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JAW INSPECTION AND MAINTENANCE 

JAW INSPECTION: S, C, and G JAWS 
WEEKLY INSPECTION 

 

 

 

With  new  S,  C,  or  G  jaw  sets,  the  teeth  will  contact  before  the  cylinders  reach  full 

stroke.  As the teeth continue to wear, the cylinders will reach full stroke and a gap will 

be apparent between the opposing jaws.  If wear continues to this point or beyond, the 

crushing efficiency may decrease and the full cylinder force will be transferred to the 

cylinder end cap (c5) and retaining cap screws (OO). 

 

 

 

This  situation  should  be  avoided.    The  jaws  or  teeth  should  be  inspected  and 

maintained to avoid this gap. 

 

JAW PROFILES:  S, C, AND G JAWS 

S, C, and G JAWS:

  Profiles can be checked against NPK original profile templates.  

Call the NPK Service Department for assistance at 1-800-225-4379. 

 

S JAWS:

  These jaws are hard-faced.  The best time to rebuild them is as soon as the 

hard face pattern is worn off.  If the hard face pattern is gone and wear is in to the jaws 

itself,  the  profile  should  be  rebuilt  to  that  of  the  template.    Do  not  allow  tip  wear  to 

exceed .75” 

(19 mm)

 compared to the template or the cylinder will bottom out. 

 

JAW BUILD-UP AND HARDFACING (M38S, M28S, and M20S) 

For build-up and hard facing of jaw, use the NPK template to check jaws so that they 

are to the original profile.  Contact NPK for the correct templates, drawing no. M3803-

9501  and  M3803-9502  (M38S),  M2803-9500  and  M2803-9501  (M28S),  and  M2003-

9500  and  M2003-9501  (M20S).    Then,  refer  to 

JAW  and  TOOTH  REBUILD 

PROCEDURE. 

 

 

Summary of Contents for M20C

Page 1: ...M28C M28K M38S M38G M38C M38K Use Genuine NPK Parts 7550 Independence Drive Walton Hills OH 44146 5541 Phone 440 232 7900 Toll free 800 225 4379 Fax 440 232 6294 Copyright 2018 NPK Construction Equipment Inc www npkce com M000 9600I 10 18 Material Processor Instruction Manual ...

Page 2: ...IFICATION 26 JAW SET IDENTIFICATION 30 PROCESSOR BOOSTER AND CYLINDER 31 HYDRAULIC INSTALLATION 40 HYDRAULIC KITS 40 FLOW DIRECTION 40 SHUT OFF VALVES 41 TEST PORT LOCATIONS 41 HYDRAULIC QUICK DISCONNECTS 43 PREVENTION OF CONTAMINATION 45 MOUNTING INSTALLATION 46 M SERIES TOP BRACKET 46 MOUNTING TO THE CARRIER 47 REMOVAL FROM THE CARRIER 47 STORAGE OF THE MATERIAL PROCESSOR 48 HOSE INSTALLATION 49...

Page 3: ... JAW CONTACT AREAS 86 S C and G JAW CONTACT AREAS 86 HARDFACING K JAWS 87 FRAME MAINTENANCE REPAIR OF MAIN FRAME 88 ROUTINE WELD REPAIR 88 CYLINDER INSPECTION AND MAINTENANCE 90 BOOSTER CYLINDER 90 DISASSEMBLY 90 INSPECTING AND CLEANING CYLINDER COMPONENTS 93 REPAIR TOOLS AND EQUIPMENT 95 ASSEMBLY 95 SLEWING RING INSPECTION AND MAINTENANCE 102 MEASURING MAXIMUM AXIAL MOVEMENT 102 ROTATION BEARING ...

Page 4: ...ESSURE INTENSIFIER SEQUENCE VALVE AND RELIEF VALVE ACTUATION 133 MATERIAL PROCESSOR SEQUENCE RELIEF VALVE AND CARRIER RELIEF VALVE SETTINGS 134 RELIEF VALVE LOCATION 134 PRESSURE INTENSIFIER OPERATION 137 PRESSURE INTENSIFIER BOOSTER 137 RAPID CONTINUOUS CLICKING IS HEARD AND THE MATERIAL IS NOT BEING CRUSHED SHEARED AS EXPECTED 137 CHECKING BOOSTED PRESSURE 138 SLOW CYCLE SPEED 139 TEST PROCEDURE...

Page 5: ... hazardous situation which if not avoided may result in minor or moderate injury ATTENTION blue notices in NPK Instruction Manuals are an NPK standard to alert the reader to situations which if not avoided could result in equipment damage WARNING FALLING OR FLYING DEBRIS decals are included with each NPK MATERIAL PROCESSOR The decal part number H100 7210 must be installed in the cab visible to the...

Page 6: ...ns see page 9 The excavator must be stable during MATERIAL PROCESSOR operation and during transport 11 Do not operate without inspection access covers in place 12 Be especially cautious around hydraulic lines Hydraulic oil can be extremely HOT Avoid skin contact with hydraulic oil It can cause severe burns 13 Protect hands and body from hydraulic fluids under pressure Escaping high pressure fluid ...

Page 7: ...ure to hazardous fumes Remove all paint grease and oil before heating cutting or welding on the MATERIAL PROCESSOR 6 Be especially cautious around hydraulic lines Hydraulic oil can be extremely HOT Avoid skin contact with hydraulic oil It can cause severe burns 7 Protect hands and body from hydraulic fluids under pressure Escaping fluid under pressure can penetrate the skin causing serious injury ...

Page 8: ...uely to reflect their relationship including proper location position orientation and or alignment DO During assembly observe all markings made during disassembly and all corresponding features of mating parts to ensure proper location position orientation and alignment During disassembly of a sub assembly place removed components on a clean dry surface in proper relative position as an aid in re ...

Page 9: ...recautions contained in this manual Failure to follow safety precautions can result in death personal injury injury to others and property damage Use replacement parts sold by NPK only NPK is not responsible for failures resulting from alterations not approved by NPK or substitution of parts not sold by NPK CARRIER COMPATIBILITY These carrier weight ranges are intended as a guideline only Other fa...

Page 10: ...5 34 5 876 26 53 100 200 1 4 2 8 MODEL Maximum Crushing Force Operating Pressure at Tip US Metric psi bar Ton Ton M20C 3 625 250 78 71 Specifications subject to change without notice Cycle time is full stroke at maximum flow Carrier flow is set at minimal operating pressure of 1000 psi 69 bar Maximum operating pressure is determined by reliefs in the crusher ...

Page 11: ...5 30 3 770 26 53 100 200 1 4 2 8 MODEL Maximum Crushing Force Operating Pressure at Tip US Metric psi bar Ton Ton M20G 3 625 250 84 76 Specifications subject to change without notice Cycle time is full stroke at maximum flow Carrier flow is set at minimal operating pressure of 1000 psi 69 bar Maximum operating pressure is determined by reliefs in the crusher ...

Page 12: ...0 21 1 535 26 53 100 200 1 4 2 8 MODEL Maximum Crushing Force Operating Pressure at Tip US Metric psi bar Ton Ton M20K 3 625 250 91 82 Specifications subject to change without notice Cycle time is full stroke at maximum flow Carrier flow is set at minimal operating pressure of 1000 psi 69 bar Maximum operating pressure is determined by reliefs in the crusher ...

Page 13: ...80 37 940 26 53 100 200 1 4 2 8 MODEL Maximum Crushing Force Operating Pressure at Tip US Metric psi bar Ton Ton M20S 3 625 250 78 71 Specifications subject to change without notice Cycle time is full stroke at maximum flow Carrier flow is set at minimal operating pressure of 1000 psi 69 bar Maximum operating pressure is determined by reliefs in the crusher ...

Page 14: ... 36 2 920 50 80 190 300 1 7 3 1 MODEL Maximum Crushing Force Operating Pressure at Tip US Metric psi bar Ton Ton M28C 3 625 250 116 105 Specifications subject to change without notice Cycle time is full stroke at maximum flow Carrier flow is set at minimal operating pressure of 1000 psi 69 bar Maximum operating pressure is determined by reliefs in the crusher ...

Page 15: ... 35 8 910 50 80 190 300 1 7 3 1 MODEL Maximum Crushing Force Operating Pressure at Tip US Metric psi bar Ton Ton M28G 3 625 250 125 114 Specifications subject to change without notice Cycle time is full stroke at maximum flow Carrier flow is set at minimal operating pressure of 1000 psi 69 bar Maximum operating pressure is determined by reliefs in the crusher ...

Page 16: ... 25 1 637 50 80 190 300 1 7 3 1 MODEL Maximum Crushing Force Operating Pressure at Tip US Metric psi bar Ton Ton M28K 3 625 250 133 121 Specifications subject to change without notice Cycle time is full stroke at maximum flow Carrier flow is set at minimal operating pressure of 1000 psi 69 bar Maximum operating pressure is determined by reliefs in the crusher ...

Page 17: ... 42 1 067 50 80 190 300 1 7 3 1 MODEL Maximum Crushing Force Operating Pressure at Tip US Metric psi bar Ton Ton M28S 3 625 250 115 105 Specifications subject to change without notice Cycle time is full stroke at maximum flow Carrier flow is set at minimal operating pressure of 1000 psi 69 bar Maximum operating pressure is determined by reliefs in the crusher ...

Page 18: ...48 4 1 230 60 100 225 380 2 1 3 8 MODEL Maximum Crushing Force Operating Pressure at Tip US Metric psi bar Ton Ton M38C 3 625 250 143 130 Specifications subject to change without notice Cycle time is full stroke at maximum flow Carrier flow is set at minimal operating pressure of 1000 psi 69 bar Maximum operating pressure is determined by reliefs in the crusher ...

Page 19: ... 45 1 142 60 100 225 380 2 1 3 8 MODEL Maximum Crushing Force Operating Pressure at Tip US Metric psi bar Ton Ton M38G 3 625 250 152 138 Specifications subject to change without notice Cycle time is full stroke at maximum flow Carrier flow is set at minimal operating pressure of 1000 psi 69 bar Maximum operating pressure is determined by reliefs in the crusher ...

Page 20: ... 30 2 766 60 100 225 380 2 1 3 8 MODEL Maximum Crushing Force Operating Pressure at Tip US Metric psi bar Ton Ton M38K 3 625 250 170 154 Specifications subject to change without notice Cycle time is full stroke at maximum flow Carrier flow is set at minimal operating pressure of 1000 psi 69 bar Maximum operating pressure is determined by reliefs in the crusher ...

Page 21: ...48 6 1 234 60 100 225 380 2 1 3 8 MODEL Maximum Crushing Force Operating Pressure at Tip US Metric psi bar Ton Ton M38S 3 625 250 147 134 Specifications subject to change without notice Cycle time is full stroke at maximum flow Carrier flow is set at minimal operating pressure of 1000 psi 69 bar Maximum operating pressure is determined by reliefs in the crusher ...

Page 22: ...aterial can be cut using multiple pass cuts APPETITE GUIDE MILD STEEL MODEL A B C D in mm in mm in mm in mm M20K 12 305 12 305 1 2 12 7 1 2 12 7 M28K 16 406 16 406 5 8 15 9 5 8 15 9 M38K 19 483 19 483 3 4 19 1 3 4 19 1 MODEL E F in mm in mm M20K 2 50 8 1 2 12 7 M28K 2 1 2 63 5 3 4 19 1 M38K 3 76 2 1 25 4 ...

Page 23: ... 23 SERIAL NUMBER LOCATION M20 ...

Page 24: ... 24 SERIAL NUMBER LOCATION M28 ...

Page 25: ... 25 SERIAL NUMBER LOCATION M38 ...

Page 26: ...w NOTE Even numbers indicate male jaws odd numbers indicate female jaws This information is welded onto the jaws in the location shown below C STYLE COMBO CUTTER G STYLE SECONDARY PRIMARY DEMOLITION K STYLE DEMOLITION SCRAP PROCESSING S STYLE PRIMARY DEMOLITION These two items will aid in identifying the exact required parts when ordering For questions please contact the NPK Service Department at ...

Page 27: ...or the demolition of concrete pillars buildings retaining walls bridges and highway barriers that contain a large percentage of steel reinforcement Approximately two thirds of the jaw opening is for cutting steel The tip one third is for breaking concrete ...

Page 28: ... 28 JAW SET IDENTIFICATION G Jaw Set Pulverizer Secondary Concrete Crusher for the downsizing of concrete and the separation of concrete and rebar ...

Page 29: ... 29 JAW SET IDENTIFICATION K Jaw Set Shear for the demolition of steel structures such as buildings and bridges as well as for processing of scrap including steel wood rubber and plastics ...

Page 30: ...cessor S Jaw Set Primary Breaker for the demolition of concrete pillars buildings retaining walls bridges and highway barriers NOTE Jaw sets can easily be removed from and installed onto the Material Processor at the job site see the JAW SET INTERCHANGE section page 110 of this manual ...

Page 31: ... the pressure well beyond the system operating pressure of the excavator The compact NPK Boosted Cylinder System provides a working force equal to a far larger un boosted cylinder which are working at excavator system pressure Because the NPK boosted cylinders are smaller they require less oil for full stroke as compared to large diameter cylinders This reduces cycle time for the NPK Material Proc...

Page 32: ...unger c20 Pilot Check Valve Assembly c21 Check Valve 1 booster piston inner B c22 Check Valve 2 booster piston inner A c23 Check Valve 3 booster sleeve B c24 Check Valve 4 booster sleeve A c25 Check Valve 5 Return c44 Swivel Manifold k2 Carrier Hydraulic Pump k7 Carrier Control Valve v1 Oil Chamber 1 v2 Oil Chamber 2 v3 Oil Chamber 3 v4 Oil Chamber 4 For a complete breakdown of parts in the booste...

Page 33: ...is directed from the carrier control valve k7 to the base end of the cylinders by way of the pilot check valve c20 in the booster assembly When there is no load condition hydraulic pressure is low and no boosted pressure is required c11 Jaw Cylinder c20 Pilot Check Valve Assembly k7 Carrier Control Valve fl1 High Pressure Hydraulic Flow fl2 Low Pressure Hydraulic Flow fl3 Intensified Hydraulic Flo...

Page 34: ... reaches a pre set value the sequence valve c16 shifts and directs oil through the control valve c15 of the booster then to the booster piston c14 This starts the boosting process The booster piston is double ended and provides boost in each direction of booster piston travel c14 Booster Piston c15 Main valve Assembly c16 Sequence Valve Cartridge fl1 High pressure Hydraulic Flow fl2 Low Pressure H...

Page 35: ...l chamber v1 is greater than the area in chamber v4 the pressure in oil chamber v4 is intensified The higher pressure oil is pushed through check valve c24 to the base end of the cylinders c11 and closes check valve c23 c11 Jaw Cylinder c14 Booster Piston c15 Main Valve Assembly c16 Sequence Valve Cartridge c23 Check Valve 3 booster sleeve B c24 Check Valve 4 booster sleeve A v1 Oil Chamber 1 v2 O...

Page 36: ...ng port C1 c26 transfers to port C2 c27 of the piston Oil is also sent to the plunger c19 end of the main valve assembly c15 This shifts the valve as shown in Fig 5 c14 Booster Piston c15 Main Valve Assembly c19 Plunger c26 Port C1 Piston c27 Port C2 Piston fl1 High Pressure Hydraulic Flow fl2 Low Pressure Hydraulic Flow fl3 Intensified Hydraulic Flow ...

Page 37: ...2 The oil in chamber v2 is intensified and sent through check valve 3 c23 to the base end of the cylinders c11 Pilot check valve c20 and check valve 4 c24 are also closed at this time c11 Jaw Cylinder c14 Booster Piston c15 Main Valve Assembly c20 Pilot Check Valve Assembly c23 Check Valve 3 booster sleeve B c24 Check Valve 4 booster sleeve A v2 Oil Chamber 2 v3 Oil Chamber 3 v4 Oil Chamber 4 fl1 ...

Page 38: ...laces the main control valve in position to direct oil to the booster piston to start the next forward piston stroke These forward and reverse piston strokes will continue as long as the excavator s control valve k7 is shifted to send hydraulic flow to the booster and cylinders and that there is sufficient resistance load to keep the booster active c14 Booster Piston c15 Main Valve Assembly c19 Pl...

Page 39: ...of the cylinders c11 A pilot signal from this flow is sent to open the pilot check valve assembly c20 which allows oil to be pushed out of the base end of the cylinders as the cylinder rods retract There is no boost actuation on the jaw open cycle c11 Jaw Cylinder c20 Pilot check valve assembly k7 Carrier Control Valve fl1 High pressure Hydraulic Flow fl2 Low Pressure Hydraulic Flow fl3 Intensifie...

Page 40: ...s electrical or manual controls hoses and fittings boom and stick piping and clamps are provided Combination kits that can be used for hydraulic hammer or compactor driver operation are available See your NPK dealer for details or call NPK direct at 1 800 225 4379 FLOW DIRECTION All NPK Hydraulic Kits The hydraulic flow to close m3 the Material Processor jaws is on the left side of the carrier loo...

Page 41: ...valves k4 on the stick k1 of the carrier Each shut off valve has an ON k5 and an OFF k6 position Make sure both shut off valves are in the ON position before operating your attachment TEST PORT LOCATIONS A NPK Hydraulic Installation Kits have pressure test gauge ports k8 in both shut off valves k4 ...

Page 42: ...tings m18 located on the attachment top bracket m7 C For older units without pressure test ports in the top bracket or for units mounted on a carrier without an NPK Hydraulic Installation Kit it is suggested that you use a correctly sized JIC swivel run tee f3 and a reducer fitting a86 between the whip hose m38 and the joint fitting m18 ...

Page 43: ...mage to the unit That damage is not covered by NPK s warranty 2 Contamination can enter the hydraulic system if the quick disconnect ends are not kept clean The quick disconnects should be capped to keep them clean If this is not done contamination in the quick disconnect will be flushed into the hydraulic system causing internal damage to the Material Processor 3 Most quick disconnects create a r...

Page 44: ...ATION HYDRAULIC QUICK DISCONNECTS NPK has approved quick disconnects Contact your NPK dealer or NPK direct at 1 800 225 4379 for proper sizing of approved NPK quick disconnects for your unit ROFLEX COUPLING STUCCI COUPLING ...

Page 45: ...raulic oil a complete disassembly and clean out must be done to ALL hydraulic components and attachments ALL of the hydraulic lines must be flushed 2 Do not allow any contaminants to mix with the hydraulic oil Take special care in preventing contamination from entering the hydraulic system through the hose or tube connection when installing or removing the attachment Always have caps and plugs rea...

Page 46: ...ut m43 Hex head Cap Screw NOTE NPK Mounting Kits using loose fit bushings to adapt the pins to the top bracket are not compatible for use with quick attaches or pin grabbers M SERIES TOP BRACKET The M Series top bracket is ported for right or left side hose access for rotation and motor case drain line connections ITEM DESCRIPTION BO Holding Valve BQ2 Rotation Motor CW Rotation Hose CX Motor Drain...

Page 47: ...n the shut off valves k4 The hydraulic lines must be handled carefully to prevent contamination from entering the Material Processor or the carrier hydraulic system REMOVAL FROM THE CARRIER 1 Retract the cylinders to open the jaws fully 2 Shut off the carrier s engine and relieve all hydraulic pressure 3 Close the shut off valves 4 Disconnect the hydraulic hoses before laying the Material Processo...

Page 48: ...ssor to the carrier are plugged AS and all hose connections are capped AR and turn shut off valves k4 to the OFF position 2 Grease all lubrication points see the GENERAL MAINTENANCE section under LUBRICATION POINTS 3 If the unit is stored outdoors retract the cylinder and cover with a waterproof tarp ...

Page 49: ...g installation Pressure applied to a twisted hose can result in premature hose failure or loose connections 3 Attach both ends of the hose to their connection points Let the hose find its natural position then tighten both ends of the hose using a wrench t6 and backup wrench t6a 4 Torque hose to specifications NOMINAL THREAD TORQUE HOSE SIZE SIZE ft lbs Nm 1 2 3 4 10 39 52 3 4 1 1 16 12 88 119 1 1...

Page 50: ...e the hose being installed is routed with the proper bend radius to prevent kinking flow restrictions or hose failures at the hose connection HOSE MINIMUM SIZE BEND RADIUS in mm 1 2 7 177 8 3 4 9 5 241 3 1 12 304 8 1 1 4 16 5 419 1 7 Hoses should be used within the following ranges of temperature TEMPERATURE RANGE F C HYDRAULIC FLUID 14 to 176 10 to 80 ATMOSPHERIC 14 to 122 10 to 50 ...

Page 51: ...sor be sure to read the safety information and perform the daily and weekly maintenance as specified in this manual DO NOT OPERATE THE MATERIAL PROCESSOR WITHOUT DEMOLITION GUARDS IN PLACE DO NOT LIFT OR LOAD BEYOND THE CAPACITY OF THE MATERIAL PROCESSOR OR THE CARRIER ...

Page 52: ...ROCESSOR ONLY FOR THE APPLICATION FOR WHICH IT IS INTENDED NPK Material Processors equipped with S style jaws are designed for the primary breakup of concrete such as pillars buildings retaining walls bridges and highway barriers S JAW APPLICATION ...

Page 53: ...OR THE APPLICATION FOR WHICH IT IS INTENDED NPK Material Processors equipped with K style jaws are designed for the demolition of steel structures and for processing steel wood rubber and plastic scrap It is not intended for processing concrete K JAW APPLICATION ...

Page 54: ...IAL PROCESSOR ONLY FOR THE APPLICATION FOR WHICH IT IS INTENDED NPK Material Processors equipped with G style jaws are designed for the downsizing of concrete the separation of concrete and rebar and some primary demolition G JAW APPLICATION ...

Page 55: ...cessors equipped with C style jaws are designed for the demolition of concrete pillars buildings retaining walls bridges and highway barriers that contain a large percentage of steel reinforcement Approximately two thirds of the jaw opening is for cutting steel The tip one third is for breaking concrete C JAW APPLICATION ...

Page 56: ...se the Material Processor with the excavator cylinders fully extended or retracted 2 Do not strike the material with the Material Processor main body DN1 or outer surface of the jaw set DO1 Do not push pull or scrape material with the Material Processor ...

Page 57: ...ny questions on operating the Material Processor please contact your local NPK dealer or call the NPK Service Department at 1 800 225 4379 4 Do not pry twist or pull with the excavator Allow the hydraulic crushing forces of the Material Processor jaw to do the work If the material does not crush completely at first open the jaws and close again in a chewing action The excavator is used as a way of...

Page 58: ...usher hydraulic installation kit without first isolating the line mounted accumulators k23 a The shut off valve k4 in the return line FT must be in the OFF k6 position for use with the processor b On some later NPK Hydraulic Installation Kits the isolation feature is done automatically through the use of an accumulator isolation valve k26 Consult with NPK at 1 800 225 4379 if you are unsure of wha...

Page 59: ...herefore it is extremely important that the following maintenance and inspection procedures be performed daily Grease all lubrication points Use moly EP2 or equivalent grease For lubrication points see GENERAL MAINTENANCE LUBRICATION POINTS Check for oil leaks at the cylinder piston rod c3 the machined surfaces 145 and at all of the Material Processor s hose and fitting connections hf1 ...

Page 60: ...or retighten to torque specifications as required See the FASTENER TORQUE section of this manual Call the NPK Service Department at 1 800 225 4379 if there are any questions regarding torque Check the moveable jaws and main frame for cracks See the FRAME CRACK AND JAW REPAIR section of this manual or contact NPK at 1 800 225 4379 for repair procedure Check the condition of the cutting blades see C...

Page 61: ...ne lubrication point on the other end M28 M38 15 strokes from a grease gun per fitting every 4 hours GR4 SLEWING RING PINION TEETH Two lubrication points 180 apart 5 strokes from a grease gun per fitting per shift GR5 MOTOR PINION One lubrication point on each side of the hydraulic motor located on the top bracket 5 strokes from a grease gun per fitting once per shift GR6 CYLINDER BASE END PINS On...

Page 62: ...d areas of the blades BG to a sharp 90 edge Use care in handling to avoid bodily harm Do not over grind the blades to the point that the surface becomes blue or discolored This will make the blades brittle Cutter blades can be flipped four times to increase service life Replace the cutter blade if it is cracked chipped or worn beyond repair ...

Page 63: ...he FASTENER TORQUE section of this manual BLADE TO BLADE CLEARANCE Fig 1 A blade to blade A A clearance of 010 to 040 0 25 to 1 00 mm should be maintained for optimum performance Install shims BH under blade BG as necessary see fig 1 SHIM KITS MODEL NPK SHIM JAW TYPE KIT PART NUMBER M20 S G C M2000 7000 M28 S G C M2800 7000 M38 S G C M3800 7000 ...

Page 64: ...o ensure that the maximum efficiency is realized DAILY MAINTENANCE Grease the two arm pins and center pivot area two times per shift using an EP 2 grease 15 pumps of grease Check the jaw weldment for cracks Contact NPK at 1 800 225 4379 for repair procedure if a crack is found Inspect for loose broken and missing fasteners Replace and re torque as required See FASTENER TORQUES Check the condition ...

Page 65: ...ercing tip to tunnel blade gap can be increased by removing the tunnel spacer which can be helpful in some piercing operations Removal of the spacer on the M20K increases the gap by 20 inch 5 mm Removal of the spacer on the M28K increases the gap by 47 inch 12 mm Removal of the spacer on the M20K increases the gap by 75 inch 19 mm Fig 2 With weld on piercing tip BD ARM BG PRIMARY CUTTING BLADE BG1...

Page 66: ...PONENT DESCRIPTION and BLADE MAINTENANCE and ADJUSTMENT Steps 1 and 2 ST2 Install the secondary blades in the drive arm Shim to the primary blades Check to ensure that the secondary blade faces are parallel See COMPONENT DESCRIPTION and BLADE MAINTENANCE and ADJUSTMENT Step 3 ST3 Install the guide blade and shim to the side of the piercing tip See COMPONENT DESCRIPTION and BLADE MAINTENANCE and AD...

Page 67: ...NT DESCRIPTION M20K M28K and M38K The arm BD contains the primary cutting blades BG spacer plates DE and piercing tip DA The drive arm BI contains the secondary blades BG1 guide blade DF spacer plate DE tunnel blade DB and spacer DC ...

Page 68: ... PIERCING TIP When replacing or turning cutting blades the following steps must be followed to achieve accurate blade shimming and final blade clearance STEP 1 Start with the male jaw BD which contains the primary blades These blades should be installed first Prior to installing the male jaw blade pocket DM needs to be free from debris and raised edges Clean pockets and remove any raised edges fro...

Page 69: ... of the primary blades BG There should be no gap d95 between either of the primary blades and the straight edge If the primary blades are being turned and a gap d3 is found between either of the primary blades and the straight edge measure the gap using feeler gauges then remove the measured amount from the high blade by grinding blade may require surface grinding at a machine shop If the differen...

Page 70: ...de clearance between the primary and secondary blades Once the primary blades are in place use thread adhesive t41 on the socket head cap screws OO Then torque to NPK specifications see the FASTENER TORQUE CHART STEP 3 Install either reconditioned used or new secondary blades BG1 into female jaw BI blade pockets DM Install socket head cap screws and tighten ...

Page 71: ...he clearance d61 at the second secondary blade and clearance d62 at the third secondary blade NPK shim packs have a variety of shims i e 005 010 024 060 and 120 Install the required amount of shims behind each secondary blade until a clearance of 005 127 mm is achieved between all primary and secondary blades One shim pack for each blade is recommended After blade shimming is complete remove the s...

Page 72: ...ing tip DA Begin closing the processor jaws until the piercing tip just enters the tunnel Stop and measure the clearance d64 between the guide blade and the side of the piercing tip Install the required amount of shims to reduce the clearance to 005 127 mm Apply thread adhesive to the socket head cap screws for the guide blade Then torque to NPK specifications see FASTENER TORQUE CHART Special Not...

Page 73: ... See K JAW BLADE MAINTENANCE AND ADJUSTMENT STEP 5 MAINTENANCE To maintain maximum piercing efficiency the piercing tip should be checked daily for wear The rate of wear that will occur is going to be influenced greatly due to the types of material being processed and the amount of piercing being done To check the jaw and tip for wear close the processor jaws until the piercing tip is beginning to...

Page 74: ...er liner for the M Series Processor K Jaw sets The reason is for repairing a jaw set that becomes slightly bent from the pivot area out to the tip Installing the taper liner should make the surfaces parallel ts1 ts2 M20K 19011029 19011030 M28K 19011031 19011032 M38K 19011033 19011034 ...

Page 75: ... amount of build up that is still required Maintain preheat of the jaw area After build up is complete it may be required to hardface the piercing tip Hardfacing will help prolong the life of the tip and increase the amount of time a tip can be used before maintenance is once again required See JAW AND TOOTH REBUILD PROCEDURE and follow the same directions REPLACING THE PIERCING TIP To install a n...

Page 76: ... of the tip should pass within 045 1 14 mm of the upper lip of the female jaw NOTE Some grinding may be required to fit the tip properly to the tunnel see Fig E Fig E 1 Remove the worn tip by carbon arcing or torch cutting 2 Prepare the surface for the new tip by grinding away any remaining slag 3 Place the new tip into its proper location 4 Dry welding rod to 300 F 150 C 5 Preheat the weld area t...

Page 77: ...mine whether the piercing tip can be built up or should be replaced STEP 1a Place a steel straight edge t15 on the face of the primary blades BG The side of the piercing tip DA should be even parallel with the primary blade face Record the amount of clearance gap d65 between the straight edge and the side of the tip see Fig A Fig A STEP 2a Close the jaws until the piercing tip DA just enters the f...

Page 78: ...he steel straight edge once again on the face of the primary blades to confirm that the side of the piercing tip and primary cutting blades are parallel STEP 5a Slowly close the processor jaws until the piercing tip DA enters the tunnel verify the clearance d66 between the lead edge of the piercing tip DA and the tunnel blade DB This clearance should be approximately 020 040 0 51 1 02 mm Additiona...

Page 79: ...s next to the guide blade DF Measure the clearance and add shims to achieve a clearance d64 of 005 127 mm see Fig D Fig D Apply thread adhesive to the socket head cap screws for the guide blade Then torque to NPK specifications see FASTENER TORQUE CHART STEP 7a After completing all welding maintenance allow the jaw BD to cool slowly ...

Page 80: ...G JAWS Profiles can be checked against NPK original profile templates Call the NPK Service Department for assistance at 1 800 225 4379 S JAWS These jaws are hard faced The best time to rebuild them is as soon as the hard face pattern is worn off If the hard face pattern is gone and wear is in to the jaws itself the profile should be rebuilt to that of the template Do not allow tip wear to exceed 7...

Page 81: ...hould be rebuilt to that of the template Do not allow tip wear to exceed 75 19 mm compared to the template or the cylinder will bottom out JAW BUILD UP AND HARDFACING M38C M28C and M20C For build up and hard facing of jaw use the NPK template to check jaws so that they are to the original profile Contact NPK for the correct templates drawing no M2804 9501 M28C and M2004 9500 M20C Then refer to JAW...

Page 82: ... 400 F 150 C 200 C 6 For joining stringer beads are best For build up weaving is acceptable Use one of the following rods or wire equivalent or equal Airco Austex 361 Cronatron 7770 Eutectic 3205 Hobart Smooth Arc MC McKay Chrome mang Stoody 2110 7 Hard face rod for tooth and structure wear surfaces Pre heat as in Step number 5 Use two passes maximum for hard facing Use one of the following rods o...

Page 83: ... M38 Processors with S C and G jaws The jaws must be built up with hard face weld when the clearance between the tip of the jaws in the closed position is worn to the extent that the material can no longer be crushed efficiently To ensure maximum crushing performance of the Processors this rebuild procedure comprised of three steps should be followed 1 Surface Preparation 2 Underlayment Weld 3 Har...

Page 84: ...alloy 205 Stoody 2110 or equal In Canada NCH Canada Inc Hi Pact 194 or equal Dry welding rod at 300 F 150 C Pre heat the jaw area to 300 400 F 150 200 C and maintain this temperature during the welding operation It is very important to maintain this temperature in cold environments Adjust weld current to rod manufacturer s specifications Peen each layer Cool slowly Cover weld in cold environments ...

Page 85: ...mperature in cold environments Adjust weld current to rod manufacturer s specifications Peen each layer Do not exceed 2 3 layers of hard face Cool slowly Cover weld in cold environments DO NOT WELD OVER OLD HARDFACING Remove all old hard facing before applying new underlay weld 1 BEFORE WELD 2 AFTER WELD CORRECT BD BI MALE OR FEMALE CRUSHER JAW DI WORN AREA we2 UNDERLAYMENT we3 HARDFACE CORRECT BD...

Page 86: ...LD PROCEDURE S JAW C JAW G JAW K JAWS Several surfaces of the K jaws have been hard faced in contact areas Hard facing we3 may be added to increase the wear life of these surfaces The best time to rebuild them is as soon as the hard face pattern is worn off If the hard face pattern is completely worn the surfaces should be rebuilt and hard faced such that they are even with or slightly above the a...

Page 87: ...he lower face of the piercing tip This pattern will allow for the most efficient piercing and the least amount of interference Peen after each pass and maintain inner pass temperature DO NOT APPLY MORE THAN TWO 2 LAYERS OF HARDFACE MATERIAL After hard facing is completed grind the piercing tip to the desired profile Do not pierce with the tip until the tip area temperature has normalized This proc...

Page 88: ...E WELD REPAIR 1 Gouge any cracks 100 using an air or electric hand held grinder t1 carbon arc t12 or torch t13 2a Grind gouged area to a 30 angle on each side to the full depth of the gouged area for plate sizes up to 3 4 19 mm thick 2b Grind gouged area to a 45 angle on each side to the full depth of the gouged area for plate sizes over 3 4 19 mm thick 3 If the crack is completely through the pla...

Page 89: ...CRYSTALLIZATION OF THE WELD AND SUBSEQUENT BREAKAGE NOTE NPK Construction Equipment Inc has developed this repair procedure based on known information about structure and material This however does not imply that repairs made using this procedure are guaranteed to be successful NPK therefore cannot warranty this procedure There is NO warranty regarding this repair either expressed or implied ...

Page 90: ... from the cylinder assembly c11 NOTE See the Booster Manual B000 9600 for booster maintenance 2 Remove the spacers bs23 o rings RR and backup rings SS from the cylinder assembly c11 3 Remove the cylinder end cap socket head cap screws OO 4 Remove the cylinder rod assembly c48 from the cylinder housing c4 ...

Page 91: ...one preferably NPK polishing wheel p n 25026030 and polish the rings until they spring out of their grooves If a ring is broken it must be replaced 6 Using a ring expander t16 remove all of the piston rings 7 If used lightly heat the rod nut set screw to loosen any thread adhesive that is present Remove the rod nut set screw c6 8 Unscrew the rod nut c1 and remove the piston c2 from the cylinder ro...

Page 92: ...TENANCE BOOSTER CYLINDER DISASSEMBLY 9 Remove the dirt seal QQ rod seal PP o ring RR and backup rings SS from the cylinder end cap c5 and discard 10 Remove the o ring RR and backup rings SS from the inside of the piston c2 and discard ...

Page 93: ...heads and threads of all fasteners and plugs and corresponding threaded bores for damage Repair or replace as required 2 Inspect all components particularly machined surfaces including all hydraulic ports for evidence of scratches scoring nicks dents wear deformity or other damage Particularly close attention should be given to o ring grooves and counter bores Repair or replace as required 3 Inspe...

Page 94: ...igh strength part It is not possible to repair the rod If the rod is bent or damaged it must be replaced 8 Clean all parts with a degreaser solvent using a Scotchbrite or equivalent cleaning pad Compressed air can cause injury or death Limit air pressure to a maximum of 30 psi 2 bars Protect your eyes with safety glasses Do not direct compressed air current at exposed skin Do not direct compressed...

Page 95: ...recommended Polishing wheel for grinder NPK p n 25026030 NPK Assembly Lube p n H010 5010 Emery cloth 200 grit Cleaning solvent ASSEMBLY 1 Install the dirt seal QQ backup ring SS and piston seal PP into the seal grooves on the inner side of the cylinder end cap c5 Install the o ring and backup ring into the outer groove ...

Page 96: ...seal backup ring and piston seal Install the cylinder end cap c5 onto the cylinder rod 3 Install the o ring RR and backup rings SS into the piston c2 Apply a light coat of hydraulic oil or NPK Assembly Lube to the o ring and backup ring after installation 4 Install the piston c2 with the dimple 24 facing away from the rod eye onto the cylinder rod c3 ...

Page 97: ...er rod nuts without set screws have a nylon patch and do not require thread adhesive 6 There are three styles of piston lock nuts c1 Lock nut set screw c6 location changes Style A shows the early factory style Style B shows the current factory style Style C shows the replacement style Style C uses a nylon patch c52 instead of a set screw Style A Style B Style C ...

Page 98: ...80 1000 8 Install the set screw If the original factory lock nuts are to be re used a dimple must be drilled into the piston rod Style A type or the piston Style B type using the existing threaded hole as a guide The maximum depth of the hole should not exceed 1 64 th inch 0 5 mm Apply a small amount of medium strength thread adhesive to the set screw before installing If the lock nut is replaced ...

Page 99: ...side diameter of the piston and piston rings 11 Install the cylinder rod assembly c48 slowly into the cylinder housing c4 taking care not to damage the piston rings c8 12 Install the cylinder end cap socket head cap screws OO and torque to the value listed below MODEL BOLT TORQUE SIZE ft lb Nm M20 M18 2 5 260 350 M28 M18 2 5 260 350 M38 M18 2 5 260 350 ...

Page 100: ...ix for M38 units new backup rings SS four quantity of six for M38 units new o rings RR and the two quantity of three for M38 units spacers bs23 then install in the corresponding counter bores of the main cylinder assembly c11 14 Apply a light coat of oil or NPK Assembly Lube to the mating surfaces of the booster main body ...

Page 101: ... eye bolts in the threaded bores on top of the booster assembly Lift and move the booster assembly using a hoist 16 Apply high strength thread sealant to the clean dry threads of the eight previously removed cap screws 17 Secure the main booster assembly to the cylinder housing using the eight cap screws and washers Tighten the cap screws in an opposing pattern Torque to value listed below MODEL B...

Page 102: ...he other end of the dial onto the top bracket face as shown Using the excavator slightly rock the processor back and forth using slight stick movement Note the movement shown on the dial Take this reading d59 in four places If your readings are greater than shown please contact the NPK Service Department at 1 800 225 4379 MODEL NEW MAXIMUM in mm M20 010 0 25 M28 010 0 25 M38 010 0 25 MAXIMUM MODEL...

Page 103: ...ding areas 3 Clean seal groove with brake clean solvent and allow time to dry completely 4 Apply a small amount of high strength adhesive into the groove and install one end of the seal Take care not to get adhesive on the lower lip of the seal 5 Insert seal into the groove and work around the slewing ring applying a small amount of adhesive every 12 in 300 mm Take care not to stretch the seal as ...

Page 104: ... main parts the Spindle Case BZ which contains the oil seals and the Spindle CA which rotates with the processor frame see Fig 1 Fig 1 LEAKAGE OF THE SEALS External leakage or internal bypassing of hydraulic fluid will require the replacement of the seals in the swivel assembly For external leakage please review the seal replacement procedure in the REPLACEMENT OF THE SEALS IN THE SWIVEL section o...

Page 105: ...ng check that the relief valve cartridges have not loosened in their blocks Fig 2 Fig 3 Test Procedure Install 0 to 5 000 psi 0 to 350 bar gauges in the NPK stop valves located on the stick of the carrier or in gauge ports in the open and close circuits located near the end of the stick for carriers without an NPK hydraulic kit Close the jaw and keep the function activated then read the pressure i...

Page 106: ...shown in Fig 4 installed to prevent rotation during repair Fig 4 STEP 1 Fig 5 Disconnect the rotation hoses m39 at the counterbalance valve BO Remove the rotation motor hoses and motor fittings f1 from the hydraulic motor Disconnect the cylinder hoses AO at the side plates of the top bracket Do not remove the cylinder hoses and fittings from the Spindle Case BZ They will be used to help lift it of...

Page 107: ...ly Pull the Spindle Case off of the Spindle the cylinder hoses can be used for this Fig 6 STEP 3 Fig 7 Inspection Visually inspect the sealing surfaces 120 of the Spindle CA for damage which may hamper the ability of the o rings to seal Polishing the surface may clean up light scratching Heavy scratching or galling may indicate rotator bearing play Fig 7 ...

Page 108: ...he o rings and back up rings with a seal pick note the order of placement Check the grooves 118 in the Spindle Case BZ for burrs or scoring damage Light grinding or polishing may be required Fig 8 STEP 5 Fig 9 Lubricate the o rings RR and back up rings SS with grease Install the back up rings first taking care not to crimp or fold them Install the o rings Refer to the illustration for o ring and b...

Page 109: ...P N H010 5010 Install the hoses onto the Spindle Case BZ Slide the Spindle Case over the Spindle which includes the relief valve cartridges c17 c18 Install the washer U and snap ring AJ Reconnect the cylinder hoses to the top bracket install the fittings into the hydraulic motor and install the hydraulic motor hoses ...

Page 110: ... model being worked on Three wood blocks 4 x 4 100 x 100 mm or larger 14 mm hex key socket available as NPK part no M380 1000 14 mm hex key wrench 1 2 drive breaker bar 3 4 or 1 2 air gun if available Brass drift pin Dead blow hammer or non metallic rod or hammer such as nylon or wood Ball peen hammer Sledge hammer NPK assembly tube p n 35027310 for the M20 and 35027200 for the M28 and M38 models ...

Page 111: ...ned with the pins parallel to the ground Changing the jaw sets with the pins perpendicular to the ground is possible but more difficult Removal of a jaw set from the Material Processor may be accomplished with more ease if the jaw set is in the open position Cap the hydraulic ports at this time 1 To place the unit in the best position wrap a lifting strap or chain around one of the cylinder sub as...

Page 112: ... wood block under the cylinder rod cover near the cylinder rod pin 4 Reposition the lifting strap or chain t4 by wrapping it through the bore of the uppermost jaw BI For safety maintain crane or lifting device engagement The unit is now positioned for detachment of the jaws from the cylinders and detachment of the jaw set from the main frame by removal of the three pins circled in the illustration...

Page 113: ...damage when the cylinder jaw pin c9 is removed 6 Early units Begin with either of the cylinder jaw pins Using a hex key socket t42 remove the two socket head cap screws OO that secure the cylinder pin lock plate Later units Begin with either of the cylinder jaw pins Using a hex key socket t42 remove the socket head bolt OO that secures the cylinder pin lock plate EARLY UNITS LATER UNITS ...

Page 114: ... c30 Later units Using a socket remove the cylinder pin locking plate c31 NOTE Left hand thread c57 EARLY UNITS LATER UNITS 8 Remove the cylinder pin as shown EARLY UNITS LATER UNITS Once the cylinder jaw pin is removed the jaw may rock forward 9 Repeat steps six through eight to detach the second jaw from the second cylinder sub assembly ...

Page 115: ...ead cap screw OO on the pivot pin nut c32 11 Using a hex key socket t42 remove the socket head cap screw OO 12 Loosen the pivot pin nut c32 with a spanner wrench or by angling a brass drift pin t43 into one of the blind holes and tapping with a hammer t29 Avoid damaging the threads in the frame ...

Page 116: ...ube NPK part no 35027310 for M20 units or part no 35027200 for M28 M38 units is used to keep the jaws united as the jaw pivot pin is removed 15 Set the assembly tube in the bore snugly against the jaw pivot pin 16 Install the assembly tube t44 by carefully driving it through the bore This action will simultaneously push the jaw pivot pin BJ out the other side and lock the jaws together Continue ca...

Page 117: ...he removal of the jaw pivot pin by pulling it out or tapping on the underside of the pin s head Avoid damaging the threads 177 when the pin is removed JAW SET REMOVAL 20 For easier removal of the jaw set DO from the main frame DN chain t4 or strap the jaws together to restrict their movement Remove the jaw set from the main frame with a crane or other lifting device by moving it horizontally out n...

Page 118: ...the jaw set DO into the main frame DN chain t4 or strap the jaws together to restrict their movement Wrap a lifting chain or strap through the bore in the upper jaw and attach it to a crane or other lifting device 2 Lift the jaw set DO and insert it horizontally into the main frame DN from the front do not move up or down For better movement control a second strap or chain can be used to help leve...

Page 119: ...ve the assembly tube Continue driving the jaw pivot pin BJ in until the head plate is flush with the main frame DN The pin may have to be turned so that it will seat properly 5 Install the pivot pin nut c32 Tighten with a spanner wrench or by driving with a brass drift pin t43 The bore on the pivot pin nut c32 must be aligned with the threaded bolt bore 75 on the main frame ...

Page 120: ...anual for the correct torque ATTACHMENT OF THE JAWS TO THE CYLINDER SUB ASSEMBLIES 7 Begin with either of the cylinder jaw pins Align the bore on the jaw with the bore on the cylinder 8 Insert the cylinder jaw pin c9 into the bore EARLY UNITS LATER UNITS 9 Early units Install the cylinder pin lock plate c30 Later units Install the cylinder pin lock plate c31 NOTE Left hand thread c57 EARLY UNITS L...

Page 121: ... a hex key socket t42 install the socket head cap screw OO securing the cylinder pin lock plate See the FASTENER TORQUE CHART section of this manual for the correct torque EARLY UNITS LATER UNITS 11 Remove the chain that is holding the jaws together Lift the unit so as to align the bore of the second jaw BD with the cylinder jaw pin bore c33 on the second cylinder c11 12 Repeat steps eight through...

Page 122: ...d with solvent and finally cleaned with compressed air Threaded holes must be cleaned with a thread tap solvent and also with compressed air Use a common chassis or wheel bearing grease on fasteners listed as lubed Grease the threads of the bolt and the contact surface under the bolt head Grease the contact surface of nuts Use a few drops of medium strength thread adhesive on the threads of fasten...

Page 123: ...190 255 LUBED M28 M16 190 255 LUBED M38 M16 190 255 LUBED CUTTING BLADE M20 M16 190 255 LUBED G S JAWS M28 M20 360 490 LUBED M38 M24 530 720 LUBED CUTTING BLADE M20 M16 190 255 LUBED C K JAWS M28 M20 360 490 LUBED M38 M24 530 720 LUBED TUNNEL FRONT M20 M16 190 255 LUBED BLADE K JAW M28 M20 360 490 LUBED M38 M24 530 720 LUBED TOOTH PLATE M20 M20 365 495 ADHESIVE G JAW M28 M24 640 870 ADHESIVE M38 M...

Page 124: ...UNITS M38 M20 360 490 LUBED WEAR PLATE M20 M12 93 125 ADHESIVE M28 M12 93 125 ADHESIVE M38 M12 93 125 ADHESIVE BOOSTER M20 M16 225 300 ADHESIVE ASSEMBLY M28 M16 225 300 ADHESIVE M38 M16 225 300 ADHESIVE SWIVEL BLOCK M20 M12 93 125 ADHESIVE TO CYLINDER M28 M12 93 125 ADHESIVE EARLY UNITS M38 M12 93 125 ADHESIVE SWIVEL BLOCK M20 M16 225 300 ADHESIVE TO CYLINDER M28 M16 225 300 ADHESIVE LATE UNITS M3...

Page 125: ...ER GUARD M28 M18 260 350 LUBED EARLY UNITS M38 M18 260 350 LUBED CYLINDER GUARD M28 M20 360 490 LUBED LATE UNITS M38 M20 360 490 LUBED WEAR PLATE M20 M12 93 125 ADHESIVE M28 M12 93 125 ADHESIVE M38 M12 93 125 ADHESIVE CYLINDER MANIFOLD M20 M16 225 300 ADHESIVE ASSEMBLY M28 M16 225 300 ADHESIVE M38 M16 225 300 ADHESIVE CHECK VALVE CAP M20 M12 93 125 ADHESIVE M28 M12 93 125 ADHESIVE M38 M12 93 125 A...

Page 126: ...E ROTATION MOTOR M20 M16 225 300 ADHESIVE M28 M16 225 300 ADHESIVE M38 M16 225 300 ADHESIVE MOTOR PINION M20 M12 93 125 ADHESIVE GEAR M28 M12 93 125 ADHESIVE M38 M12 93 125 ADHESIVE COUNTERBALANCE M20 M12 95 130 LUBED VALVE M28 M12 95 130 LUBED M38 M12 95 130 LUBED COUNTERBALANCE M20 M12 95 130 LUBED VALVE PLATE M28 M12 95 130 LUBED M38 M12 95 130 LUBED SWIVEL MANIFOLD M20 M20 430 580 ADHESIVE ASS...

Page 127: ...4 12 1 1 16 12 1 79 88 107 119 1 16 1 5 16 12 1 108 113 146 153 1 1 4 20 1 5 8 12 1 127 133 172 180 ORFS ENDS NOMINAL SIZE FITTING DASH SIZE THREAD SIZE NUMBER OF FLATS FROM FINGER TIGHT TORQUE ft lb Nm 1 2 8 13 16 16 1 25 1 75 32 35 43 48 3 4 12 1 3 16 12 1 25 1 75 65 70 88 95 1 16 1 7 16 12 1 25 1 75 92 100 125 136 1 1 4 20 1 11 16 12 1 25 1 75 125 140 170 190 ...

Page 128: ...her the NPK Material Processor or the carrier s hydraulic system hydraulic installation kit for the Material Processor Checking the hydraulic pressure and flow will determine if the problem is in the Material Processor or the carrier If the pressure and flow to the Processor are correct the problem is in the Material Processor LOSS OF POWER Loss of power can be caused by a low carrier relief valve...

Page 129: ...aws fully open and fully closed Setting should be 3 625 psi 250 bar Check relief cartridges for tightness Tighten the relief valve cartridges Check relief cartridges for mis adjustment Reset to 3 625 psi 250 bar If unable to adjust replace the cartridge Check the o rings and backup rings of the relief valve cartridges Replace the o rings and backup rings of both relief valve cartridges Pilot check...

Page 130: ...eplace the sequence valve cartridge NOTE The sequence valve cartridge is not adjustable Check the o rings and backup rings of the sequence valve cartridge Replace the o rings and backup rings of the sequence valve cartridge Booster control valve assembly Dis assemble the main valve and inspect the spring plungers and for free movement of the spool Polish or replace as necessary Booster assembly Di...

Page 131: ...re gauge g8f 5000 psi 350 bar Test port adapter g20 to fit 4 SAE female port in NPK shut off valve k4 Test hose t81 5000 psi 350 bar rated RELIEF VALVE CHECKING AND SETTING PROCEDURE NPK Hydraulic Installation Kits provide shut off valves k4 with test ports k8 in both the jaw open m4 and close lines m3 Install pressure test hoses in both test ports ...

Page 132: ...e end of the stick B Turn the shut off valve k4 in the close circuit to the OFF position k6 C Start the carrier Set the throttle to the FULL position Actuate the hydraulic circuit to close the jaws D The pressure reading should be at least 200 psi 14 bar above the Material Processor operating pressure Note If the excavator relief setting is less than 200 psi 14 bar above the Material Processor ope...

Page 133: ...nsifier or cylinder leakage E Open the Material Processor jaws to the fully open position and hold for 10 seconds Check the pressure reading on the gauge and compare to the specified Material Processor relief valve setting If it is not the same reset the Material Processor relief valve accordingly PRESSURE INTENSIFIER SEQUENCE VALVE AND RELIEF VALVE ACTUATION Close the jaws without material in the...

Page 134: ...LIEF VALVE RELIEF VALVE VALVE SETTING SETTING SETTING psi bar psi bar psi bar M20 ALL 2 950 205 3 625 250 3 825 265 M28 ALL 2 950 205 3 625 250 3 825 265 M38 ALL 2 950 205 3 625 250 3 825 265 RELIEF VALVE LOCATION The Material Processor relief valve cartridges close c17 and open c18 are located in the relief blocks bs24 that are bolted to the rotary joint assembly BN ...

Page 135: ...ve cartridges Booster sequence valve cartridge Observe sequence valve operation See PRESSURE INTENSIFIER SEQUENCE AND RELIEF VALVE ACTUATION Replace the sequence valve cartridge NOTE The sequence valve cartridge is not adjustable Check the o rings and backup rings of the sequence valve cartridge Replace the o rings and backup rings of the sequence valve cartridge Booster control valve assembly Dis...

Page 136: ...ings and backup rings Clean the orifice and replace the o rings and backup rings See Service Bulletin SB04 4 Pilot check valve assemblies Inspect the booster inlet pilot check valve assemblies for damaged seats Replace the inlet pilot check valve assemblies Booster assembly Check poppets and seats Replace poppets and seats as necessary Check all o rings and backup rings Replace all o rings and bac...

Page 137: ...ue until the material is either cut crushed or the Material Processor meets full resistance At full resistance the clicking will slow dramatically or sometimes stop completely PRESSURE INTENSIFIER BOOSTER The control valve bs10 sequence valve bs4 and booster assembly bs27 make up the pressure intensifier assembly RAPID CONTINUOUS CLICKING IS HEARD AND THE MATERIAL IS NOT BEING CRUSHED SHEARED AS E...

Page 138: ...ivel adapter onto the male adapter No thread sealant required 4 Close the jaws all the way Pressure will rise to the point where intensification starts P1 on page 133 Then it will go up to the full boosted pressure of approximately 12 000 psi 800 bar When the clicking of the booster slows it is at full intensification click click click etc is normal If the clicking continues rapidly and will not s...

Page 139: ...NPK shut off valve k4 Test hose t81 5000 psi 350 bar rated Loading type hydraulic flow meter t36 100 gpm 380 l m hydraulic flow capacity TEST PROCEDURE Install a pressure gauge into the test port of the jaw close circuit left shut off valve as seen from the operator s position Fully stroke the Material Processor cylinders Measure the attachment operating pressure SLOW CYLINDER SPEED PROBLEM CAUSE ...

Page 140: ...k pressure with the jaws fully open and fully closed Setting should be 3 625 psi 250 bar Check relief cartridges for tightness Tighten the relief valve cartridges Check relief cartridges for mis adjustment Reset to 3 625 psi 250 bar If unable to adjust replace the cartridge Check the o rings and backup rings of the relief valve cartridges Replace the o rings and backup rings of both relief valve c...

Page 141: ... Install the flow meter t36 between the Material Processor close m3 and open lines m4 as shown Typically the jaw close line is on the left and the jaw open is on the right of the Material Processor looking from the operator s seat 2 Determine the return line pressure pressure drop Open both shut off valves k4 and energize the Material Processor close switch Measure the pressure on the flow meter g...

Page 142: ... f1 to zero restriction fully open Set the engine throttle to the maximum full position Energize Material Processor to close switch Slowly turn the loading valve knob fm1 clockwise and record the pressure and flow at regular pressure intervals pr on graph paper Record pressure on one axis of the graph and flow fl on the other This is the circuit flow chart Refer to the MODEL SPECIFICATIONS section...

Page 143: ... OR THE CARRIER 1 Remove the hoses m3 and m4 from the joint fittings on the outside of the Material Processor s frame and close the shut off valves on the carrier 2 Cap AR the joint fittings and plug AS the hoses Fitting size is 20 JIC IF THE JAW DRIFTS The problem is in the cylinder intensifier pilot checks or internal leakage in the swivel manifold of the Material Processor GX IF NO DRIFT OCCURS...

Page 144: ...rocessor MODEL ROTATION APPROXIMATE CARRIER RELIEF SPEED FLOW VALVE SETTING rpm gpm lpm psi bar M20 6 5 10 2 5 4 10 15 3 000 205 M28 6 5 10 2 5 4 10 15 3 000 205 M38 6 9 2 5 4 10 15 3 000 205 Adjust the rotation flow so that the rpm is within the guidelines shown for the model number you have Flows are checked at a normal operating pressure of 1000 psi 70 bar The relief listed in the above chart i...

Page 145: ...e valve pressure settings for both directions adjust counterbalance valve pressure settings Replace counterbalance valve Broken pinion gear or hydraulic motor shaft Check pinion gear and hydraulic motor shaft Replace pinion gear or hydraulic motor Unit will not hold position Pressure setting of Material Processor rotation counterbalance valves Check counterbalance valve pressure settings for both ...

Page 146: ...ition the attachment so it will not rotate c Attempt to rotate the unit in both directions Each gauge should read 2000 psi 138 bar d If 2000 psi 138 bar is not achieved adjust the cross port relief valve cartridges ma4 on the counterbalance valve BO e If adjustment is not possible call the NPK Service Department at 1 800 225 4379 2 Check motor shaft and pinion gear UNIT WILL NOT HOLD POSITION Foll...

Page 147: ...OTH PLATE male jaw BG PRIMARY BLADE BG1 SECONDARY BLADE BN ROTARY JOINT ASSEMBLY BO ROTATION VALVE BQ2 HYDRAULIC MOTOR bs35 BOOSTER ASSEMBLY BT SLEWING RING c11 CYLINDER ASSEMBLY c32 PIVOT PIN NUT c35 MANIFOLD BLOCK DN MAIN FRAME DP LOCK PIN m 7 TOP BRACKET m18 JOINT FITTING ...

Page 148: ...S FOR COMMON PROCESSOR CYLINDER COMPONENTS bs35 BOOSTER ASSEMBLY bs38 SWIVEL BLOCK bs41 MANIFOLD BLOCK c 1 CYLINDER ROD NUT c 2 PISTON c 3 CYLINDER ROD c 4 CYLINDER MAIN BARREL c 5 CYLINDER END CAP c 8 PISTON RING ...

Page 149: ... 149 WARRANTY STATEMENTS ...

Page 150: ... 150 WARRANTY STATEMENTS ...

Page 151: ...ERIAL NUMBER ______________ NPK INSTALLATION KIT NUMBER ___________________________ EXCAVATOR MANUFACTURER MODEL NUMBER SERIES SERIAL NUMBER DATE OF INSTALLATION __________________ DATE OF 20 HOUR INSPECTION ___________WARRANTY REGISTRATION SENT SERVICE RECORD DATE ...

Page 152: ... Copyright 2018 NPK Construction Equipment Inc www npkce com M000 9600I 10 18 Material Processor Instruction Manual ...

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