

Revision 3
I. Preventive Maintenance Overview
All machine parts wear with use. This wear does not always result in out-and-out
equipment failure, but rather in a creeping out of tolerance that can cause gradual
deterioration of results. Preventive maintenance must be performed on a regular basis at the
correct intervals to thwart this degradation.
A conscientiously applied program of preventive maintenance is required because it will

result in longer life and enhanced reliability for the equipment.
Preventive maintenance is the systematic care, inspection and servicing of equipment to

maintain it in a serviceable condition and to detect and correct early and minor problems
before expensive and time consuming repairs or replacement parts are required. Preventive
maintenance 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 industrial
equipment.
The proper operation and use of equipment contributes to preventive maintenance as much as
the inspections and services prescribed in this section.
NLB strongly recommends that log sheets be filled out for each piece of equipment or
accessory. The log sheets are valuable records which, when properly filled out, will serve as
a master record indicating the condition of each component and when inspections were
made. These records will also save time and money by aiding in the proper diagnosis of
chronic problem areas.

Revision 3
A. Preventive Maintenance Program
If preventive maintenance is to mean anything, it must be scheduled. The very best way to
schedule preventive maintenance is through the institution of a thorough ongoing program
using some sort of scheduling chart or computerized tracking system to check compliance.
When this is performed on a timely basis, the incidence of emergency repairs tends to
subside.
B. Maintenance Record Form
All maintenance personnel should document any maintenance or repairs they perform. An
hour meter provided on the control panel is helpful for this purpose. A maintenance record
form should be used to record the actual maintenance accomplished, and using the hour
meter to determine when various preventive maintenance should be accomplished.
A sample "Maintenance Record" form is included at the end of this section.
C. Abnormal Environmental Conditions
Operation under adverse temperature conditions, dust, corrosive vapors, or 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 plunger lubricator
from freezing. If water will freeze during shut-down periods, then the entire system must
be drained to prevent damage to pump and piping. A non-freezing, non-corroding liquid
must then be forced from the suction line into the pumping chambers to force the fluid out
of the pumping chambers (V: Winterizing Procedure in this section).
2. Dusty Conditions
Air-borne abrasives will deposit themselves on plungers and crosshead extensions,

shortening the lives of plungers, packings, extensions, seals, and may be drawn through the
high pressure pump's power end breather, contaminating oil and shortening bearing life.
Make efforts to protect the high pressure water jetting unit against such dust and grit.

Revision 3
3. Corrosive Vapors
Care should be made to eliminate the exposure of the high pressure water jetting unit to
corrosive gases to prevent contamination of the high pressure pump's power end.
4. High Humidity
High pressure water jetting units exposed to high humidity, unless operated continuously,
will accumulate condensation in the the high pressure pump's power end and oil plunger
lubricator. Take periodic oil samples from the drain connections. If water is detected, then
the oil must be changed.
D. Safety
The subject of safety has been discussed elsewhere in this manual. The reader is referred to
Section 2: SAFETY and to other cautions and warnings to be found throughout this manual.
However, because preventive maintenance requires such close contact with the high pressure
water jetting unit, caution must be exercised every minute. Here is a brief review of some of
the safety basics 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 tolerate, horseplay in the work area.
• Review all safety information pertaining to the work you are about to do.
• All electrical components associated with this system are to be maintained in accordance
with approved practices. Never use jumper wires across fuses, fuse holders or circuit
breakers.
• Do not work on anything that is supported ONLY by lifting jacks or a hoist. Always
use blocks or proper stands to support the product before performing any service work.
• Dump all high pressure before any lines, fittings, or related items are removed or
disconnected. Be alert for possible pressure when disconnecting any device from a
system that utilizes pressure.

Revision 3
• Avoid personal injury. Use a chain hoist, or get assistance, when lifting components that
weigh 50 lb. (23 kg) or more. Make sure all lifting devices (chains, hooks, or slings) are
in good condition and are of the correct capacity. Make sure hooks are positioned
correctly. Always use a spreader bar when necessary. The lifting hooks must not be
side loaded.
• To avoid bums, be alert for hot parts on components that have just been 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 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

pressurewater jetting unit.

Revision 3
II. Preventive Maintenance Intervals
The basic "tool" of preventive maintenance is visual inspection. During this inspection,
screws should be tightened, adjustments done if needed, component wear noted, modest
amount of lubrication performed, etc.
The following pages provide guidelines for visual inspection, preventive maintenance and
adjustment instructions for the high pressure water jetting unit. Inspect each component at
the suggested interval. If, upon inspection, a component needs adjustment, lubrication or
replacement, perform the required maintenance as part of the preventive maintenance
program.
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 high pressure pump, in particular, the lubricant level.
Note:
Even though the indicated interval for the high pressure pump crankcase oil change
is every 500 hours or six (6) months, the first change should be at 125 hours. See
IV: Lubrication Instructions in this section.
Note:
Manufacturer's nameplate data and instructions take precedent over the following
recommendations:

Revision 3
A. Electrical Components, Control Panel & Push Button Station
WARNING:
SERVICING AN ENERGIZED ELECTRICAL SYSTEM CAN BE HAZARDOUS,
SEVERE INJURY CAN RESULT FROM ELECTRICAL SHOCK OR BURN.
RECOMMENDED PRACTICE IS TO DISCONNECT ELECTRICAL SYSTEM FROM
THE POWER SOURCE.
Periodic Inspection
Electrical components should be inspected periodically. Inspection intervals should be based
on environmental and operating conditions, and adjusted as indicated by experience. An
initial inspection within three (3) or four (4) months after delivery is suggested. Applicable
parts of the following guidelines should be used:
Contamination
If inspection reveals that dust, dirt, moisture or other contamination has reached 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 the electrical system for
proper functioning under controlled conditions that avoid hazards in the event of a
malfunction.
1. Daily or Approximately Every Eight (8) Hours of Operation
Operating Mechanism
a. Check gauges, switches, and push buttons for proper functioning and freedom from
sticking or binding. Replace any broken, deformed or badly worn parts. Check for, and
re-tighten securely, any loose fasteners.
Pilot Light
a. Check bulbs for burn out or damaged lens.

Revision 3
2. Weekly or Approximately Every 40 Hours of Operation
Fuse
a. Check for proper size of fuse and tightness of fuse clips and terminals.
Motor (If Applicable)

a. Check for dirt, dust or debris at ventilating air inlets. Never allow dirt to accumulate
near air inlets. Never operate motor with air passages blocked.
B. Mechanical Components
1. Daily or Approximately Every Eight (8) Hours of Operation
Diesel Engine
Preventive maintenance begins with day-to-day awareness of the condition of the engine
and its systems. Check for the following:
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 needed.
WARNING:
DO NOT REMOVE THE RADIATOR CAP FROM A HOT ENGINE. WAIT UNTIL
THE TEMPERATURE IS BELOW 122°F (50°C) BEFORE REMOVING THE
PRESSURE CAP. FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY
FROM THE HEATED COOLANT SPRAY OR STEAM. REMOVE THE FILLER
CAP SLOWLY TO RELIEVE COOLANT SYSTEM PRESSURE.

Revision 3
d. Visually inspect the drive belt for intersecting cracks. Transverse cracks (across belt
width) are acceptable. Longitudinal cracks (direction of belt length) that intersect with
transverse cracks are not acceptable. Replace the belt if it is frayed or has pieces
missing (Figures 5-1and5-2).
Figure 5-1. Belt inspection (outside).
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).
3. Drain the fuel-water separator of water and sediment until clear fuel is visible.

Revision 3
Caution:
Do not overtighten the valve. Over-tightening can damage the threads.
4. Push the valve up and turn the valve clockwise to close the drain valve.
Note:
If more than two (2) ounces (2.9 ml) is drained, refill the filter to help prevent hard
starting.
g. Apply a small amount of lubricant to the throwout collar on the power take-off through
the fitting on the tapered part of the housing.
High Pressure Pump

a. Listen for any deviations from quiet and smooth operation.
b. After approximately one (1) hour of operation, touch the side of the pump on the power
end to see if the operating temperature is normal (should be warm, but not hot to the
touch).
c. Check to see if crankcase 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.
Water Inlet Bag Filter - PM3350 (Optional)

a. Check Filter Bag (PM6962), clean or replace as necessary.
Water Inlet Bag Filter - FSPSS (Optional)

a. Check Filter Bag (FSP85-02), clean or replace as necessary.
2. Weekly or Approximately Every 40 Hours of Operation
High Pressure Pump

a. Check oil in crankcase for water or other contaminants. This can be accomplished while
the pump is running, if needed, by drawing a small 2 oz. (2.9 ml) sample from the drain

Revision 3
connection. If the oil is contaminated (milky or cloudy appearance), then it must be

changed before any water jetting operations can be accomplished.
b. Make sure plungers are screwed tightly into the crosshead stubs.
V-belts
a. Check belt tension frequently. Belt tension may be affected by stretching of the belts or
by wear to the contact surface of belts and sheaves. Belt slippage on the sheaves 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-belts before failure occurs.
Water Inlet Bag Filter - PM3350 (Optional)

a. Check Flat Gasket (PM9144) and Lid 0-ring (PM9143) for wear, replace as necessary
(Figure 5-3).

Revision 3
FLAT GASKET
NLB P /N PM9144
BAG FLANGE
WITH SERRATED
SEALING FACE
1OK FILTER BAG

NLB P/N PM6962
PERFORATED FILTER SUPPORT

BASKET, NLB P /N PM12542
Figure 5-3. Close-Up of Optional Water Inlet Bag Filter (PM3350) Sealing Arrangement.

Revision 3
3. Monthly or Approximately Every 160 Hours of Operation
Diesel Engine
a. Apply a small amount of lubricant to the pilot bearing through the hole in the clutch
shaft and to the shaft bearings through the fitting located at the housing hub.
High Pressure Pump

a. Check all bolts for tightness on the fluid end of the pump. Tighten if needed. For
torque specifications, refer to Section 8: REPAIR.
b. Check the crankcase breather for dirt. Clean if needed.
Note:
Operating under adverse temperature conditions, dust, corrosive vapors, or
moisture requires more frequent inspecting of the crankcase breather.
4. Every Three (3) Months or Approximately Every 250 Hours of

Operation
Diesel Engine
a. Change lubricating oil and filter. Refer to MANUFACTURERS' LITERATURE included
with this manual.
b. Visually inspect the air intake piping for cracked 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 cleaning or replacing air cleaner element.
High Pressure Pump

a. Check plunger packing and bushings for wear. Replace if worn or leakage is excessive.
Refer to Section 8: REPAIR.
a. Cylinder tie stud bolts must be torqued to specifications listeded in Section 8: REPAIR.
If they are not, the bolts will break under high cyclicloading imposed on them. Bolt
failure will result in any or all of the following: the separation of the fluid cylinder from
the power frame; the fracture of the side of the frame itself; damage to plungers, stubs or
stuffing box components; as well as potential personal injury.

Revision 3
Couplings
a. Feel set screws and keys to determine if coupling halves are tight on the shafts.
Manually turn the shafts to feel, if possible, for excessive play in the coupling. Look for
evidence of angular or parallel misalignment between the shafts.
5. Every Six (6) Months or Approximately Every 500 Hours of

Operation
Diesel Engine
a. Change fuel filter. Refer to MANUFACTURERS' LITERATURE included with this
manual.
b. Check antifreeze concentration. Use ethylene-glycol based antifreeze to protect engine
to -37°F (-37 ° C) throughout the year.
c. Change coolant filter. Refer to MANUFACTURERS' LITERATURE included with this
manual.
High Pressure Pump

a. Check sealing surfaces of the fluid cylinder 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 in this section. Remove the crankcase and optional gear-pac
covers, if so equipped, during the oil change. Wipe the interior clean with lint-free
rags-- do not use paper towels. Inspect for worn parts or abnormal conditions. Check
the torque on the connecting rod bolts. Refer to Section 8: REPAIR.
6. Every Year or Approximately Every 1000 Hours of Operation
Diesel Engine
a. Check valve clearance. Refer to MANUFACTURERS' LITERATURE included with this
manual.

Revision 3
b. Inspect drive belt, tensioner bearing and fan hub. Refer to MANUFACTURERS'
LITERATURE included with this manual.
Water Jetting Unit Bolts and Screws

a. Make sure that all bolts and screws are tight.
b. Remove V-belt guard. Check to see that shafts are parallel and that sheaves are in
proper alignment.
7. Every Two (2) Years or Approximately Every 2000 Hours of

Operation
Diesel Engine
a. Flush coolant system. Refer to MANUFACTURERS' LITERATURE section for
information.
b. Inspect vibration dampener for alignment. Refer to MANUFACTURERS' LITERATURE
section for information.
c. Inspect air compressor for carbon build up. Refer to MANUFACTURERS'
LITERATURE for instructions.
Ill. Suggested Component 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 the MANUFACTURERS' LITERATURE
section in this manual.
Wipe exterior surfaces of equipment to remove dust, oil, and other foreign deposits. Unless
otherwise noted in the "REMARKS" column below, wash components with hot soapy water
and rinse thoroughly with clean water. Use solvent to remove hardened deposits. Carefully
remove dust and debris from interior parts by wiping or blowing as required. Do not use
paper towels. Do not create air-borne dust.
© Copyright August, 2000 NLB Corporation 5-1 5

Revision 3
COMPONENT CLEAN REMARKS
A. Couplings Semi-Annually
B. Diesel Engine See MANUFACTURERS' LITERATURE
C. Guards Semi-Annually
D. High Pressure Semi-Annually Wipe clean with lint-free rags.

Pump Breather
E. High Pressure After first oil change, Wipe clean with lint-free rags.
Pump Crankcase then annually.
F. High Pressure Semi-Annually Remove all sludge formation for

Pump Plunger Well trouble free operation.
G. Plunger Lubricator Semi-Annually Clean with mineral spirits.
H. Shafts Annually
I. Sheaves Semi-Annually
J. Springs Semi-Annually After cleaning, wipe with a cloth

moistened with a light machine
oil (SAE 10).
K. Structural Parts Annually
L. Valves Annually
M. V-belts Semi-Annually Clean with a cloth dampened

with denatured alcohol.
N. Water Inlet Annually Clean with hot soapy water &

Filter Assembly ammonia solution. Blow off
with clean air. Do not use a wire
brush.

Revision 3
IV. Lubrication Instructions

Any special lubricating instructions for vendor equipment in the high pressure water jetting
units are covered in the MANUFACTURERS' LITERATURE section in this manual.
Manufacturer's recommendations set forth for this equipment must be followed for that
equipment.
Unless specified otherwise, service intervals specified are for operating hours in moderate
temperatures. Adjust service intervals accordingly for operation in abnormal conditions.
The suggested lubrication instructions and service intervals are for illustration purposes only.
NLB does not warrant that adherence to these suggestions will necessarily result in proper
lubrication. NLB disclaims any responsibility for equipment and/or accessory failure that is
due to the lack of or improper lubrication. NLB suggests that you consult with your
lubrication supplier for recommendations that will suit your specific requirements.
Note:
Manufacturer'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 INTERVAL
SAE 15W40 10° to 110°F 15.0 qts. Three (3) Months or
(-12 ° to 43 °C) (14.2 l) standard pan 250 Hours- with new
only filters
SAE 10W30 -10° to 68°F (-23 ° 17.2 qts. (16.3 l) total
to 20 °C) system
Power Take-Off
For anti-friction bearings, use any high grade lithium base grease lubricant that can handle a
high operating temperature of 200°F (93.3 °C).
Caution:
To avoid dirt filled from being injected into the bearings, clean off the grease
fittings before connecting the grease gun.
The bronze type collar design needs lubrication daily or after every 10 hours of operation.
The ball bearing type needs to be periodically lubricated every 100 hours of operation. The
sealed-for-life type ball bearing collar needs no lubrication.

Revision 3
IV. Lubrication Instructions

Any special lubricating instructions for vendor equipment in the high pressure water jetting
units are covered in the MANUFACTURERS' LITERATURE section in this manual.
Manufacturer's recommendations set forth for this equipment must be followed for that
equipment.
Unless specified otherwise, service intervals specified are for operating hours in moderate
temperatures. Adjust service intervals accordingly for operation in abnormal conditions.
The suggested lubrication instructions and service intervals are for illustration purposes only.
NLB does not warrant that adherence to these suggestions will necessarily result in proper
lubrication. NLB disclaims any responsibility for equipment and/or accessory failure that is
due to the lack of or improper lubrication. NLB suggests that you consult with your
lubrication supplier for recommendations that will suit your specific requirements.
Note:
Manufacturer'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 INTERVAL
SAE 15W40 10° to ll0°F 15.0 qts. Three (3) Months or
(-12 ° to 43 °C) (14.2 l) standard pan 250 Hours- with new
only filters
SAE 10W30 -10° to 68°F (-23 ° 17.2 qts. (16.3 l) total
to 20 °C) system
Power Take-Off
For anti-friction bearings, use any high grade lithium base grease lubricant that can handle a
high operating temperature of 200°F (93.3 °C).
Caution:
To avoid dirt filled from being injected into the bearings, clean off the grease
fittings before connecting the grease gun.
The bronze type collar design needs lubrication daily or after every 10 hours of operation.
The ball bearing type needs to be periodically lubricated every 100 hours of operation. The
sealed-for-life type ball bearing collar needs no lubrication.

Revision 3
Caution:
Do not lubricate the sealed-for-life type pilot bearing during service
procedures. Damage to the engine crankshaft could result from trapped
grease pressure. Normally the clutch shaft will not be drilled, but if it is,
install a plug to prevent inadvertent greasing.
High Pressure Pump Crankcase

Before the pump has been operated for the first time, the crankcase must be filled to the
indicated level with the lubricant specified for the ambient temperature range. The oil level
should be 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 crankcase. You must clean
the crankcase at the initial oil change and at least once a year thereafter.
Gear-Pac (Optional)
SAE 15W40 2.5 qts. (2.4 l) Initial at 125 hrs., then every
six (6) months or 500 hours
thereafter

Revision 3
L-SSi Oil Plunger Lubricator

The stuffing boxes on your NLB high pressure water jetting unit have been provided with a
mechanical lubricator which is belt driven from the pump crankshaft. This automatically
places oil on the plungers. Packing and plunger life is greatly extended, under all conditions,
by providing this lubrication.
Safe level sight feed is standard equipment. The sight feed glass in the Model L-55i pump is
dependent on a vacuum seal. Oil enters the sight glass chamber on the downward or suction
stroke of the plunger and is delivered on the upward or pressure stroke of the plunger.
The safe level sight feed serves a double purpose. First, a flow rate can be determined by
counting the drops of oil delivered per minute. Second, the sight feed serves as a warning
device when excess 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 tanks to remove such air before it enters the
lubricator.
L-SSi Oil Plunger Lubricator Drip Flow Adjustment

The lubricator may be adjusted to provide varying rates of flow.
Conversion factors based on SAE 15W40 oil at room temperature:
1 drop = Average drop size .0023 cu. in.

500 drops = 1 cu. in.
1 pint of oil = 12,608 drops
Adjustment of drip rate may be accomplished by loosening the lock nut with a wrench
(Figure 5-4). Turn the adjusting screw clockwise (downwards) for less oil, or turn it
counter-clockwise (upwards) for increased oil drip rate.
Figure 5-4. Drip rate adjustment.

Revision 3
If the lubricator reservoir should be allowed to run dry, refer to Section 8: REPAIR - L-55i
Oil Plunger Lubricator - Pump Priming.

SAE 15W40 Four (4) qts. (3.8 l) Automatic, adjustable.
Optional reservoir with low 10-12 drops per minute
level shutdown: 20.0 qts.
(18.9 l)
Note:
Handling and disposal of used lubricating oil may be subjected to international,
federal, state, and local law regulation. Use authorized waste disposal facilities,
including civic amenity sites and garages providing authorized facilities for receipt of
used lubricating oil. If in doubt, contact the Environmental Protection Agency or
appropriate agency in your area for details on laws and services.
Estimated L-55i Oil Plunger Lubricator Reservoir Refill Intervals

The standard lubricator reservoir holds four (4) qts. (3.8 l)
Based on 10 drops per minute: 48 hours
Estimated L-55i Oil Plunger Lubricator Reservoir Refill Intervals

The optional lubricator reservoir holds 20.0 qts. (18.91)
Water Plunger Lubricator - Optional

The cartridge flanges on your NLB high pressure water jetting unit have been provided with
fittings which deposit water directly onto the plungers as the high pressure pump runs.
Packing and plunger lives are greatly extended by this lubrication. The lubricator was
factory adjusted for 1/3 gallon (1.2 l) of water per plunger per minute. Flow is constant but
pressure is limited to the plant inlet water supply pressure.

Revision 3
V. Winterizing Procedure
Caution:
Do not drain the hoses and assume the high pressure pump is drained. Water
always remains trapped inside the pump. Water freezing in the high pressure
pump will damage the pump, such damage is not covered by the NLB
warranty.
Service People Required: 1

Recommended Tools: Adjustable wrenches
Supplies: Two (2) gallons (7.6 l) of coolant, 50% concentration of non-toxic propylene
glycol low silicate antifreeze (rv antifreeze). Plan for additional quantities when the diesel
engine radiator also requires coolant. Refer to Section 3: PRODUCT OVERVIEW -
Specifications.
When the high pressure water jetting unit is to be left in temperatures 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 recommended procedure for this is listed in the following steps:
a. Remove all high pressure hoses. Carefully drain all water from high pressure hoses,
and re-install.
b. Drain all water from the water tank through the drain valve (Figure 5-5).
Figure 5-5. Drain valve location.
c. After the tank is drained, open the top of the tank. Reach in and turn the pump suction
elbow in an upwards direction (Figure 5-6). Remove the filter screen.

Revision 3
Figure 5-6. Turn pump suction elbow upwards.
d. Start the diesel engine and engage the power take off. Start pouring coolant into the
vertical pipe (Figure 5-7).
Figure 5-7. Pour antifreeze solution in vertical pipe.
e. Keep pouring coolant until the color 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 coolant as needed.

MAINTENANCE RECORD
EQUIPMENT DATE OF PARTS REPLACED OR TECHNICIAN'S
HOURS RESULT OF INSPECTION COMMENTS
SERIAL NO. INSPECTION REPAIRED INITIALS
Revision 0
TABLE OF CONTENTS
SECTION 6
TROUBLE-SHOOTING

I. Trouble-Shooting Guidelines ..................................... . 6-2
A. Safety .................................................... . 6-2
II. Trouble-Shooting Procedures ..................................... . 6-3
A. Trouble-Shooting Tips ....................................... . 6-3
B. Trouble-Shooting Diagnostic Process ........................... . 6-4
III. Trouble-Shooting Guide ......................................... . 6-5
A. Symptoms ................................................. . 6-5
1. Excessive Pulsation in High Pressure Pump Discharge ........... . 6-5
2. Excessive Unit Vibration .................................. . 6-5
3. High Pressure Pump Discharge Pressure - High
(Above Unit Rating) ...................................... . 6-6
4. High Pressure Pump Discharge Pressure - Low ................ . 6-6
5. Excessive High Pressure Pump Noise ........................ . 6-7
6. Excessive V-belt Slippage or Wear .......................... . 6-7
B. Diesel Engine .............................................. . 6-8

Revision 2
I. Trouble-Shooting Guidelines
The trouble-shooting section of this manual is intended to supply essential information so

that repairs can be made to the NLB Corporation Models 1312D, 1012D, 812D, 612D,
512D, 412D, 3.512D, 312D, 1060D, 860D, & 760D high pressure water jetting units. The
information contained within this section will help you perform trouble-shooting procedures
safely, efficiently and solve problems quickly.
A. Safety
However, because preventive maintenance requires such close contact with the high pressure
water jetting unit, caution must be exercised every minute. Here is a brief review of some of
the safety basics 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 tolerate, horseplay in the work area.
• Review all safety information pertaining to the work you are about to do.
• All electrical components associated with this system are to be maintained in accordance
with approved practices. Never use jumper wires across fuses, fuse holders or circuit
breakers.
• Do not work on anything that is supported ONLY by lifting jacks or a hoist. Always
use blocks or proper stands to support the product before performing any service work.
• Dump all high pressure before any lines, fittings, or related items are removed or
disconnected. Be alert for possible pressure when disconnecting any device from a
system that utilizes pressure.
© Copyright December, 1999 NLB Corporation 6-2

Revision 2
• Avoid personal injury. Use a chain hoist, or get assistance, when lifting components that
weigh 50 lb. (23 kg) or more. Make sure all lifting devices (chains, hooks, or slings) are
in good condition and are of the correct capacity. Make sure hooks are positioned
correctly. Always use a spreader bar when necessary. The lifting hooks must not be
side loaded.
• To avoid burns, be alert for hot parts on components that have just been 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 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 pressure water jetting units are relatively straightforward
operating machines. For this reason, ordinary trouble-shooting methods will suffice in
almost every case.
A. Trouble-Shooting Tips
The following trouble-shooting tips are offered to assist the technician in tracking down
problems:
• Take a few minutes to carefully listen to the unit and observe it in operation. Learn to
recognize the normal noises and operating conditions of the unit. This will enhance
your ability to notice any unusual machine behavior.

Revision 2
• Maintain a record of all service performed on the equipment. This record will provide
valuable information to assist you in stocking spare parts and scheduling preventive
maintenance.
Note:
A maintenance log form is found in Section 5: PREVENTIVE MAINTENANCE.
B. Trouble-Shooting Diagnostic Process
The trouble-shooting guide will aid in identifying the probable cause of a malfunction and
establish the most effective corrective action.
The probable causes of each malfunction are listed from the most likely to the least likely to
occur. The corrective 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 problem.
c. Identify the most likely cause.
d. Follow the corrective action procedure.
If the symptoms in the chart do not correspond to any malfunction in the guide, or if the
problem is not determined or eliminated by the corrective action, contact NLB's Customer
Service Department. Refer to Section 10: CUSTOMER SUPPORT.

Revision 2
Ill. Trouble-Shooting Guide
A. Symptoms
1. Excessive Pulsation in High Pressure Pump Discharge
Excessive pulsation in the high pressure pump discharge piping or hoses is evidenced by a
hose leading to the accessory lance or foot control valve oscillating back and forth more than
1-1/16" (27 mm).
Probable Cause Corrective Action

a. Insufficient water in tank Fill water in tank. This condition could be caused by
water shut off to the high presure water jetting unit.
Check water supply to source.
b. Pump not primed Accomplish the following:

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.
c. Valves sticking open This condition is caused by a piece of dirt or an object

stuck between the valve and seat. Clean and deburr
valve.
d. Valve springs broken Replace. See Section 8: REPAIR.
e. Valves scored Replace. See Section 8: REPAIR.
f. Belts slipping Adjust.
2. Excessive Unit Vibration

a. Excessive pump See Symptom #1: Excessive Pulsation in High Pressure
pulsation Pump Discharge.
b. Excessive engine See diesel engine manual in the MANUFACTURERS'

vibration LITERATURE section of this manual.

Revision 2
3. High Pressure Pump Discharge Pressure - High (Above Unit

Rating)
a. Excessive engine speed Adjust speed control by adjusting throttle linkage.
b. Too small of nozzle Replace with proper size nozzle.
c. Too small of discharge Replace with proper size hose.

hose
d. Inaccurate pressure Replace.

gauge
4. High Pressure Pump Discharge Pressure - Low

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. Inaccurate pressure Replace.

gauge

Revision 2
5. Excessive High Pressure Pump Noise
Note:
It must be understood that the valves in the high pressure pump's fluid cylinder are
inherently noisy. The typical noise from the valves may be mistaken for bearing
noise in the pump.

a. Insufficient lubricant Fill the high pressure pump's crankcase to raise oil level
levels to the top mark on the sight gauge. Check level again
with the pump running. The oil level should now be even
with the lower mark on the sight gauge. If enough oil is
in the crankcase, proceed to Probable Cause "b".
b. Loose plungers Check to see if any plungers are loose from the crosshead
stubs. If loose, apply 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:

REPAIR.
d. Worn crosshead or Check crosshead clearances with cylinder wall and

crosshead pins crosshead pin. Refer to Section 8: REPAIR.
e. Pump cavitation See Symptom #1: Excessive Pulsation in High Pressure

Pump Discharge.
6. Excessive V-belt Slippage or Wear

a. Belt tension too low Adjust belt tension.
b. Gritty material between Clean sheaves.

belt and sheaves
c. Sheaves not locked to Align sheaves on shaft and tighten down set screws.
shaft
d. Loose belt A new belt may stretch substantially during the first two
(2) weeks of use. Check tension frequently.
e. Oil or grease on belt Replace belt.

Revision 2
B. Diesel Engine
Refer to the MANUFACTURERS' LITERATURE section in this manual.

Revision 0
TABLE OF CONTENTS
SECTION 7
SPECIAL TOOLS

I. Special Tool Identification ........................................ 7-2

Revision 2
I. Special Tool Identification
The 1312D, 1012D, 812D, 612D, 512D, 412D, 312D, 3.512D, 312D, 1060D, 860D, & 760D
high pressure water jetting units require these special tools when repairs are performed to the
high pressure pump. These tools are part of the recommended spare parts kit.
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
For Use on Fluid Cylinder Tie Stud Nuts

Revision 2
s 2
m 1'
PM12969 Belt Tensioning Gauge
For Use on V-belts

Revision 11
TABLE OF CONTENTS
SECTION 8
REPAIR

I. Repair Overview ................................................ 8-2
A. Safety ..................................................... 8-2
1. General Safety Precautions for Service Personnel ................ 8-2
2. Specific Safety Precautions for Service Personnel ................ 8-3
B. Suggested Standard Shop Practices .............................. 8-4
1. Repair Procedures ......................................... 8-5
2. Repair Tips .............................................. 8-5
II. High Pressure Water Jetting Unit Repairs ............................ 8-7
A. High Pressure Pump .......................................... 8-7
1. Fluid End ............................................... 8-7
a. Plunger Packing and Stuffing Boxes ....................... 8-7
b. Suction and Discharge 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 Contol ....................................... 8-78
1. Seal and Piston Replacement ................................ 8-78
III. Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-80
A. Electrical Diagram - CUMMINS Diesel Engine .................... 8-80
B. Electrical Diagram - JOHN DEERE Diesel Engine ................. 8-82
*:To check which by-pass valve is on your unit, refer to page 3-3.

Revision 2
I. Repair Overview
This section is intended to supply essential information for the repair of NLB Corporation
Models 1312D, 1012D, 812D, 612D, 512D, 412D, 3.512D, 312D, 1060D, 860D, & 760D
high pressure water jetting units. The information contained within this section will help you
perform servicing procedures efficiently and solve problems quickly.
A. Safety
The high pressure water jetting units and accessories have been designed with safety in mind.
Service personnel shall exercise and promote safety at all times to avoid potential injuries
and/or equipment damage.
1. General Safety Precautions For Service Personnel
Safety precautions must be exercised every minute during the servicing 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, resulting in slippery
floors, must be cleaned up before performing any work on the equipment.
• Provide suitable receptacles (e.g., pans, trays, etc.) to catch and retain fluids so as to
not create a hazardous work area.
• As a general rule, it is recommended that safety shoes and glasses be worn. Do not
wear any jewelry (e.g., watches, rings, bracelets, etc.) while servicing the equipment.
• If the equipment needs to be started in order to confirm the intended repair work, be
sure that you know how to stop it.
• Never attempt to perform any service functions or clean around the equipment while it
. .
is runnmg.
• Use the proper tools for the specific job.

Revision O
Caution:
The use of improper tools can result in injury to personnel and/or costly
damage to equipment.
• Be sure all tools, parts and rags are cleared away from any moving parts after servicing
the equipment.
2. Specific Safety Precautions For Service Personnel
• High pressure water may remain in the unit for a prolonged period of time after
shutdown of the high pressure water source. Make sure to bleed down all unit pressure
before service is attempted to any part of the unit.
• Some of the fittings, connection or parts are equipped with weep holes. Do not touch
these weep holes with your bare hands or try to stop the flow of water by clogging the
holes.
• When breaking any high pressure connection, 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 designated manufacturer specifications.
• Do not step or lean on high pressure water tubing. You may break the connection and
cause leakage.
• Use only high pressure fittings, valves and tubing which are certified for the pressure
rating when making alterations or additions to the high pressure water jetting unit.
• Use only original equipment NLB replacement parts.
• Double check to insure that all pressure is relieved from the system before proceeding
with repairs.

Revision O
B. Suggested Standard Shop Practices
The following are suggested standard shop practices
• Use a clean workbench in a dust and dirt free work environment. Do not create
air-borne dust.
• Use lint-free material for wipe cloths. Do not use paper towels.
• When blowing off parts with compressed air, use only clean dry air. When flushing
parts with a solvent, use only clean filtered fluid.
• Protect all machined and lapped mating surfaces against nicks, scratches and burrs.
• Before assembling, make sure that all parts are clean, free of metal particles, dirt,
dust, etc.
• Use extreme care when aligning close tolerance machine parts for assembly. 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
repair the threads or replace the component before final assembly.
• Inspect all surfaces (especially polished surfaces) for cracks, pits, unusual marks,
surface wear or rubbing. Repair or replace all questionable parts.
• Always use Teflon™ tape to wrap threaded ends of components before assembly.
• Notify NLB Customer Service Department for all repair requirements which cannot be
handled locally.

Revision 6
1. Repair Procedures
The repair procedures are arranged as step-by-step instructions. Most procedures include
illustrations to assist the service personnel in repairing NLB Corporation Models 1312D,
1012D, 812D, 612D, 512D, 412D, 3.512D, 312D, 1060D, 860D, & 760D high pressure
water jetting units.
Repairs of various equipment operating systems, as well as assemblies and sub-assemblies,

are covered in this section. For additional reference in part identification, the service
personnel can also examine the exploded and/or cross section views and other illustrations
included elsewhere in this manual. (the individual component drawings in Section 9: PARTS
and the overall assembly drawings of the jetting unit in Section 3: PRODUCT OVERVIEW).
Accessories for the high pressure water jetting units are covered separately in their respective
manuals. Accessory manuals should be included in the binder. For more information,
contact NLB Customer Service Department (Section 10: CUSTOMER SUPPORT 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 the problem before
operating the unit.
• Read all of the information on the procedure that is involved before performing the
actual repair. If you have any questions, call the NLB Corp. Customer Service
Department (Section 10: CUSTOMER SUPPORT).
• Carefully study and understand all of the emphasized material (Notes, Cautions and
Warnings) in the repair procedure.
• Disconnect the electrical system from the battery and relieve the system water pressure
before performing any repair.
• If a repair is attempted while the battery is connected, or the water system is

pressurized, take all the extra precautions that are necessary to safely perform the repair
and avoid personal injuries or equipment damage.
• Routinely check for loose belts or wire connections.
© Copyright October, 2001 NLB Corporation 8-5

Revision 2
• Routinely check high pressure water lines and fittings for leaks. High pressure water
leakage is wasted energy.
• Inspect all around the area for parts, tools and rags before 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.

Revision 6
II. High Pressure Water Jetting Unit Repairs
A. High Pressure Pump
1. Fluid End
Because of the precise machining and stringent metallurgical specifications required for safe
and proper operation, only NLB parts should be used when repairing the high pressure
pump.
Maintenance will be required if the leakage from any packing exceeds six (6) drops per
second, if any other part allows any water to leak, or if the pump is not performing properly.
The following procedure provides for disassembly and repair of the complete liquid end.
Repair of only one part of the liquid end will not require complete disassembly.
Note:
Refer to Section 9: PARTS for breakdowns and parts lists for the following
procedures:
a. Plunger Packing and Stuffing Boxes

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
wrench 200-600 lb.-ft. (270-810 Nm) and a 3/4" drive torque wrench 15-100 lb.-ft.
(20.2-135 Nm)
Parts (Subject to inspection): Packings, plungers, bushings, stuffing boxes, & backup rings
Supplies: 10 oz. (300 ml) cup of SAE 15W40 oil, bottle of blue LOCTITE®, and a tube of
light grease
WARNING:
DISCONNECT THE BATTERY NEGATIVE(-) CABLE 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.

Revision 6
Removal of Stuffing Boxes:
1. Remove the wing nuts from each side of the plastic cover. Raise the plastic cover up
while being careful not to catch or stretch the hoses. Remove the hose clamps from each
hose. Remove all three (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.

Revision 6
3. Use a 1-1/2" combination wrench on the plunger and a pipe wrench firmly held on the
square surface (to keep it from rotating) of the crosshead stub (Figure 8-1). Unscrew
the plunger from the crosshead stub (a considerable torque will be required to initially
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 Allen bolt socket.

Revision 6
5. After the stuffing bolts have been completely loosened, tap and carefully pry on the
stuffing box until it breaks loose from the fluid cylinder. Grasp the stuffing box and
remove it from the 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 of the stuffing box.
© Copyright October, 2001 NLB Corporation 8-1 0

Revision 6
7. Remove lubrication fitting on the stuffing box. Insert Special Tool (PD-33A or
PD-34B Packing Drift) into the stuffing box and gently tap on the end of the Special
Tool with a ball-peen hammer (Figure 8-7).
Figure 8-7. Tapping the drift tool to remove packing and bushings.
8. Drive the drift tool in as far as it will go and the packing will come out (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 Ring (Item #15) is .002 to .004" (.051 to .102 mm). You must
replace the backup ring if the clearance has reached .007" (.178 mm).

Revision 6
10. The new packing elements are in the correct order when packaged. Make sure that they
are kept 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.

Revision 6
11. Keep the packing and bushings in correct order during assembly (Figure 8-11).
Install the Backup 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.

Revision 6
13. Use your fingers to insert each bushing and packing set piece (Figure 8-13) and use
Special Tool 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.

Revision 6
14. After the bushings and the packing set have been installed, carefully push the plunger
into the stuffing box (Figure 8-15). Work the plunger through the packing, with a
gentle twisting motion, until the wrenching surface is up against the stuffing 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-ring.

Revision 6
Stuffing Box Installation:
16. Replace the stuffing box on the pump body and start four (4) Allen bolts by hand. The
packing spring tension inside the stuffing box will tend to hold the stuffing box away
from the fluid cylinder (Figure 8-17).
Figure 8-17. Inspecting gap between stuffing box and fluid cylinder.
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. 7 Nm) for A-Cylinders and 150 lb.-ft. (203.4 Nm) for B-Cylinders.
1 4
3 2
Figure 8-18. Tightening Allen bolts in sequence.

Revision 6
18. After the stuffing box is properly installed, push the plunger up towards the crosshead
stub (Figure 8-19).
Figure 8-19. Pushing the plunger up towards crosshead stub.
19. Apply a generous bead 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.

Revision 2
b. Suction and Discharge Manifolds and Valve Assemblies

Recommended Tools: Assorted pipe wrenches, Special Tool (ST 1-5/8" Socket Adapter)
Special Tool (ST 1-3/4" Socket Adapter), 3/4" socket & ratchet wrench, slotted screwdriver,
0-ring pick, 3/4" drive torque wrench 200-600 lb.ft. (270-810 Nm), two (2) each 1/2"-13
eye bolts, and a chain hoist
Supplies: Clean lint-free rags and a tube of valve grinding compound
Parts (Subject to inspection): View upon disassembly of unit
Note:
procedures:
WARNING:
DISCONNECT THE BATTERY NEGATIVE(-) CABLE FIRST. BLEED DOWN ALL
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 (Figure 8-22) to remove the
Allen bolts from the manifolds. Use Special Tool (ST 1-3/4" Socket Adapter), or 3/4"
hex stock, for the discharge manifold. Use Special Tool (ST 1-5/8" Socket Adapter), or
5/8" hex stock, for the suction manifold. Leave at least two (2) bolts partially engaged
to prevent the manifold from falling off before removal.
Figure 8-21. Inserting Special Tool into Allen bolts.
© Copyright December, 1999 NLB Corporation 8-1 8

Revision 2
Figure 8-22. Removing Allen bolts.
3. When removing the discharge manifold, have two (2) people, 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

Revision 2
4. Two (2) people - one (1) person on each end, are needed to hold up the ends of the
suction manifold. Remove the two (2) partially engaged Allen bolts and then carefully
pull the manifold away (Figure 8-24). Place the manifold on a clean workbench.
Figure 8-24. Removing the suction manifold
Caution:
The manifolds are heavy. To avoid personal injury, use two (2) people, one (1)
person at each end, to remove.
Scratches or other damage to the 0-ring sealing surfaces on the manifolds
and the cylinder adjacent to the valves will cause leaks.
Removal, Refinishing & Installation of Valve 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 stainless steel seating surfaces of the valve and seat will allow for occasional
refinishing. The need for "lapping" or "polishing" will depend directly on the unit
operating conditions, the type of fluid being pumped and presence of abrasives or
other foreign matter in the fluid. Excessively worn parts should be replaced with
new.

Revision 2
5. After the manifolds have been removed to a clean workbench, the valves are exposed.
Lift or pull the valve assemblies from the main fluid cylinder by hand (Figure 8-25).
Figure 8-25. Removing the valve assemblies.
6. Inspect 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.

Revision 2
7. To inspect the seating surfaces, separate the valve and seat from the valve stop (Figure
8-27).
Figure 8-27. Separating the valve and valve seat from the stop.
8. Remove the 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.

Revision 2
9. To refinish the valve seat, apply valve grinding compound on either the valve or the seat
(Figure 8-29) and put the valve back into the seat.
Figure 8-29. Applying valve grinding compound.
10. Insert a screwdriver into the top of the valve and rotate the valve against the valve seat.
Keep shifting the parts so that both surfaces are evenly resurfaced (Figure 8-30).
Figure 8-30. "Lapping" 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
the refinished valve assemblies (Figure 8-26).
12. Place the clean valve assemblies into the proper ports in the main fluid cylinder (Figure
8-25).

Revision 6
Installing Suction or Discharge Manifolds:
13. Wipe clean, with lint-free rags, all mating surfaces. Place the suction and discharge
manifolds into their proper locations. The design of the mounting bolt holes, size, and
valve porting insures correct component alignment only. Hand start the manifold bolts.
14. To avoid non-uniform loading 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 manifold bolts.
Figure 8-32. Tightening suction manifold bolts.
15. Connect all piping and accessories.

Revision 6
c. Fluid Cylinder
Service People Required: 2 (1, if a chain fall or hoist is available)

Recommended Tools: Assorted pipe wrenches, Special Tool (ST4-1012 Wrench Adapter),
3/4" combination wrench, 3/4" drive torque wrench 200 to 600 lb.-ft. (270 to 810 Nm), two
(2) each 1/2"-13 UNC eye bolts, plastic scraper, and a chain fall or hoist (if available)
Parts (Subject to inspection): View upon disassembly of unit
Supplies: Clean, lint-free rags and a tube of light grease
WARNING:
DISCONNECT THE BATTERY NEGATIVE(..:.) CABLE FIRST. BLEED DOWN ALL
Note:
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 suction and discharge piping.
2. Disconnect plungers from crosshead stubs (Refer to Section 8.JIAI a: Plunger Packing
and Stuffing Boxes).
3. Remove stuffing boxes from fluid cylinder.
4. Remove suction and discharge manifolds (Refer to Section 8.JIAI b: Suction and
Discharge Manifolds and Valve Assemblies).
5. Remove valve assemblies.
6. Install two (2) 1/2"-13 UNC eye bolts into the tapped holes in the top of the fluid
cylinder.

Revision 6
7. Use Special Tool (ST4-1012) (Figure 8-33) and torque wrench (Figure 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.

Revision 6
9. Carefully pull the fluid cylinder away from the power frame. Do not damage the
alignment holes or the dowel pins that are just above the cylinder tie stud holes on the
face of the power frame (Figure 8-35). If a chain fall or hoist is unavailable, the
fluid cylinder may also be carefully lifted off by two (2) people - one (1) at each end.
Figure 8-35. Locating dowel pins.
Caution:
Do not damage the dowel pins that are located on the face of the power frame
(just above the cylinder tie stud holes) or the corresponding 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 or hoist attached, or by manually lifting with two (2) people, one (1)
person at each end, carefully push the fluid cylinder into place against the power frame.
Line up the dowel pins on the power frame face (Figure 8-35) to the corresponding
alignment holes in the fluid cylinder.

Revision 6
Caution:
Cylinder tie stud bolts must be torqued to specifications. If they are not, the
bolts will break under the high cyclic loading imposed on them. Bolt failure
will result in any or all of the following: the separation of the fluid cylinder
from the power frame; the fracture of the side of the frame itself; damage to
the plungers, stubs or stuffing box components; as well as potential severe
personal injury.
Cylinder tie stud nuts must be installed with the mating surface (side without
embossed identification lettering) towards the fluid cylinder or damage can
occur to fluid cylinder and power frame; as well as potential severe personal
injury.
12. Install the fluid cylinder bolts. Tighten down the fluid cylinder evenly to the power
frame with the Special Tool (ST4-1012) (Figure 8-33). Use the torque wrench to
final tighten the bolts to the specified 300 lb.-ft. (407.6 Nm) (Figure 8-34).
13. Make sure that all mating surfaces 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 accessories.
2. Power End

Recommended Tools: Assorted pipe wrenches, 1/2" drive ratchet, 3/4" and 7/8" socket,
soft-faced hammer, 15 to 100 lb.-ft. (20.2to135 Nm) torque wrench, 2.3765 to 2.3770"
(60.363 to 60.376 mm) ream bit, ream motor, 12" steel rule, small Allen wrench set, assorted
arbors and arbor press, dial indicator gauge, acetylene or propane torch, and a chain fall or
hoist (if available)
Parts (Subject to inspection): Oil seals, gaskets and other parts as needed
Supplies: Clean lint-free rags, 9.0 qts. (8.5 l) capacity oil pan, two (2) each 3/8" eye bolts,
two (2) each l"-8 UNC rods (threaded on one end), a block of wood, tube of valve grinding
compound, and 9.0 qts. (8.5 l) SAE 15W40 oil

Revision 6
Note:
procedures:
To completely dismantle the power end, the coupling or sheave must be removed
from the crankshaft. If the pump is equipped with a gear-pac, the main gear must
be removed.
1. Drain the oil from the high pressure pump crankcase.
2. Disconnect each Plunger (Item #17) from the Crosshead Stubs (Item #31 ). Push the
plungers into the fluid end (Refer to Section 8./1.A.l.a.: Plunger Packing and Stuffing
Boxes).
3. Remove the Splash Deflectors (Item #33). Remove crosshead stub deflectors, if so
equipped.
4. Dislodge the Crosshead Stub Seal Flanges (Item #36) by pulling from frame bore, after
removing each Crosshead Stub Seal Flange Bolt (Item #34) 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 loosening during operation.
6. Remove the Crankcase Inspection Plate (Item #13).
7. Disconnect the Connecting Rods (Item #21) from the Crankshaft (Item #26) by
removing the connecting rod bolts, caps and rod bearings. Push each rod and crosshead
assembly as far as possible toward the fluid end. Keep each bearing with each cap, if
the bearings are in good condition, so they can be assembled in the same position. Match
the set numbers (1,2,3, etc.) stamped on the rods and caps when assembling.

Revision 6
8. Remove both Crankshaft Bearing Retainers (Items #2 & #23), keeping Shims (Item #3)
with retainers for assembly. The crankshaft may now be removed from 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.

Revision 6
9. The Connecting Rod (Item #21) and crosshead assemblies may now be removed (Figure
8-38). If the crosshead assembly is in good condition, it must be 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.

Revision 6
Removal & Replacement of Main Bearings:
The two (2) main bearings are tapered roller type bearings. The Outer Crankshaft Roller
Bearing Races (cup-shaped) are a slip fit in the power frame. The Crankshaft Roller
Bearings (cone-shaped) are an interference fit on the crankshaft. (Refer to the assembly
drawings of the Power End in Section 9: PARTS). New main bearings must be replaced as a
unit: a new race with a new tapered bearing.
11. Remove the Outer Crankshaft Roller Bearing Races (Item #4) from the power frame by
tapping the races with a wood block and a soft-faced hammer.
12. Remove the Crankshaft Roller Bearings (Item #5) from the crankshaft by puller, press
or torch. If a torch is to be used, care must be exercised not to damage the crankshaft 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 (Figure 8-40).
The connecting rod bearings are made in two (2) halves and are a matched set. The bearings
are steel with a layer of babbitt on the surface. Each bearing piece has a small
wedge-shaped alignment tab that fits into the groove on the rod or cap.
The Wrist Pin Bushing is made of bronze. A hole in the middle of the bushing allows oil to
flow into the hole in the connecting rod. The wrist pin bushing is pressed into the small end
of the connecting rod and is held in place by a set screw.

Revision 6
Oil Passage
Connecting Rod Bolts
Connecting Rod Bearings
Figure 8-40. Connecting rod bearings and bushings.
14. Remove the Connecting Rod Bearings (Item #22) from each rod and cap. If the
bearings are snug or pinched, use a soft-faced hammer and a wood block to tap the
bearing loose. Drive in the direction of the groove in the rod so that the surfaces are not
damaged. Stubborn parts may need to be oiled or heated slightly to help break them
free. Keep the matched sets together with the same rod assemblies if you intend to use
them again.
15. Remove the Set Screw (Item #30) from the end of the Wrist Pin (Item #32). Use a
suitable arbor to press out the wrist pin bushing from the small end of the connecting
rod. Do not damage the inside surface of the rod.
16. Clean the connecting rod surface and inspect for scratches 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 installation. Insert the new
bearings as a set into a matching rod and cap assembly. The wedge-shaped tab on the
bearing babbitt surface will fit one way only into correct position in the rod or cap
groove. Do not mix the halves or interchange with different bearings.
18. When the bearings are correctly inserted, position the rod and cap around the crankshaft
to install. Lubricate the connecting rod internal bolt threads and fasten the rod to the cap
with Connecting Rod Cap Bolt Lock Washers (Item #20) and Connecting Rod Cap Bolts
(Item #19). Torque the cap rod bolts to 40 lb.-ft. (54 Nm).

Revision 6
Power End Assembly:
Reverse the steps to assemble the power end.
1. Install new oil, oil seals and gaskets.
Crankshaft End Play:
When the pump is built, the crankshaft end play is set at 0.001 to 0.005" (0.03 to 0.12 mm).
Only when replacing a crankshaft or a main 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. Checking crankshaft end play.

Revision 6
When shimming is complete, connecting rods and pin bearings should be positioned near
center of crosshead opening (Figure 8-42). If 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
J
Crosshead /
Crosshead Pin Bearing
Crosshead Pin
Note:
Provide gap on both sides of crosshead so bearing does not rub.
Figure 8-42. Shimming frame caps.

Revision 6
TORQUE VALUES TABLE 8-A
Fluid & Power End

Part Required Torque (Lubricated)
Pound-Feet Newton Meter
Stuffing Box Bolt - A-Cylinders 300 406.7
Stuffing Box Bolt - B-Cylinders 150 203.4
Suction Manifold Bolt 300 406.7
Discharge Manifold Bolt 450 612
*Tie Stud Bolt 300 406.7
Crosshead Pin Screw 15 20
Connecting Rod Bolt 40 54.6
Frame Cap Bolt 35 47.2
Crankcase Cover Bolt 15 20
Stub Seal Cap 35 47.2
*Plunger-to-Crosshead Stub 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 (Or Adjust) When

Part Clearance Exceeds:
Inches Millimeters
Crosshead in Power Frame .011 .28
Crosshead Pin Bearing over Crosshead .005** .12**
Pin
Connecting Rod Bearing over Crankshaft .012 .30

Revision 6
Replace Parts (Or Adjust) When

Part Clearance Exceeds:
Inches Millimeters
Crankshaft End Play .003 to .005 .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).

Revision 6
B. BV10-650 By-Pass Valve
Figure 8-43. BVJ0-650 By-Pass Valve.
Note:
The repair procedure assumes that the bypass-relief valve is already removed from
the high pressure water jetting unit.
Note:
procedures:
Because of the precise machining and stringent metallurgical specifications required for safe
and proper operation, only NLB parts should be used when repairing the BVl0-650 By-Pass
Valve.

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 Dexron®
automatic transmission fluid, measuring cup, mineral spirits, lint-free towels, jar of 600 grit
lapping compound, tube of medium strength blue LOCTITE® or an equal strength anaerobic
adhesive, a tube of light grease, and a jar of anti-seize compound

Revision 6
DISASSEMBLY:
Note:
For illustration purpose only, Rubber Bumper (Item #19) and Rubber Bumper (Item
#20) are shown removed.
1. Clamp the Seat Frame (Item #4) in a bench vise (Figure 8-44).
Figure 8-44. Clamping seat frame.
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 ).

Revision 6
5. Unscrew the Body (Item #1) from the Seat Frame (Item #4) (Figure 8-46).
Figure 8-46. Unscrewing the body from the seat frame.
6. Invert the Body (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.

Revision 6
7. Stand the Body (Item #1) in an upright position on a clean workbench. Use a clean
metal rod about 24" long and 1/2" or smaller in diameter to 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 of the 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.

Revision 6
10. If the Pin (Item #2) and the Seat (Item #3) are worn, either lap the two (2) parts together
with 600 grit lapping compound, or reverse each part end-for-end. If you are reversing
the Pin (Item #2), polish any water deposits from the pin so that it will not bind in the
bores of the Body (Item #1 ), and move the Deflector (Item #17) 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 of the pin.
Caution:
Failure to replace a worn Deflector (Item #17) will result in damage
to the Body (Item #1).
11. Apply blue LOCTITE® to the threads of the Set Screw (Item #18) before installing the
Deflector (Item #17).

Revision 6
12. Install a new 0-ring (Item #14) and both Backup 0-rings (Item #13) on the Pin (Item
#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.

Revision 6
14. Insert the Seat (Item #3) into the Body (Item #1) (Figure 8-52).
Figure 8-52. Inserting the seat into the body.
15. Install a new 0-ring (Item #14) in the face of the Seat Frame (Item #4).
16. Lock the Seat Frame (Item #4) 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 and face of the seat frame.
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.

Revision 6
19. Stand the valve upright and pour two (2) ounces (59 ml) of Dexron® automatic
transmission fluid (ATF) into the body (Item #1) (Figure 8-54).
Figure 8-54. Pouring Dexron® automatic transmission fluid into the body.
20. Use a clean metal rod 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).

Revision 6
Figure 8-56. Disc spring arrangement.
22. Place the second Disc Spring (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).

Revision 6
24. Install the disc spring assembly into the Body (Item #1) and push it in until it bottoms
(Figure 8-57).
Figure 8-57. Installing disc springs into the body.
25. Slide the Disc (Item #7) onto 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).

Revision 6
Note:
A 7/8" (22.2 mm) section, cut from the 0-ring (Item #14) can be used to plug the
Cap 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.

Revision 6
C. BV10-400 By-Pass Valve
Figure 8-59. BVJ0-400 Valve.
Note:
Note:
procedures:

Recommended Tools: 2" adjustable wrench, bench vise, needle-nose pliers, 0 to 50 lb.-ft.
(0 to 68 Nm) adjustable torque wrench, 50 to 300 lb.-ft. (68 to 137 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 rod, and lint free rags
DISASSEMBLY:
1. Clamp the Seat Frame (Item #4) in a bench vise.
2. Loosen the Jam Nut Handle (Item #15).

Revision 6
3. Unscrew the Subassembly Adjuster (Item #9) until there is no spring force on 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).

Revision 6
6. Carefully grasp the nose of the Pin (Item #2) with pliers and pull it from the Body (Item
#1) (Figure 8-62). Catch the oil that drains from two (2) cavities in the body.
Figure 8-62. Pulling pin from the body.
7. Loosen the Subassembly Adjuster (Item #9) until there is no spring force on the screw.
8. Remove the Cap Nut (Item #8) from the 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).
13. If the seating surface of the Pin (Item #2) or the Seat (Item #3) are worn, either lap the
two (2) parts together or replace them.

Revision 6
14. Install a new 0-ring (Item #12) and Backup Ring (Item #14) on the Pin (Item #2). Coat
with oil or grease (Figure 8-63).
Figure 8-63. Installing 0-rings 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.

Revision 6
18. Set the Seat (Item #3) on top of the Seat Frame (Item #4) (Figure 8-65).
Figure 8-65. Setting the seat on 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.

Revision 6
21. Reach through the top with a long clean rod and push the Pin (Item #2) onto the Seat
(Item #3). Use pliers to raise the pin about 1/4" (6.3 mm) off the seat (Figure 8-67).
Repeat this procedure several times to expel air from the cavity above the pin and to
keep the valve from squealing.
Figure 8-67. Expelling air from 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 (Item #5).

Revision 6
26. Continue to stack the springs, face up, face down (end with the top spring face up),
(Figure 8-68). Add ATP, if needed, to bring the level above the top of the Spring
Guide (Item #5).
28. Slide the Disc (Item #7) onto the top of the Guide 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 200 lb.-ft. (272 Nm) (Figure 8-70).
Figure 8-70. Tightening the seat frame

Revision 6
32. Loosen the Subassembly Adjuster (Item #9).

Revision 6
D. BV20-260 By-Pass Valve
Figure 8-71. BV20-260 Valve.
Note:
Note:
procedures:

Recommended Tools: 2" adjustable wrench, bench vise, needle-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 rod, and lint free rags
DISASSEMBLY:
1. Clamp the Seat Frame (Item #4) in a bench vise.
2. Loosen the Jam Nut Handle (Item #18).

Revision 6
3. Unscrew the Subassembly Adjuster (Item #9) until there is no spring force on 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).

Revision 6
6. Carefully grasp the nose of the Pin (Item #2) with pliers and pull it from the Body (Item
#1) (Figure 8-74). Catch the oil that drains from two (2) cavities in the body.
Figure 8-74. Pulling pin from the body.
7. Loosen the Subassembly Adjuster (Item #9) until there is no spring force on the screw.
8. Remove the Cap Nut (Item #8) from the 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).
13. If the seating surface of the Pin (Item #2) or the Seat (Item #3) are worn, either lap the
two (2) parts together or replace them.

Revision 6
14. Install a new 0-ring (Item #12) and Backup Ring (Item #17) on the Pin (Item #2). Coat
with oil or grease (Figure 8-75).
Figure 8-75. Installing 0-ring 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.

Revision 6
18. Set the Seat (Item #3) on top of the Seat Frame (Item #4) (Figure 8-77).
Figure 8-77. Setting the seat on 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.

Revision 6
21. Reach through the top with a long clean rod and push the Pin (Item #2) onto the Seat
(Item #3). Use pliers to raise the pin about 1/4" (6.3 mm) off the seat (Figure 8-79).
Repeat this procedure several times to expel air from the cavity above the pin and to
keep the valve from squealing.
Figure 8-79. Expelling air from 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 (Item #5).

Revision 6
26. Continue to stack the springs, face up, face down (end with the top spring face up),
(Figure 8-80). Add ATF, if needed, to bring the level above the top of the Spring
Guide (Item #5).
28. Slide the Disc (Item #7) onto the top of the Guide 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 200 lb.-ft. (272 Nm) (Figure 8-82).
Figure 8-82. Tightening the seat frame

Revision 6
32. Loosen the Subassembly Adjuster (Item #9).

Revision 6
E. NSP 2000 Rupture Disc Valve Assembly
Note:
procedures:

Recommended Tools: 1-1/4" and 1-1/8" open end wrenches, small screwdriver or 1/8"
(3.2 mm) rod, a small adjustable wrench
Parts: New Rupture Disc (Item #2)
Supplies: Teflon Tape TM
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 the inside of the Body (Item
#1) and "fish" out the Washer (Item #3) and the Rupture Disc (Item #2).

Revision 6
4. Place the new Rupture Disc (Item #2) into the Body (Item #1) with the "dome" facing
outwards. Make sure it is seated properly. Place the new Washer (Item #3) against the
Rupture Disc (Item #2) with lip facing the "dome" (Read "Caution" note below and
refer to Figure 8-84).
Beveled inside ~~ge faces "dome"\ NSP 2001-3 Washer
F--- I \
I
b- -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 hose, using Teflon tape wrapped on the pipe fittings to the hose
TM
connection.

Revision 6
F. NSP 3000 Rupture Disc Valve Assembly
Note:
procedures:

Recommended Tools: 1-1/4" and 13/16" combination wrenches, small screwdriver or 1/8"
(3.2 mm) rod, a small adjustable wrench
Parts: New Rupture Disc (Item #3)
Supplies: Anti-seize compound
1. Relieve system pressure. Remove hose and fittings that are connected to the Rupture
Disc Valve 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 (Item #4) and Body Seat (Item #5).
4. Reassemble in the order shown below (Figure 8-86) Place the new Rupture Disc (Item
#3) and Washer (Item #2) into the Body (Item #4) as illustrated. They must be seated
properly.

Revision 6
NSP 3001·1 VALVE BODY

NSP 3001·5 CONE SEAL NSP 3001·4 CAP
NSP 3001·3 WASHER
NSP 3002·20 RUPTURE DISC
Figure 8-86. Rupture disc valve assembly.
Caution:
Always replace the elbow in the end of the assembly and tighten it
securely. It MUST be pointing AWAY from the operator. The elbow
acts as a deflector which 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 hose using anti-seize compound on the pipe
fittings to the hose connection.

Revision 6
G. L-55i Oil Plunger Lubricator
Note:
procedures:
Pump Description:
The Model L-55i Lubricator Pump is an improved version of the previous Lincoln Model
55i Lubricator Pump. Pump performance and serviceability have been improved. The pump
has been simplified and the number of parts have been reduced. The number of seals have
been reduced by creating a unit pump body and sight glass, thus reducing the number of
service parts and possible leak problems.
Pump Operation:
The pump is operated by a rotating cam against the pump rocker arm, causing the pump's
plunger to reciprocate within its bore in the pump body.
The pump output is set by the adjusting sleeve on the top of the pump body. The sleeve
limits the stroke length of the pump plunger thus limiting the pump output. Full pump
output may 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 reservoir, through the suction tube and
into the outside passage in the sight glass. The oil will enter the dropper and drip into the
sight glass reservoir, replacing the oil removed by the suction stroke. The quantity of oil
delivered may be determined by counting the drops of oil falling out of the dropper.
Discharge Stroke:
As the plunger moves upward, oil is forced from the plunger bore through the outlet checks
and into the lubrication feedline. The suction check prevents any backflow of oil into the
sight glass assembly and allows any oil that may bypass the plunger to be returned to the
sight glass area through a return passage.

Revision 6
Starting Instruction:
1. Remove the dropper from the sight glass and fill approximately 1/3 full with oil.
2. Manually operate the pump with priming stem until the oil flows from the pump outlet
without air bubbles.
3. Connect the feedline to the pump outlet union and manually operate the pump with the
priming stem until the feedline is filled.
4. Connect the feedline to the lubrication point. A feedline check valve at the lubrication
point is recommended and is available as an accessory item.
5. Refill the sight glass to the 1/3 full level with SAE 15W40 oil.
6. Refill the lubricator reservoir and adjust the pump output.
Setting Pump Output:

Count the number of drops falling through the sight glass in one minute. Set the adjusting
sleeve to obtain the desired quantity and secure the setting with the locknut.
Conversion Factors*
1 drop= 0.002 cubic inch
500 drops= 1 cubic inch
1 pint= 12,608 drops
*Conversion factors 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, instead of oil, enters the plunger bore and cannot be compressed
to a high enough pressure to be forced out of the pump against the feed line back pressure.
Airlocking is caused either by entrained air being separated from oil by the vacuum in the
sight glass, or by air entering the pump when the oil level in the lubricator reservoir is lower
than the suction tube inlet. Severely agitated oils, such as oil supplied from the crankcase,
will usually contain entrained air. An airlock can be easily detected since, when it occurs, no
oil will be visible in the sight glass. If entrained air is found to be a problem, either a
pressurized pump supply or a settling tank should be utilized.

Revision 6
An airlock can be eliminated by refilling the lubricator reservoir and sight glass, loosening
the outlet union at the pump outlet, and manually operating the pump with the priming stem
until no air bubbles appear at the pump outlet. The airlock may reoccur if the cause is not
found and eliminated.
Over Fill:
Over filling is caused by the oil absorbing the air in 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
dropper open for very long as this will allow all the oil in the sight glass to drain out and
possibly cause an air lock condition.

Revision 6
Lubricator Pump Priming:

Recommended Tools: Small adjustable wrench
Parts (Subject to inspection): Review upon inspection
Supplies: Container of mineral spirits and lint-free rags
1. Should the lubricator reservoir be allowed to run dry (Section 5: MAINTENANCE

for capacity specifications), it may be necessary to prime each pump again. This
procedure is accomplished by opening the Union Nut (Item #2), but not the compression
fitting, attached to the Union Sleeve Assembly (Item #1 ).
2. Operate the flushing button by hand until all air is purged from the pump.
3. The hand flushing unit also serves as feed adjustment and indicates plunger stroke.
4. Should the pump unit become inoperative, it is recommended that clean mineral spirits
be used, hand flushing while suction tube is submerged. Continued flow of bubbles
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
condensation is harmful to the lubricator as well as the equipment being lubricated.
6. Sight feed glass is equipped with quick sealing plug which can be removed to break the
vacuum in the glass and allow excess oil accumulation to be carried away. Removing
this plug momentarily and observing that the oil stream in the two (2) small drilled
channels drops out of sight is sufficient. Replace plug. Repeat this procedure as often
as necessary; however, do not allow sight glass to remain open for any extended period
of time, otherwise air will enter the system and could possibly cause an air lock.

Revision 6
H. V-belt
Note:
procedures:
Service People required: 2 (1 if a chain hoist is available)

Recommended Tools: Chain hoist, 9/16" socket & ratchet, Special Tool (PM12969 Belt
Tensioning Gauge), set of assorted Allen wrenches, large adjustable wrench, wide flat blade
screwdriver, and a finishing file
Parts: New V-belts
Supplies: Container of clean light machine oil (SAE lOW) and lint-free rags
WARNING:
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. Remove guard bolts with 9/16" socket and ratchet and, with the assistance of another
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 never be forced over sheaves. More belts are broken from this practice
than from actual failure in service.
5. Belt tension should be reasonable. When in operation, the tight side of the belt should
be in a straight line from sheave to sheave with a slight bow on the slack side.
Insufficient tension can cause rapid belt wear and failure. Check belt tension weekly or
after 40 hours of operation with Special Tool (PM12969 Belt Tensioning Gauge) (Figure
8-87).

Revision 6
n
~
BELT TENSIONING GAUGE
(NLB P/N Pt.112969)
DRIVEN
PULLEY
Figure 8-87. Checking belt tension.
6. Tension the V-belt until readings are obtained as shown on V-BELT TENSIONING
VALUES TABLE 8-B.
V-BELT TENSIONING VALUES

TABLE 8-8
V-belt Tension D =Deflection New V-belt

NLB Part Tool Required Distance Deflection Force
Number Min/Max
A-1012 PM12969 Belt .406" (10.3 mm) 13. 70/14.63 lb .
Tensioning (6.17/6.58 kg)
Gauge
Used V-belt Recommended Recommended Power Band

Deflection Force Static Tension Static Tension Length Multiplier
Min/Max New V-belt Used V-belt
Min/Max Min/Max
11.84/12. 77 lb. 208.2/223.0 lb. 178.4/193.3 lb. 1.0094/1.0117
(5.33/5. 75 kg) (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 eliminating the possibility of premature belt failure.
8. Keep belts clean. Use no belt dressing. If belts slip, clean with cloth dampened with
alcohol and readjust belt tension.
9. Install guard and tighten retaining bolts.

Revision 6
10. Keep extra belts stored in a cool, dark and dry place.

Revision 6
I. 4071-10 Throttle Control
1. Seal and Piston Replacement
Note:
procedures:
Service people required: 1

Recommended Tools: Adjustable wrench
Parts (subject to inspection): Seal, (Item #1) and Piston, (Item #2)
Supplies: Tube of light grease and a jar of anti-seize compound
Note:
procedures:
Caution:
Replacement parts must be genuine NLB parts. The use of any
other parts could create a hazardous situation. Also, the use of
other parts will void all warranties on this equipment.
WARNING:
DISCONNECT THE BATTERY NEGATIVE(-) CABLE FIRST OR TURN
DISCONNECT SWITCH TO THE "OFF" POSITION, FIRST. BLEED DOWN ALL
1. The Seal, (Item #1) is installed onto the Piston, (Item #2) (Figure 8-88). The seal is a
five-piece design and is packaged with a replacement retaining clip and assembly
schematic for quick reference. It is important to orient the seal as shown, otherwise
leakage may occur. After the Seal, (Item #1) is installed into the Piston, (Item #2), a
light coating of grease should be applied to the seal and piston assembly to assist with
installation into the adapter bore.

Revision 6
\ RETAINING CLIP
\ ~EXPLODED SEAL ASSEMBLY
\ \
-i-o~~rn:-
tiQIE:: PISTON SHOWN FOR REFERENCE ONLY
-1~::v:J-------=+-
Figure 8-88. Installing seal onto piston.
2. The seal and piston assembly (Figure 8-88 should be installed into the Adapter, (Item
#12) by carefully inserting the seal and piston 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 heavy-duty, continuous cycling.

Revision 6
J. 4071-20 Throttle Control
1. Seal and Piston Replacement
Note:
procedures:
Service people required: 1

Recommended Tools: Adjustable wrench
Parts (subject to inspection): Seal, (Item #1) and Piston, (Item #2)
Supplies: Tube of light grease and a jar of anti-seize compound
Note:
procedures:
Caution:
Replacement parts must be genuine NLB parts. The use of any
other parts could create a hazardous situation. Also, the use of
other parts will void all warranties on this equipment.
WARNING:
DISCONNECT THE BATTERY NEGATIVE(-) CABLE FIRST OR TURN
DISCONNECT SWITCH TO THE "OFF" POSITION, FIRST. BLEED DOWN ALL
1. The Seal (Item #1) is installed onto the Piston (Item #2) (Figure 8-90). The seal is a
five-piece design and is packaged with a replacement retaining clip and assembly
schematic for quick reference. It is important to orient the seal as shown, otherwise
leakage may occur. After the Seal (Item #1) is installed into the Piston, (Item #2), a
light coating of grease should be applied to the seal and piston assembly to assist with
installation into the adapter bore.

Revision 6
\ RETAINING CLIP
\ \ EXPLODED SEAL ASSEMBLY
\ ~
-1-bJ-~~~-
@IE:: PISTON SHOWN FOR REFERENCE ONLY
--+-H-1~::e:J- - ---- -j-
Figure 8-90. Installing seal onto piston.
2. The seal and piston assembly (Figure 8-90) should be installed into the Adapter, (Item
#12) by carefully inserting the seal and piston 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 heavy-duty, continuous cycling.

~F· "" ' LTI/
~F· ,~,
T • LC'W 'WATER
LEVEL
• 31 ,LTC,,
(R LC'W CRANKCASE
DIL LEVEL
LC'W LUBE
CIL LEVEL
LC'W INL£T
'WATER PRESSURE
AIR COMPRESSOR
OVER TEMPERATURE
~ • ~F· ~
,-,
,LT6,.
(R LC'W 'WATER
LEVEL
INLET 'WATER
PRESSURE NCT LC'W
AIR CCMP. TEMP.

NCT HIGH
O:> I CRS
I (8)11(6)
O:> n 16 VATER TR1 SIL1A

0
~ ,<JD 'WATER NOT LD'W _42_ - - -<Y'Vo- PTO ENGAGE
,ao~ ~
-
- l's-t 17 0- - - - - - -
<S SEC.> SOLENOID
+ + TS~2 J 43_ _ _ -<Y'Vo-

SCLIB
PTO DISENGAGE
o-- - - - - - - - fG-1 SOLENDID
,CAI>
FUEL GAUGE
TDl'\E.
LEVtl. SENDER
fP 'o/ATER fP 'o/ATER
~T 4~ STIJP 46
DUMP VALVE
-0 ~ -i2..U>-- - - - SDLENDID
CR!O
J)RIMNG NOTES!
""' (6)
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 JETTING UNIT•
TUATMIPlfi
......
DO NOT SCALE DltA.wtNG
NLB Cor
~J~_J#J
muc
DIAGRAM, El..ECTRICAL.
2 IJIESEL. IJlllVER$H..
<STNG!MD - CIJllR!L Ill)()
N'.IN-ELECTROOC ENGINES El.ECTRCINIC ENGINES
.JUMPER TO BE INSTAU.£11 FDR EACH
IJ'TDIAl. F"DIT\llE !!!!" INSTAU.£11
) SEE TABLE #1 SEE TABLE #1

NOTE #4 NOTE #4
CR2
CDll.C4>
CR3
0>1&.<4>
SS-1
CR4
TRANSMISSIIJN NEUTRAL SVITCH Q)ll.(4)
CRS
PTll Q)fl,.(4)
TRI
a>tl.(4)
~
-1
00
I
00
ENGINE INTERFACE TABLE
(TABLE #1)
NOTE#1 NOTE#2 NOTE#3 NOTE#4
POS!TlVE VOLTAGE SOURCE

NEGATIVE VOLTAGE
SOURCE FAULTCONNEC110N #1 FAULT CONNECTION #2
I ELECTRONIC/NON-
ELECTRONIC
WIRE #2 CONNECTED TO WIRE #60 CONNECTED TO WIRE 1f70 CONNECTED TO
ENGINE MODEL WIRE #4 CONNECTED TO ...
N.C CONTACT (MURPHY ENGINE CHASSIS
CUMMINS #M11 SWITCH) GROUND NLS WIRE #4 ENGINE FUEL SOLENOID NON-ELECTRONIC
DRAV!NG lllTES!
CUMMINS INST. PANEL. CUMMINS 15 PIN PLUG PIN ENGINE FUEL SHUT-OFF L> THIS IS A GENERIC DRA\JING, IT IS lllT INTENDED
CUMMINS #N14 CUMMINS INST PANEL, TERM #5 TERM #12 #1 SOLENOID NON-ELECTRONIC TO REPRESD<T A SPECIFIC VATER .JETTING UNIT.
2.> ALL F"DIT\llES ARE ~ IT IS T1£ RESl'Ctl-
ENGINE 24VDC SWITCHED CUMMINS OEM INTERFACE
S!Bn.ITY IF T1£ USER TO DETERMINE VHICH
POWER SOURCE - KEY SWITCH ENGINE CHASSIS "B" CONNECTOR P!N #35,
IPT!llNS APl'LY TO EACH VATER .JETTING UNIT,
CUMMINS #QSK (ACC} GROUND ENGINE ECM GROUND WIRE #-037 ELECTRONIC
ENGINE 24VOC SWITCHED

POWER SOURCE - KEY SWITCH ENGINE CHASSIS CUMMINS OEM "B"
CUMMINS #QSX'l5 (lGN) GROUND ENGINE ECM GROUND CONNECTOR PIN #23 ELECTRONIC
N.C. CONTACT (MURPHY ENGINE CHASSIS NLB AIR THROTTLE

CUMMINS #83.9 SWITCH} GROUND NLB WIRE #4 SOLENOID NON-ELECTRONIC
N.C. CONTACT (MURPHY ENGINE CHASSIS NLB AIR THROTTLE

CUMMINS #85.9 SWITCH) GROUND NLB WIRE #4 SOLENOID NON-ELECTRONIC
CUMMINS "ISC" INPUT
ENGINE CHASSIS ECM"B" CONNECTOR PIN
CUMMINS #C8.3 KEY SWITCH, !GN. POSmoN GROUND ENGINE ECM GROUND #28 ELECTRONIC
CUMMINS "ISC" INPUT

ENGINE CHASSIS ECM"B" CONNECTOR PIN
CUMMINS #QSC8 3 KEY SWITCH, !GN. POSmON GROUND ENGINE ECM GROUND #28 ELECTRONIC
ENGINE CHASSIS
CAT#3306 ENGINE TERM. #14 GROUND ENGINE TERM. #24 TERM. #6 ON CAT. TD1 NON-ELECTRONIC
JNST. PANEL GROUND INST. PANEL CONNECTOR

CAT#C9 KEY SVV!TCH (RELAY TERM.) LUG INST PANEL GROUND LUG PIN #9 (GEEN WIRE) ELECTRONIC
INST. PANEL GROUND INST. PANEL CONNECTOR

CAT#C12 KEY SWITCH {RELAY TERM.) LUG INST PANEL GROUND LUG PIN #9 (GEEN WIRE) ELECTRONIC
!NST. PANEL GROUND INST. PANEL CONNECTOR
CAT#C16 KEY SWITCH (RELAY TERM.) LUG "NST PANEL GROUND LUG PIN #9 (GEEN WIRE) ELECTRONIC
!NST. PANEL GROUND INST PANEL CONNECTOR

CAT#31268 KEY SWITCH (RELAY TERM.) LUG INST PANEL GROUND LUG PIN #9 (GEEN WIRE) ELECTRONIC
100
101
102
103
104
~
105 '"""" 1H1E 'WR: f'llS AWO WK.
106 ~-----------,
COt.P. Mt. t:aiP. CIL. I
5~-L~--
107tS-1 1ans-2 -+ AIR COMPRESSOR TEMP.
107
jJ 7 NOT HIGH
• 0- 1ot1PS I
5__ ........,,_-------; INLET WATER PRESSURE
106 b- I NOT LOW
109 7 0- -'-----tOOLT II FUEL l.EVEL

TRANSDUCER
110 s 0- L-~------ ~I DISOiARGE PRESSURE

IS LOW
111 t 0- 9--~------
111FS
6
-t PWNGER LUBE l.EVEL
NOT LOW
,. 112F'S
1~--0,-0--------iI
112 10 0- CRANK CASE OIL LE'JB...
6 I NOT LOW
11 0- 1L-~-------+ WATER l.EVEL

113
0 NOT LOW
U4P8 I
114 12 0- I.!_ _ _,r._ - - - - - - -; EMERGENCY STOP
I
115 .. 0- ~-> I PUIAP FAULT "
116 "'0- -->

"' II PUIAP FAULT 12
I
117
I
I
t18P9 I
118 >O Q-!-fl--'l!!.-_,r._-------' FAULT RESET
119
120
121
122
123
124
125
126 DDClllJlll"TlOM I DA.ft

WATPtlALI inttATMENTI
-= = t~ I
127
UN~AH~~~m DO NOT sew: DRAWING
128 ::0 I=.

"::rt--~
129 Dlt.T.SHOOX
CK../,.__
130
131
132
Revision 5
TABLE OF CONTENTS
SECTION 9
PARTS

I. Model & Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
II. Assembly Drawings & Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
A. High Pressure Pump Fluid End (A-Cylinders) ..................... 9-4
B. High Pressure Pump Fluid End (B-Cylinders) ...................... 9-7
C. High Pressure Pump Power End (A & B-Cylinders) ................. 9-10
D. *BVl0-650 By-Pass Valve .................................... 9-13
E. *BVl0-400 By-Pass 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) . . . . . . . . . . . . . . . . . . . . . . . 9-39
Q. Water Plunger Lubricator - Optional ............................. 9-40
*: To check which by-pass valve is on your unit, refer to page 3-3.

Revision 4
I. Model & Serial Numbers
The model and serial numbers are identification of the major components. NLB
continuously strives to improve equipment as new developments occur. With the model and
serial number identification, the exact configuration of your unit can be identified. A
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
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 serial numbers are included in the order.

Revision 2
II. Assembly Drawings & Part Lists
The assembly drawings and part lists included in this section are intended to accurately
document the parts for the equipment included in the 1312D, 1012D, 812D, 612D, 512D,
412D, 3.512D, 312D, 1060D, 860D, & 760D high pressure water jetting units. All repair or
spare parts orders should include the part numbers as identified in this section for accurate,
timely servicing of the high pressure water jetting units.
Assembly drawings assist the user in ordering replacement parts. It is arranged by type of
assembly so that individual parts or replacement assemblies can be 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
needed.
d. Confirm the quantity required per assembly.
e. Order the part by the NLB part number.
f. To order replacement parts, call toll-free 1-800-227-7652.
Note:
Items that are available from local sources are usually excluded from parts lists.
These include clamps, washers, screws, nuts, and some hoses. In some
assemblies, these items are identified on the illustration.

Revision 12
A. High Pressure Pump Fluid End (A-Cylinders)
ITEM# PART# DESCRIPTION QTY.

1 L-643-2 Bolt, Suction, Manifold 12 Ea.
2 NC-359 Manifold, Suction 1 Ea.
*4 NC-322/323 Seat, Valve (Suction & Discharge) 6Ea.

N-320 Valve, Suction/Dischargt: 6 Ea.
(3 Ea.
*5
for 13K
units)
5 tCM17572 Valve, Suction/Discharge (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.
N-353-10 Plunger, l" 3 Ea.
*17
N-353-11 Plunger, l-1/8" 3 Ea.
N-353-12 Plunger, l-1/4" 3 Ea.
18 N-366 Flange, Stuffing Box Retainer 3 Ea.

Revision 9
ITEM# PART# DESCRIPTION (Continued ...) QTY.

19 N-643-2 Bolt, Stuffing Box Retainer Flange 12 Ea.
20 N-301 Nut, Fluid Cylinder Tie 2Ea.
21 N-302 Stud, Fluid Cylinder Tie Stud 2Ea.
-- tCM17570 Spacer, Vertical (1012D High Efficiency) 3 Ea.
-- tCM17571 Spacer, Horizontal (1012D High Efficiency) 3 Ea.
Shaded Area: Recommended for spare parts.

*: Items included in the high pressure pump spare parts kit. The following are the available
high pressure 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-ll WL Recommended Spare Parts Kit 1012 Pump, 1-1/8" Plungers (Water Lube)
t: Additional Items used in the 1012D High Efficiency unit with l" plungers.
Note:
In addition, three (3) of each of the following are included in all 13K units: Spacer,
Stuffing Box #CP14914 and Spacer, Volumetric Discharge #CP14915.

Revision 9
~ ' \ .
-~-~ tHorizontal Spacer
D tVertical Spacer
For stuffing box oiler fittings order part

no. PM12330
A- Cylinders High Pressure Pump Fluid End
t: Additional Items used in the 1012D High Efficiency unit with 1" plungers.

Revision 7
B. High Pressure Pump Fluid End (B-Cylinders)

1 NCB-643-3 Bolt, Cylinder, Fluid, Bare 12 Ea.
2 NCB-359 Manifold, Suction 1 Ea.
3 AA..:.1860 0-ring 15Ea;
4 NCB-322/323 Seat, Valve (Suction & Discharge) 6 Ea.
*5 NCB-320/321 Valve 6 Ea.
6 NCB-334/335 Spring, Valve (Suction & Discharge) 6Ea.
7 NCB-369 Stop, Valve (Suction & Discharge) 6 Ea.
8 NCB-300 Cylinder, Bare Fluid 1 Ea.
9 NCB-360 Manifold, Discharge, 1 Ea.
10 Bolt, Discharge Manifold 8Ea.
*12 Spring, Packj1lg . 3Ea.•
N-341-13 Bpslli~g;Tllroat;.1.-3/8" •······3.Ea;
N--341..'.14 J311$hi~g, Throat,.1-1/2" ·3Ea.
*13
N-341-15 J3.u.slll~g, Th,roat, 1-5/8" ..
3Ea.
N.:.341-16 Bushing, ·.Throat, 1-:-3/4" 3.Ea>
1637 p~c~~~·)-318'' 3SetS·
1700 Jlafk}ng; 1::-1/2" 3.Sels:
*14 1701 Pac~$, 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.
N-353-14 Plunger, 1-1/2" 3 Ea.
*17
N-353-15 Plunger, 1-5/8" 3 Ea.
N-353-16 Plunger, 1-3/4" 3 Ea.
18 NCB-366 Flange, Stuffing Box Retainer 3 Ea.
19 NCB-643-3 Bolt, Stuffing Box Retainer Flange 12 Ea.
20 N-301 Nut, Fluid Cylinder Tie 2Ea.
21 N-302 Stud, Fluid Cylinder Tie Stud 2Ea.

*: Items included in the high pressure pump spare parts kit. The following are the available
high pressure pump spare parts kits:

Revision 4
ITEM# DESCRIPTION
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)

Revision 4
For stuffing box oiler fittings order part

no. PM12330
B-Cylinders High Pressure Pump Fluid End

Revision 12
C. High Pressure Pump Power End (A & B-Cylinders)

1 1/2-13x1HH Bolt, Crankshaft Bearing Retainer 12 Ea.
2 N-132 Retainer, Bearing (Blind End) 1 Ea.
3 N-134 Shim, Crankshaft Roller Bearing 2 Sets
**4 N-107 Bearing, Crankshaft with Race 2Ea.
**5 N-107 Bearing, Crankshaft with Race 2Ea.
6 Stock Plug, Optional Vent 2Ea.
7 N-634 Cap, Breather 1 Ea.
8 Stock Rivet, Drive 2Ea.
9 L-179 Tag, Oil Fill 1 Ea.
10 N-649 Plug, Oil Fill 1 Ea.
11 N-100 Frame, Power 1 Ea.
12 N-620 Gasket, Crankshaft Inspection Plate 1 Ea.
13 N-154 Plate, Crankshaft Inspection 1 Ea.
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~shllft Oil .·
. 1 Ea:
25 Stock Key, Crankshaft 1 Ea.
26 N-103 Crankshaft l Ea.
27 Stock Plug, Optional Sight Gauge Mounting 1 Ea.
28 Stock Plug, Optional Oil Fill 1 Ea.
29 N-120 Bushing, Wrist Pin 3 Ea.
30 Stock Screw, Set 6 Ea.
31 N-117/122 Crosshead With Stub 3 Ea.
32 N-119 Pin, Wrist 3 Ea.
N-123 or Deflector, Splash 3 Ea.
33
tN-123-V

Revision 12
ITEM# PART# DESCRIPTION (Continued ...) QTY.

34 Stock Bolt, Crosshead Stub Seal Flange 6 Ea.
38 N-650 Pin, Fluid Cylinder Alignment Dowel 2Ea.

N-621 Gasket, Crosshead Cover Plate 1 Ea.
N-620 Plate, Crosshead Inspection 1 Ea.

*: 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.

Revision 4
High Pressure Pump Power End

Revision 7
D. BV10-650 By-Pass Valve

1 DV12619 Body 1 Ea.
.
.. *2 BV12620 Pin 1 Ea.
·.. ·
*3 BV12621 Seat 1 Ea~
4 CV12622 Frame, Seat 1 Ea.
5 BV12623 Guide, Spring 1 Ea.
6 BV12624 Bushing, Guide 1 Ea.
7 I BV12625 Disc 1 Ea.
8 BV12626 Nut, Cap 1 Ea.
9 BV12627 Screw, Adjuster 1 Ea.
11 BV12628 Spring, Disc 21 Ea.
*13 AA~179.1 R,ing, Backup 2 Ea.
..
'i<14 AA-:1250 O;;..ring 2Ea.
15 BV12629 Handle, Adjuster 1 Ea.
16 PM12632 Pin, Spring, Slotted 1 Ea.
*17 BV12630 Deflector 1 Ea.
*18 10-32xl/4SS Screw, Set 2Ea.
19 PM15934 Bumper, Rubber 1 Ea.
20 PM15935 Bumper, Rubber 1 Ea.
21 BM16267-2 Handle, Jam, Nut 1 Ea.
Shaded: Recommended for spare parts.

*:Items included in spare parts kit BV12635.

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+>-
I.RH
I.RH
I.RH
TH
00 HOT SCALE ORA.WING
l"'-l U/2 N?T (Rtt)
Rd:D# 3651-l
Revision 12
E. BV10-400 By-Pass Valve

1 DV8166 Body 1 Ea.

7 BV8196 Disc 1 Ea.
8 BM6957 Nut, Cap 1 Ea.
9 BV10943 Adjuster 1 Ea.
11 19 Ea.

*:Items included in Spare Parts Kit BV11316.

4
REF
......... _
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------
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--..I D SCALE: 2X
NPT FEMALE
A.
-W
I.
D IDELETED ITEM #10, '3/8-24JN', JAM NUT; ADDEDl6/19/02 LRH I
ITEM #15, '8M16267-3', HANDLE. QTY-1
c I DELETED 0-RING BACK-UP (AA-1790) FROM IS/29/98 I BH
B IUPDATED
DWG TO REFLECT DESIGN CHANGES IS/15/97 I SP
ITEM #12 QTY
A I UPDATED DWG NR
8V10-400
REV DESCRIPTION DATE I BY
MATERIAL: TREATMENT:
~ 1" NPT MALE REFER TO SOM #
8V10-400
~ (REF) STANDARD TOLERANCES
UNLESS OTHERWISE SPECIFIED DO NOT SCALE DRAWING
.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 NLB Cor
OR. RUSHO I 0
~}~195
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 llAY NOT BE DISCLOSED TO
UNAUTHORIZED PERSONS WITHOUT EXPRESS
BV10-400, WRITTEN CONSENT Of' NLS CORPORATION.
BY-PASS VALVE DRAWING NO. REV.
APPROXIMATE WEIGHT: 8 lbs ASSEMBLY
CV9581 D
6 '
7 l
'
\
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......
co
\
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Revision 12
F. BV20-260 By-Pass Valve

1 DV8166 Body 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.

*: Items included in Spare Parts Kit BV11317.

9
.......... ',
'\
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'
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SCALE: 2X
4-
,
'I
'
D IDELETED ITEM 610, '3/8-24JN', JAM NUT; ADDED ITEM 6/18/02 I LRH
#18, 'BM16267-3', HANDLE, QTY-1
C ITEMS #9 & #16 ARE NOW A WELDED SUB-ASSEMBLY 10/8/96 NR
B REVISED ITEM #12; ADDED ITEM #1 7 8/26/96 NR
A ADDED ITEM #16 12/8/95 NR
REV DESCRIPTION DATE BY
REFER TO B/M
'BV20-260'
STANDARD TOLERANCES
.00 t010 MACHINED SURFACES ~
.000
.0000
.00:5
0005 OTHER SURFACES 1 :zv
FRACTIONS ±1/32 AHOl.£S ± .s'
REMOVE ALL BURRS ANO SHARP EDGES NLB Co .
OR. BOW ES
CK./Al"""t-.
I ~/~B/95
0
UATE 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 DISCLOSED TO
UNAUTHORIZtO PERSONS WITHOUT EXPlltSS
BV20-260, WRITTEN CONSENT or NLB CORPORATION.
20k BY-PASS DRAWING NO. \REV.
NL8 P/N 8V20-260 VAL VE ASSEMBLY
CV9138 D
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_....
- • REFER TO SHEET #1
R DESCRIPTION DATE I BY
REFER TO B/M
'BV20-260'
STANDARD TOLERANCES
UNLESS OTHERWISE SPECIF"IED DO NOT SCALE DRAWING
.00 t-010 -ED SURFACES 83..f
:~ t=s OTHER SURFACES 12V
FRACTIONS ±1 /32 ±
AllGl.£S S
REMOVE ALL BURRS AND SHARP EDCES NLB Cor
DR !DATE
. RUSHO 5/10/95
Cl<./At"t". OATE "lllr Uflll
IAll#M:"lllm l.tTKIL
2111130IECICll0.-~48313
IUml
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, WRITTEN CONSENT or NLB CORPORATION.
20k BY-PASS DRAWlNG NO. REV.
VALVE ASSEMBLY
CV9138 D
Revision 7
G. 124 - 1 1/2 Water Tank Filter

1 124-11 Bowl 1 Ea.
2 124-12 Gasket, Buna-N (Standard) 1 Ea.
3 NLB 124-1.1/2-80 Screen,. so Mesh ···.·.
lEa.
4 124-13 Strainer Head 1 Ea.
124 - 1 1 /2 Water Tank Filter

Revision 7
H. NSP-2000 Rupture Disc Valve Assembly
ITEM # PART# DESCRIPTION QTY.

1 NSP-2001-1 Body 1 Ea.
NSP"":2002-5 J)isc, ~upture~!led,SK l.Ea;.
Nsp.:.2002.:.6 J)i~c~Jlnptufo~ Pink, 6K '.0lEa:
NS}>;.;~Q02".'8 Di~c,.Rµptu;re, Bia.ck, .SK' ::tEa~
NSP:~~002··.JO Dis~i.R~ptute./Silver,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.

*: 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
---
---

Revision 7
I. NSP-3000 Rupture Disc Valve Assembly

1 NSP-3001-04 Cap 1 Ea.
2 NSP-3001-03 Washer 1 Ea.
..
3 NSP-3002;,,.15 Disc, Rupture, lSK, Brown : .·
lEa:
... :
3 NSP-3002-20 Di~c, Rupture, 20.K, Gold lEa;
4 NSP-3001-01 Body 1 Ea.
5 NSP-3001-02 Seat, Body 1 Ea.
6 03-ST-ELB-40-SS Deflector, Safety Pop Off 2Ea.

*:Not shown

Revision 7
J. L-55i Oil Plunger Lubricator
ITEM# DESCRIPTION QUANTITY

:
.. 69879 Replacement Screen Assembly {':· ·. ..
15 Screen Assembly 1 Ea.
..· : :
250136 Suction Tube .·· •·
... :.· ·.
19 Suction tube 1 Ea.

:
250142 Sight Glass Replacement Kit ..
20 Sight glass seal ·••··· ;;. 1 Ea.

22 Sight glass 1 Ea.
23 0-ring 1 Ea.
24 Dropper 1 Ea.
250143 . J>.ump.'ft{ounting Kit .:
•··. :• :
6 Mounting Screw 2Ea.

7 Belleville Washer 2 Ea.
11 Pump Mounting Gasket 1 Ea.
;
250144 Pump. Seal Kitfor Model 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 Outlet Check KitforModet880560 (3/8'!Pump) :·. ~·ii(
... ······ ;· ..... >
3 Adapter Assembly (with Check Balls) 1 Ea.

4 Backup Ring 1 Ea.
5 0-ring 1 Ea.
•.
... · ;.:. :·
250167. RockerArmfor Series ':-4. "ReplacementKit.•. .· :·.· :;\; •h:
8 Cotter Pin 1 Ea.
9 Pivot Pin 1 Ea.
12 Spring (Plunger Return) 1 Ea.
13 Spring Retainer 1 Ea.
14 Rocker Arm 1 Ea.

Revision 7
ITEM# DESCRIPTION QUANTITY

.· ..
250169 Priming Unit Assembly
25 Priming Unit Assembly 1 Ea .
250171 Replacement Dropper Assembly
...
.·····.•..
23 0-ring 1 Ea.
24 Dropper 1 Ea.
250172 PumpSealKitforModel880550 (114" Pump)
26 Backup Ring (Outlet Body) 1 Ea.
27 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.
·..... .\.
250173 Outlet CheckKitforModel 880550 (1/4"Pump) .· ·.
26 Backup Ring 1 Ea.

27 0-ring 1 Ea.
28 Adapter Assembly (with Check Balls) 1 Ea.
250225 Rocker Arm Kit- Series "B" or Newer .·.•.
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 parts kits highlighted above. Individual service parts and
parts not listed above are not available.

Revision 7
L-SSi Oil Plunger Lubricator Parts 0

ITEM 21
STEEL BALL
©
ITEM 23
0-RING (BROWN)
0 0
ITEM 18
STEEL BALL
~
ITEMS
ITEM16
COTTER PIN
0-RING (BLACK)
c=::::i
ITEM 29
GROOVED PIN
ITEM 7
BELLEVILLE WASHER
I'---·
o
--wm
ITEM 9
PIVOT PIN
0 ITEM 20
SEAL (BLACK)
ITEM 11
0 ITEM4
PUMP MOUNTING
GASKET
0 ITEM 27
BACKUP RING (WHITE) 0-RING (BLACK)
0 ITEM 5
0-RING (BLACK)
ITEM 6
MOUNTING SCREW
0ITEM 26
BACKUP RING (WHITE)

Revision 7
L-55i Oil Plunger Lubricator
=~!
r--~-t-~~ I
2
114• PUMP TOllOU1i TO
a.ooa.-.........
~60
'° Rlt<lEA
6'!
TO 40 IN -1.85
TIGlfT
l'LUS l/4 T'UllH.
28 4
27
[
l~---ir:::E:;±::;:i..t- -=-~--#
'°BOCKER ARM PIVOT DETAIL

(SER!ES wA"l
NOTE! W!!!l!U Am.>.Clll G OOCQR - · ntl! f:xJliTlllG
PIVOT ?Iii! IS 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.
© 11
Indicate& Change
17
., ¥~::I
I
RQCKER ARM f'IVOT DE"fAIL
<SERIES ~a~>
NOTE: ""'"* tu:l".ACltiG MCKEii - . TH£
tXJsfliilO PIVOT PIN IS ro RE ll\£11SID OUT AIOID
1\101'E; HO'TCHW ENC Of
$1\ICTIOlll TUBE !fl'l!M 191 lll
TO a! ASS!M61.ED llO'O THE
v1SCAl!l)£!). l't!Pt.AC!WITH GOOOV!l>l'tll UT'fM 12&). FOOT VALVE SOOY •TW 11!.

Revision 7
K. 2180 Float Valve

1 PM9599 Ball, Float Valve, 8" Plastic 1 Ea.
2 2180-2 Rod, Float Valve, 18" 1 Ea.
2180-3 Body, Float Valve 1 Ea.
Consisting of:
(1) 2180-12 Plunger Assembly
(1) 2180-5 Seal/Disc (Set)
3 (1) 2180-4 Linkage, Valve
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, Drop 1 Ea.

Revision 7
2180 Float Valve
I
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BJ I
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5:
Wl-
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<(Z 0
>-

Revision 7
L. 4071-10 Throttle Control
ITEM
#
. 1 PM14983.. Seal •.·· ·.
. .. ' )} r.\ 1 St.
·· Piston . . ·•. .
. ·\2 .· .· BM14981 .··..
. \ !Ea.
3 BM15088 Stop, Adjustable 1 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.

rrR
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LiljHI ~I
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rij
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11Ll.
~
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©
\el
,
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··········-·1
1 ,-~-------,,,
----
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I\) 10,000 PSI THROTltE CONTRa. 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
Revision 7
M. 4071-20 Throttle Control
ITEM
#
1 PM14983 .. Seal ·.. .
. lSt.
.·... .
2 BM14981 <.~:; Piston lEa.
3 BM15088 Stop, Adjustable 1 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 4 Ea.
10 BM15083 Bracket 1 Ea.
11 BM15089 Tab, Operating 1 Ea.
12 BM15084 Adapter 1 Ea.

~ILQJRI
~Je e-i '
@==ll~~-~A
-~'"'"''
,n @ ©, ,I,! v
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·e ©
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~\
&
10,000 PSI THROTll.E CONlRQ. 40,000 PSI THROTll.E CONlRQ.
+::- REFER TO B/1.1 f4071-10 REFER TO B/1.1 f4071-40
I >< SI< !
~ ~
20,000 PSI M<OTll.E CONlRQ. 24,000 PSI THROTll.E CONlRQ.
REFER TO B/1.1 f4Q71-20 REFER TO B/1.1 f4071-24
Revision 7
N. 1012 Gear-Pac Speed Reducer

100 --- Power Frame 1 Ea.
103 --- Crankshaft 1 Ea.
107 --- Crankshaft Bearing 1 Ea.
128 --- Main Gear 1 Ea.
129 --- Pinion & Shaft 1 Ea.
133 --- Crankshaft Frame Cap 1 Ea.
135 --- Pinion Shafts Frame Outer 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.

Revision 7
1012 Gear-Pac Speed Reducer
~
0
.-... Ol 0 0
"'..
O> N
O> 0 ~ .... 0

Revision 7
0. Discharge Piping - 101208

Dwg. DLE6008-58
ITEM
#
1 DP9678 Manifold 1 Ea.
2 BVl0-400 BVl0-400 By-Pass Valve 1 Ea.
3 CM3557 Valve, Rupture 1 Ea.
4 10-ELB-90-6T-S Elbow 1 Ea.
5 2008 Gauge, Pressure 1 Ea.
6 NQC-22-F Coupler 1 Ea.
7 WP3-1/2-01 Hose 1 Ea.
8 10-PLG-6T-S Plug 2Ea.
9 BP9679 Snubber, Pressure Gauge, lOK 1 Ea.
10 . . AA-1660 ·.· ·•
Q~@.g
. lEa.
·.
11 PM9001 Filter, Snubber 1 Ea.

12 BM9186 Washer, Brass 1 Ea.
13 BM9210 Nut, Jam 1 Ea.
14 10-CL-NIP-XXS-S Elbow, Street 1 Ea.
15 10-04-RB-6T-S Bushing, Reducer, Threaded 3 Ea.
16 NQC-22 Coupler, Quick Set 1 Ea.
19 CM10063 Bracket, Manifold 1 Ea.
20 04-14-NIP-160-S Nipple 2Ea.
Note:
For the information on the discharge piping of other units, contact the NLB
Customer Service Department.

NOTE: WHEN
NOTE!
/
/ ----------- /
c.o
I
(,.)
CX>
DETAIL 'A'
~
'
+ + muc
PIPING. DISCHARGE.
10120 & E
WITH MANIFOLD
Revision 7
P. Water Inlet Bag Filter - PM3350 (Optional)

ITEM
#
1 PM9143 0-ring, Lid lEa.
2 PM9144 Gasket, •Flat 1·Ea..
3 PM6962 Bag, Filter 1Ea.

Revision 7
Q. Water Plunger Lubricator - Optional

Dwg. CM15967
ITEM
#
1 04-PLG-6T-S Plug 2Ea.
2 06-03-RB-6T Bushing, Reducer 1 Ea.
3 DM2666-56 Tubing, Air 5 Ft.
6 PM2666-6 Fitting, Air 1 Ea.
7 BM12032 Manifold 1 Ea.
8 Y0012 Fitting 1 Ea.
10 PM2518 Tubing, Parflex Clear PVC 9 Ft.
11 PM14811 Bracket, Mounting, Water Lube Manifold 1 Ea.
13 PM4136 Valve, Flow Control, Air 3 Ea.
14 14-TEE-40-SS Tee 1 Ea.
15 14-CL-NIP-40-SS Nipple 1 Ea.
16 14-06-RB-6T-S Bushing, Reducer 1 Ea.
17 02-PLG-40-S Plug, Square Head, Threaded 2Ea.
18 LO-ST-ELB-40-SS Elbow, Street 1 Ea.
19 10-04-RB-6T -S Bushing, Reducer 1 Ea.
21 PM11995 Hose 3 Ft.
22 PM7329 Fitting, Hose 2Ea.
23 PM7328 Adapter, Hose 2Ea.
25 04-ELB-90-40-S Elbow 1 Ea.
26 04-60-NIP-40 Nipple 1 Ea.

WATER TANK
DP8239 SHOWN
FOR REFERENCE
PUMP UNIT
20153A SHOWN
FOR REFERENCE
/~
:0
1...... ~~='"'''"'~~"""'""""'§
STREET ELBOW FROM

TANK PPG,
'DM15908'
RE DESCRIPTION DATE BY
MATERIAL: SEE B/M TREATMENT:
CM15967
STANDARD TOLERANCES
.oo i-010 llACHlllED SURFACES 83,.T
.000 .oos
.oooo .oooe OlllER SURFACES 1zv
FRACTIONS :1:1/n ~:I: JI'
REMOVE ALL BURRS AND SHARP EDGES NLB Cor ...,.
DR.SPRAGUE
CK./APP. IDATE --~~~-
ORIENTATION OF FITTINGS FOR

SCALE
1 /8" -1"
I1 SHEET
OF 1
'IDDllDIE (248) l2A-5ll55
INFORMATION SHOWN ON 11115 DOCUMENT IS
I TITLE PROPRIETARY AND MAY NOT BE DISCl.OSED TO
225 SERIES PUMP UNITS PIPING, WATER LUBE,
WRITTEN CONSENT OF NLB CORPORATION.
3 PLGR, DC, 1 OK & 20K DRAWING NO. I REV.
TRAILER MOUNT UNITS
CM15967
Revision O
TABLE OF CONTENTS
CUSTOMER SUPPORT
SECTION 10

I. NLB Corp. Customer Service Department ........................... . 10-2
A. Business Hours ............................................. . 10-2
B. How To Reach The NLB Corp. Customer Service Department ........ . 10-2
C. Non-Business Hours Emergency Customer Service ................ . 10-2
II. Ordering Parts ................................................. . 10-3
A. Ordering Procedure .......................................... . 10-3
III. Warranty Policy ............................................... . 10-4
IV. Parts Return Authorization (RA) Process ............................ . 10-5
A. Parts Received Damaged ..................................... . 10-5
B. Parts Return Authorization (RA) Number ........................ . 10-5
1. How To Acquire An (RA) Number .......................... . 10-5
C. Parts Return Directives ....................................... . 10-6
D. Parts Return Authorization Procedures .......................... . 10-6
1. Parts Ordered In Error By Customer - Returned For Credit ....... . 10-7
2. Unused Parts - Less Than One Year Old - Returned For Credit .... . 10-7
3. Parts Shipped In Error By NLB Corp. - Returned For Credit ...... . 10-7
4. Parts Returned For Repair ................................. . 10-8
5. Parts Returned For Warranty Repair Or Replacement ............ . 10-8
v. How To Package Parts To Be Returned ............................. . 10-10
VI. Return Authorization Form ....................................... . 10-11

Revision 2
WARNING:
I. NLB Corp. Customer Service Department
NLB Corp. recognizes the important role of the customer in eliminating and decreasing
equipment downtime and/or unscheduled maintenance. For this purpose, NLB Corp. has
pledged to contribute the technical assistance needed to help customers during equipment
installation and/or operation through NLB Corp. Customer Service.
Located at NLB Corp. 's World Headquarters in Wixom, Michigan, USA, Customer Service
is staffed with trained, knowledgeable 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 conveniently available to assist customers by phone during
business hours: (EST) 8:00am to 6:00pm - Monday through Friday
8:00am to 12:00 noon - Saturday
as well as by mail and FAX.
B. How To Reach The NLB Corp. Customer Service Department
NLB Corp.
Customer Service
29830 Beck Road
Wixom, MI 48393-2824
(248) 624-5555 or 1-800-227-7652
FAX: (248) 624-0538
C. Non-Business Hours Emergency Customer Service
To order emergency parts during non-business hours contact NLB Corp. Customer Service
in Wixom, Michigan, at the following number:
1-800 227-7652

Revision O
II. Ordering Parts
Section 9: PARTS identifies the high pressure water jetting components and their
accompanying part numbers. The section is typically arranged with major assemblies first,
followed by subassernblies. Whenever possible, the parts list for complicated assemblies
includes exploded view illustrations. These illustrations can be helpful in understanding how
to operate and disassemble each assembly. Recommended spare parts are shown 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 an estimated
shipping date when the order is placed. Sarne-day shipments can be made in the event of an
equipment breakdown only if the requested part is in stock and the order is received before
3:00 pm EST.

Revision O
Ill. Warranty Policy
All components manufactured by the seller are warranted to be free from defects in material
and workmanship under normal use and service for a period of one year from date of
shipment. At its option, the seller may either repair defective parts or furnish new parts free
of charge, FOB at the seller's factory. This warranty will only apply upon the seller's
determination, after inspection, that such parts are defective in material or workmanship.
The warranty expressed in this paragraph shall constitute buyer's exclusive remedy.
Equipment and accessories not manufactured by the seller are only warranted to the extent 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 installed, misused, altered, abused, or
neglected. Under no conditions will the seller be liable for any delays or consequential
damages or losses in the fulfillment of this warranty.
The seller's liability under this warranty is limited to the repair and replacement of defective
parts as stated above and the seller is not responsible for any damages, expenses, or losses of
income resulting from such defects.

Revision O
IV. Parts Return Authorization (RA) Process
This section discusses the parts Return Authorization (RA) process. In order for parts
returned to NLB Corp. to be processed quickly and efficiently, customers returning parts for
any reason must follow the procedures in this section.
A. Parts Received Damaged
All shipments leaving NLB Corp. are packaged according to good standard packaging
practice. NLB Corp. cannot be held responsible for any parts damaged in transit.
Responsibility for damaged shipment lies with the common carrier. When parts are received
in damaged condition but with shipping container intact, the customer should make a
"CONCEALED DAMAGE REPORT" to the carrier within three business days of the
delivery. All claims will be made by the customer to the common carrier. Whenever
possible, NLB Corp. will be glad to render the 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 require an RA Number. Parts will
not be accepted for return without an RA Number.
Obtaining an RA Number is no guarantee of warranty or credit.
1. How To Acquire An RA Number
Please use this method when returning parts for any purpose:
Contact NLB Customer Service by calling 1-800-227-7652 (in the USA and Canada), or
(248) 624-5555, and ask for an RA Number and instruction on how to return parts.
Before You Call
NLB Customer Service representatives care about the quality of service they provide. You
can help them to provide accurate, complete answers to your question by having the
following information:

Revision O
A. Company name, address, telephone number, and FAX number
B. Shipping address (if address is different from the company's address)
C. Your name, telephone number and FAX number (if your telephone number and FAX
number is different from the company's numbers)
D. Original purchase order number
E. Itemized list of parts being returned, as well as quantity, part number or serial number,
and physical description of each part
F. Details of the system from which the parts were removed, if appropriate, i.e., job
number, model number, serial number, and hours of use, if available
G. Reasons for returning parts
H. Any additional information that will assist in 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 credit under any
conditions.
D. Parts Return Authorization Procedures
All parts returned to NLB Corp. will be managed according to the Parts Return
Authorization Procedures. Utilizing these procedures guarantees efficient and appropriate
handling of all parts returned to NLB.
There are five different procedures to follow, depending upon the reason for returning the
parts, as explained on the following pages.

Revision 0
1. Parts Ordered In Error By Customer- Returned For Credit
A. Acquire an RA Number. Return parts shipping prepaid to NLB Corp.
B. The parts will be examined by Customer Service to make sure they are unused, 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 the customer as to their
disposition.
Note:
Non stocked or special parts are not returnable.
2. Unused Parts Returned For Credit - Less Than One Year Old
A. Acquire an RA Number. Return parts shipping prepaid to NLB Corp.
B. The parts will be examined by NLB Customer Service to make sure they are unused, 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 the customer as to their
disposition.
Note:
Non stocked or special parts are not returnable.
3. Parts Shipped In Error By NLB Corp. - Returned For Credit
A. Acquire an RA Number.
B. The parts will be examined by NLB Customer Service to make sure they are unused, 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, and the originally ordered
parts will be shipped to the customer along with a refund of shipping costs. When the
claim is approved. a credit memorandum for the originally ordered parts will be
forwarded to the customer. This credit can be used on future orders.

Revision O
C. If returned parts are not in new condition, NLB will notify the customer as to their
disposition.
D. If the replacement parts are in stock, they will be shipped within three business days or
on the same day for urgent requests.
4. Parts Returned For Repair
B. NLB will provide a verbal, or upon request, a written quotation for the repair cost,
including labor, assuming the equipment can be repaired. Return freight will be charged
as incurred.
C. Customer will issue a purchase order for the repair amount.
D. Damaged or worn parts will be returned to the customer along with the new parts. If the
customer does not wish to have the damaged parts returned, he must notify NLB in
writing.
E. If parts are not repairable, not 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
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, or Faxing
NLB Customer Service.
Note:
Warranty service extends only to the original purchaser and is not transferable or
assignable without NLB Corp. 's prior consent.
C. NLB Customer Service will evaluate and test all returned parts thought to be defective
by the customer for warranty consideration to make sure they are covered by the NLB
Corp. warranty. A warranty claim will be handled in the most prompt manner as
possible. After a warranty determination is made, the parts will be handled accordingly.

Revision O
Parts Found To Be Defective Under Terms Of This Warranty
A. If the parts are found to be defective under the terms of this warranty, NLB Customer
Service will decide whether the parts will be repaired or replaced. The repaired or new
replacement parts will be shipped to the customer without charge. Shipping charges,
however, are not covered under warranty.
B. If parts are urgently needed while the new equipment is still under warranty, NLB Corp.
recommends the customer issue a new purchase order for the required parts.
C. If the parts are in stock, they will be shipped within three business days. If they are not
in stock, the 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, Customer
Service will notify the customer.
B. The customer, at his option, may:

1. Issue a purchase order to have the parts repaired.
2. Request that the parts be returned (at his expense).
3. Request that the parts be scrapped at NLB (requires written request).
4. If no notification is received from the customer within 10 business days, the original
parts will be returned at the customer's expense.

Revision O
V. How To Package Parts To Be Returned
Please use this method when packaging parts to be returned:
A. Fill out the RA form with all applicable information and include in the package being
returned. Use the preprinted label found on the RA form and ship prepaid to NLB Corp.
"ATTENTION CUSTOMER SERVICE" or to a location stipulated by the contacted
Customer Service representative. 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 appear on the shipping label and all
shipping documentation. All inquiries concerning the returned parts must also
reference this number.

RETURN AUTHORIZATION
Return This Authorization Form with package
NLBCorp.
I NLBCorp.
29830 Beck Road D -Wixom, Ml 48393
29830 Beck Road (248) 624-5555 D Fax (248) 624-0538
Wixom, Michigan 48393-2824 Customer Service (800)227-7652
Attn: Customer Service Department Ship To: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Telephone (248) 624-5555 D Customer Service: (800)227-7652
Fax: (248)624-0538
R.A. # Phone:
......................................... ..
c;;iei;;~·i/d~ii~diin;,·:·~5-;, ;;;;-;,;~·;;i~'ii'i~;:,~r .......................................
Fax:
See your manual for Return Authorization instructions
or call NLB Customer Service to find out how to acquire
a Return Authorization (RA) number.
Repair and Service

NLB Model# 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 failure
--------------------~
New Part Sent Date Customer Order #
Return to Stock - Please review NLB return policy

Customer PO# NLB Part#
----------------------
NL B Shipper#
Customer Invoice #
------------
Re as on for returning part
------------------------------------
Restocking Fee Yes No
Customer Service Representative: Date:

-----------
Revision 11
MANUFACTURERS' LITERATURE
Diesel Engine
CUMMINS
JOHN DEERE
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

1012 Series Pump Unit Rev12 Oct2005

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Revision 12

1312D, 1012D, 812D, 612D,

© Copyright October, 2005 NLB Corporation

© Copyright September, 1999 NLB Corporation 0-1

MASTER TABLE OF CONTENTS

DESCRIPTION PAGE NUMBER

Section 3 - PRODUCT OVERVIEW

Section 4 - OPERATION CONTROL

Section 5 - PREVENTIVE MAINTENANCE

© Copyright June, 2005 NLB Corporation 0-2

MASTER TABLE OF CONTENTS (Cont.)

Section 7 - SPECIAL TOOLS

Section 10 - CUSTOMER SUPPORT

Electronic Engine Controller (JOHN DEERE Diesel Engine)

© Copyright June, 2005 NLB Corporation 0-3

MASTER TABLE OF CONTENTS (Cont.)

MANUFACTURERS' LITERATURE (Cont.)

© Copyright June, 2005 NLB Corporation 0-4

© Copyright June, 2005 NLB Corporation 0-5

DESCRIPTION PAGE NUMBER

I. Purpose & Objectives of Manual. ................................... 1-2

© Copyright September, 1999 NLB Corporation 1-1

I. Purposes & Objectives of Manual

Reliability of mechanical equipment depends largely on sound maintenance procedures. All

© Copyright September, 1999 NLB Corporation "1 -2

To order replacement parts call toll-free 1-800-227-7652.

II. Manual Organization

© Copyright September, 1999 NLB Corporation 1 -3

B. Illustrations & Photographs

© Copyright September, 1999 NLB Corporation 1-4

DESCRIPTION PAGE NUMBER

© Copyright January, 2001 NLB Corporation 2-1

I. Safety Precautions That Must Be Observed By User

A. Operator Safety Equipment

© Copyright September, 2003 NLB Corporation 2-2

© Copyright April, 2003 NLB Corporation 2-3

B. Pre-Service Safety Check List

© Copyright January, 2001 NLB Corporation 2-4

PRE-SERVICE SAFETY CHECK LIST - HIGH PRESSURE WATER CLEANING

Figure 2-1. Pre-Service Safety Check List.

© Copyright January, 2001 NLB Corporation 2-5

C. Recommended Safety Procedures Decal

© Copyright January, 2001 NLB Corporation 2-6

IMPORTANT RECOMMENDED SAFETY PROCEDURES

1. SAFETY EQUIPMENT TO BE WORN BY OPERATORS.

2. THE LANCE MUST ALWAYS BE DIRECTLY POINTED AT THE WORK AREA.

3. THE OPERATOR MUST MAINTAIN GOOD FOOTING.

5. NON OPERATORS SHOULD NEVER APPROACH THE OPERATOR WITHOUT FIRST

6. THE OPERATING PRESSURE SHOULD NEVER EXCEED THAT WHICH IS NECESSARY TO

7. NO UNAUTHORIZED ATTACHMENTS OR MODIFICATIONS SHOULD BE MADE TO THE UNIT.

8. OPERATORS SHOULD BE CHANGED ON FREQUENT INTERVALS TO AVOID FATIGUE.

10. EQUIPMENT SHOULD BE PROPERLY MAINTAINED AS OUTLINED IN THE MAINTENANCE

11. ALL OPERATORS SHOULD BE PROPERLY TRAINED AS OUTLINED IN THE MAINTENANCE

Figure 2-2. Recommended Safety Procedures Decal.

© Copyright January, 2001 NLB Corporation 2-7

II. Safety Aspects of High Pressure Water Cleaning Systems

High Pressure Pump

© Copyright January, 2001 NLB Corporation 2-8

B. Personal Protective Equipment

Eye and Face Protection

© Copyright January, 2001 NLB Corporation 2-9

© Copyright January, 2001 NLB Corporation 2-10

Personal Protective Equipment

© Copyright January, 2001 NLB Corporation 2-11