NPK M35G Instruction Manual Download Page 102

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102

TROUBLESHOOTING

PRESSURE INTENSIFIER OPERATION

NPK’s exclusive pressure intensifier system is used in NPK M35 Material Processors to

boost cylinder pressure to increase the jaw closing forces. When the intensifier is

working properly, a rapid clicking sound will be heard, indicating that the pressure

intensifier is being actuated as the jaws begin to close against resistance. As the jaws

grasp tighter onto the material, the clicking will begin to slow down. This slowing will

continue until the material is either cut/crushed or the M35 Material Processor meets full

resistance. At full resistance, the clicking will slow dramatically or sometimes stop

completely.

PRESSURE INTENSIFIER (BOOSTER)

The control valve (bs10) and booster assembly (bs27) make up the pressure intensifier

assembly.

RAPID CONTINUOUS CLICKING IS HEARD AND THE

MATERIAL IS NOT BEING CRUSHED/SHEARED AS

EXPECTED

This indicates that the problem is not a relief setting, but it is in the intensifier or the

cylinder of the M35 Material Processor. This requires further investigation by a

mechanic/technician, see

“INTENSIFIER CHECKS”

(clicks – does not slow down)

section on page 101.

Summary of Contents for M35G

Page 1: ... M35S 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 9601B M35 Material Processor Instruction Manual 10 18 ...

Page 2: ...IER 32 STORAGE OF THE M35 MATERIAL PROCESSOR 33 HOSE INSTALLATION 34 WHIP HOSE INSTALLATION TIPS 34 OPERATING INSTRUCTIONS 36 OPERATING TECHNIQUES AND PRECAUTIONS 40 GENERAL MAINTENANCE 42 DAILY INSPECTION AND MAINTENANCE 42 LUBRICATION POINTS 43 HOSE INSTALLATION TIPS 44 CUTTER BLADE MAINTENANCE 46 G and S JAWS 46 M35K JAW MAINTENANCE 48 DAILY MAINTENANCE 48 CUTTER BLADE MAINTENANCE 49 K JAWS 49 ...

Page 3: ... TORQUE SPECIFICATIONS 90 HOSE TORQUE SPECIFICATIONS 92 TROUBLESHOOTING 93 DETERMINE THE TYPE OF PROBLEM 93 DETERMINE THE CAUSE OF THE PROBLEM 93 LOSS OF POWER 93 TROUBLESHOOTING GUIDE FOR LOW POWER 94 RELIEF VALVE CHECKS 94 MEASURING OPERATING PRESSURES 96 RELIEF VALVE CHECKING AND SETTING PROCEDURE 96 PRESSURE INTENSIFIER SEQUENCE VALVE AND RELIEF VALVE ACTUATION 98 M35 MATERIAL PROCESSOR RELIEF...

Page 4: ... 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 5: ...ns see page 8 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 6: ...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 7: ...tion 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 assembly Always inspect threaded areas on components Rep...

Page 8: ...e safety precautions 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 EXCAVATOR COMPATIBILITY These carrier weight ranges are intended as a guideline o...

Page 9: ... 38 6 981 50 80 190 300 1 6 3 1 MODEL Maximum Crushing Force Operating Pressure at Tip US Metric psi bar Ton Ton M35G 3 700 255 127 115 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 10: ...0 22 559 50 80 190 300 1 6 3 1 MODEL Maximum Crushing Force Operating Pressure at Tip US Metric psi bar Ton Ton M35K 3 700 255 125 113 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: ... 43 1 092 50 80 190 300 1 6 3 1 MODEL Maximum Crushing Force Operating Pressure at Tip US Metric psi bar Ton Ton M35S 3 700 255 110 100 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: ...ties listed below are based on a single pass cut Larger material can be cut using multiple pass cuts APPETITE GUIDE MILD STEEL MODEL A B C D in mm in mm in mm in mm M35K 16 406 16 406 5 8 15 9 5 8 15 9 MODEL E F in mm in mm M35K 2 1 2 63 5 3 4 19 1 ...

Page 13: ... 13 SERIAL NUMBER LOCATION M35 ...

Page 14: ... 14 JAW SET IDENTIFICATION G Jaw Set Pulverizer Secondary Concrete Crusher for the downsizing of concrete and the separation of concrete and rebar ...

Page 15: ... 15 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 16: ...ker for the demolition of concrete pillars buildings retaining walls bridges and highway barriers Jaw sets can easily be removed from and installed onto the Material Processor at the job site see the JAW SET INTERCHANGE section page 78 of this manual ...

Page 17: ...re well beyond the system operating pressure of the excavator The compact NPK Boosted Cylinder System provides a working force equal to a far larger non boosted cylinder which is working at excavator system pressure Because the NPK boosted cylinder is smaller it requires less oil for full stroke as compared to a large diameter cylinder This reduces cycle time for the NPK Material Processor To open...

Page 18: ...c15 Main Valve Assembly c17 Relief Valve close c18 Relief Valve open c19 Plunger 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 c26 Port C1 Piston c27 Port C2 Piston c28 Port C3 Piston c44 Swivel Manifold c47 Small Plunger k2 Carrier Hydra...

Page 19: ...o be crushed or sheared is encountered oil is directed from the carrier control valve k7 to the base end of the cylinders by way of the pilot check valves c20 in the booster assemblies 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 ...

Page 20: ...lose the hydraulic pressure in the booster unit starts to rise which redirects the hydraulic 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 ...

Page 21: ...Because the area of the booster pistons in oil chambers v1 is greater than the area in chambers v4 the pressure in oil chambers v4 is intensified The higher pressure oil is pushed through check valves c24 to the base end of the cylinders c11 and closes check valves c23 c11 Jaw Cylinder c14 Booster Piston c15 Main Valve Assembly c23 Check Valve 3 booster sleeve B c24 Check Valve 4 booster sleeve A ...

Page 22: ...ons c14 reaches their full stroke oil entering port C1 c26 transfers to port C2 c27 of the pistons Oil is also sent to the plunger c19 end of the main valve assemblies 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 ...

Page 23: ...okes the booster pistons toward oil chambers v2 The oil in chambers v2 is intensified and sent through check valves 3 c23 to the base end of the cylinders c11 Pilot check valves c20 and check valves 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 Oi...

Page 24: ...ntrol valve spools toward the plungers This places the main control valves in position to direct oil to the booster pistons 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 boosters and cylinders and that there is sufficient resistance load to keep the booster active c...

Page 25: ...ected through the boosters to the rod ends of the cylinders c11 A pilot signal from this flow is sent to open the pilot check valve assemblies 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 ...

Page 26: ...sed 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 looking from the operator s seat and to open m4 the jaws is on the right SHUT OFF VALVES Most NPK Hydraulic Installation Kits use ...

Page 27: ...rts k8 in both the pressure and return joint fittings 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 28: ...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 29: ...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 30: ...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 31: ...Nut 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 M35 SERIES TOP BRACKET The M35 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 ...

Page 32: ...e shut off valves k4 The hydraulic lines must be handled carefully to prevent contamination from entering the M35 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 M35 Material Proc...

Page 33: ...rocessor 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 34: ...ing 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...

Page 35: ...sure 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 36: ...r be sure to read the safety information and perform the daily and weekly maintenance as specified in this manual DO NOT OPERATE THE M35 MATERIAL PROCESSOR WITHOUT DEMOLITION GUARDS IN PLACE DO NOT LIFT OR LOAD BEYOND THE CAPACITY OF THE M35 MATERIAL PROCESSOR OR THE CARRIER ...

Page 37: ...IAL PROCESSOR ONLY FOR THE APPLICATION FOR WHICH IT IS INTENDED NPK M35 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 38: ...OR THE APPLICATION FOR WHICH IT IS INTENDED NPK M35 Material Processors equipped with K style jaws are designed for the demolition of steel structures and for processing of steel wood rubber and plastic scrap It is not intended for processing concrete K JAW APPLICATION ...

Page 39: ...ROCESSOR ONLY FOR THE APPLICATION FOR WHICH IT IS INTENDED NPK M35 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 40: ...o not push pull or scrape material with the M35 Material Processor 3 For the most efficient operation open the jaw only wide enough to grasp the material Grasp the material to be crushed as deep into the throat of the M35 Material Processor as possible Do not force the material into the jaw If you have any questions on operating the M35 Material Processor please contact your local NPK dealer or ca...

Page 41: ...r cutters on the S and G jaw sets to cut rod over 1 1 4 in diameter 6 Do not operate the M35 Material Processor on an excavator with an NPK combination Hydraulic Hammer Crusher 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 Inst...

Page 42: ...ylinder piston rod c3 the machined surfaces 145 and at all of the M35 Material Processor s hose and fitting connections hf1 Inspect the hydraulic hoses for wear damage or oil leakage Inspect for loose broken and missing fasteners Replace and 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 ar...

Page 43: ...brication point on the other end later K jaws 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 44: ...e hose failure or loose connections Attach both ends of the hose to their connection points Let the hose find its natural position then tighten both ends using a wrench and backup wrench 3 Torque hose to specifications see HOSE TORQUE SPECIFICATIONS NOMINAL THREAD TORQUE HOSE SIZE SIZE ft lbs Nm 1 2 3 4 16 109 80 3 4 1 1 16 12 245 180 1 1 5 16 12 272 200 1 1 4 1 5 8 12 250 250 4 All hoses change i...

Page 45: ...nstalled is routed with the proper bend radius to prevent kinking flow restrictions or hose failures at the hose connection 6 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 46: ...ng 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 DO NOT WELD CUTTER BLADES Torque the cutter blade bolts OO to specification see the FASTENER TORQUE section of this man...

Page 47: ...WS 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 M35 S G 1618210 ...

Page 48: ...sure 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 of t...

Page 49: ...rt numbers PIERCING TIP TO TUNNEL BLADE GAP M35K The piercing 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 M35K increases the gap by 20 inch 5 mm Fig 2 With bolt on piercing tip BD ARM BG PRIMARY CUTTING BLADE BG1 SECONDARY CUTTING BLADE BH SHIM PACK drive arm only BI DRIVE ARM DB TUNNEL BLADE D...

Page 50: ...mary blade faces are parallel See COMPONENT DESCRIPTION and BLADE MAINTENANCE AND ADJUSTMENT Steps 1 and 2 ST3 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 ST4 Install the tunnel blade in the drive arm See COMPONENT DESCRIPTION and BLADE MAIN...

Page 51: ...DESCRIPTION M35K The arm BD contains the primary cutting blades BG spacer plates DE and a two piece bolt on piercing tip DA The drive arm BI contains the secondary blades BG1 tunnel blade DB spacer DC guide blade DF and spacer plate DE ...

Page 52: ...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 piercing tip and primary blades These blades should be installed first Prior to installing the male jaw blade pocket and piercing tip pockets DM need to be free from debris and raised edges Clean pockets and remove any rais...

Page 53: ...screws OO provided Use thread adhesive t41 when installing the cap screws Each primary blade BG will have a spacer plate DE placed between the blade and blade pocket Install the blades spacers and socket head cap screws OO into the male jaw and tighten STEP 2 Using a steel straight edge t15 place the edge across the face of the piercing tip DG and the primary blades BG ...

Page 54: ...If the gap is found at the piercing tip the primary blade or blades may require surface grinding at a machine shop If the gap between the primary blades and the piercing tip is excessive install new primary blades It is imperative that the primary blade faces are parallel even in order to achieve correct blade clearance between the primary and secondary blades Once the primary blades are in place ...

Page 55: ...passing the first secondary blade BG1 stop closing the jaws and measure the clearance d60 between the two blades Record the clearance example 015 or 381 mm Continue closing the jaws stopping to record the clearance d61 at the second 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 o...

Page 56: ...ary blade and apply thread adhesive Then torque to NPK specifications see the FASTENER TORQUE CHART STEP 4 Install either a reconditioned used or new tunnel blade DB into the female jaw tunnel blade pocket DM Then tighten the socket head cap screws OO Slowly close the male BD and female BI jaws until the piercing tip DG enters the tunnel blade pocket 149 ...

Page 57: ...hieve the above clearances After blade shimming is complete remove the socket head cap screws OO for the tunnel blade and apply thread adhesive Then torque to NPK specifications see the FASTENER TORQUE CHART STEP 5 The female jaw BI also has two guide blades DF and two spacer plates DE The blades are located directly across from each other Install either reconditioned used or new guide blades into...

Page 58: ...il the piercing tip just enters the tunnel Stop and measure the clearance d63 between the guide blades and the sides of the piercing tip Install the required amount of shims to reduce these gaps to 005 127 mm After blade shimming is complete remove the socket head cap screws OO for the guide blades and apply thread adhesive Then torque to NPK specifications see the FASTENER TORQUE CHART ...

Page 59: ... 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 arm BD until the piercing tip is beginning to enter the drive arm BI tunnel If a large gap d91 is noted and the tip is rounded 151 this is an indication that the piercing tip requires attention It is also an indication that the tip is in ...

Page 60: ...s gap JAW PROFILES G and S JAWS G and S JAWS Profiles can be checked against NPK original profile templates Contact 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 t...

Page 61: ... small teeth are 97 25 mm high for the M35 Tip wear of the two large teeth may affect crushing efficiency This profile can be rebuilt to that of a template TEETH BUILD UP AND HARDFACING M35G For build up and hardfacing of teeth use the NPK template t72 to check teeth so that they are to the original profile CY Contact NPK for the correct template drawing no M3500 9500 Then refer to JAW and TOOTH R...

Page 62: ...d jaw wear will occur on the M35S and M35G Processors 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 M35S or M35G this rebuild procedure comprised of three steps should be followed 1 Surface Preparation 2 Und...

Page 63: ... Eutectic 3205 Postalloy 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...

Page 64: ...to maintain this temperature 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 hardfacing 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 H...

Page 65: ...ould be rebuilt and hard faced such that they are even with or slightly above the adjoining blades See HARDFACING K JAWS HARDFACING K JAWS If hardfacing is to be performed the jaw must be preheated to 300 400 F 150 200 C before hardfacing is applied Failure to preheat the tip area will cause the hardfacing to crack and chip off prematurely Using a suitable hard face rod apply the material in strin...

Page 66: ...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 67: ...E CRYSTALLIZATION OF THE WELD AND SUBSEQUENT BREAKAGE NOTE NPK Construction Equipment 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 68: ... the cylinder assembly c11 NOTE See the Booster Manual B000 9601 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 69: ...ne 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 Lightly heat the rod nut set screw c6 to loosen any thread adhesive that is present Remove the rod nut set screw 8 Unscrew the rod nut c1 and remove the piston c2 from the cylinder rod c3 Remo...

Page 70: ...ANCE 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 and discard ...

Page 71: ... 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 Inspect dr...

Page 72: ...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 air...

Page 73: ... Emery cloth 200 grit Cleaning solvent ASSEMBLY 1 Install 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 2 Apply hydraulic oil or NPK Assembly Lube to the inner surface coating the previously installed dirt seal backup ring and piston seal Install the cylinder end cap onto th...

Page 74: ...embly Lube to the o ring and backup ring after installation 4 Install the piston c2 onto the cylinder rod c3 5 Apply high strength thread adhesive to the clean dry threads of the cylinder rod 6 Install cylinder rod nut c1 onto cylinder rod c3 and torque to the listed value below MODEL THREAD TORQUE SOCKET PART SIZE ft lb Nm SIZE NUMBER M35 M70 x 3 0 3 200 4 300 100 mm 16087553 ...

Page 75: ...iston rings with the splits in the piston rings opposing each other 9 Apply hydraulic oil or NPK Assembly Lube to the inner surface of the cylinder housing and to the outside diameter of the piston and piston rings 10 Install the cylinder rod assembly c48 slowly into the cylinder housing c4 taking care not to damage the piston rings c8 ...

Page 76: ...nter bores of the main cylinder c11 13 Apply a light coat of oil or NPK Assembly Lube to the mating surfaces of the booster main body 14 With the aid of an assistant carefully orient and align the eight mounting flange fastening holes of the booster assembly bs35 with the corresponding eight threaded bores of the cylinder assembly c11 If necessary install two eye bolts in the threaded bores on top...

Page 77: ...R TOOLS AND EQUIPMENT 16 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 BOLT TORQUE SIZE ft lb Nm M35 M16 x 2 225 300 ...

Page 78: ...socket available as NPK part no 35004600 12 mm hex key wrench available as NPK part no 25004120 17 mm hex key wrench available as NPK part no 25004170 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 Qty 2 20 JIC steel caps If removed jaw set is to be stored it is recommended to Grease Set on a wood pallet Us...

Page 79: ...ING All processor positioning will be done with the excavator DETACHMENT OF THE EYE AND FORKED JAWS FROM THE CYLINDER SUB ASSEMBLIES 1 Using the excavator maneuver the M35 processor into a vertical position K JAWS ONLY Insert a wood block t20 between the jaws and close the jaws as shown This will prevent the jaws from closing too far 2 Using a hex key socket remove the four 12 mm socket head cap s...

Page 80: ...VAL OF THE JAW SET ASSEMBLY FROM THE MAIN FRAME 5 Using the excavator position the jaw set on a sturdy pallet The forked jaw FS must be resting on the top surface of the pallet Prop the back of the forked jaw up using a block of wood t20 as shown This is to allow for clearance when unhooking the jaw set from the processor frame 6 Remove the four retaining pin bolts c42 and the four lock plates c43...

Page 81: ... pin stop 131 or through the jaw frame GB and flush with the processor frame 8 Using the excavator unhook the processor s main frame assembly DN1 from the jaw set assembly DO1 at the hook pin c46 JAW SET STORAGE If the removed jaw set is to be stored pack the bushings with grease lay the jaw set on a wood or metal pallet and cover with a waterproof tarp if storage is outside ...

Page 82: ...plates c43 to the four jaw frame pins c41 NOTE Keep threading the retaining pin bolts until the jaw frame pin stops against the pivot bushing c45 located in the processor s main frame DN 3 Line up the cylinder pin bores with the jaw pin bores and push the cylinder pins c9 into place 4 Install the cylinder jaw pin lock plates c30 Using a hex key socket install the four 14 mm socket head cap screws ...

Page 83: ... of the processor Indicate the 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 M35 010 0 25 MODEL MAXIM...

Page 84: ...o main parts the Spindle Case BZ which contains the oil seals and the Spindle CA which rotates with the M35 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 sect...

Page 85: ...ting 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...

Page 86: ...hoses m39 at the hydraulic motor It is not necessary to remove the hoses from the counterbalance valve Remove the counterbalance valve and its mounting plate as a unit from the M35 processor frame Remove the case drain not shown and port 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...

Page 87: ...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 88: ...e 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 ba...

Page 89: ...tall 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 counterbalance valve install the fittings into the hydraulic motor and install the hydraulic motor hoses ...

Page 90: ...rease the contact surface of nuts Use a few drops of medium strength thread adhesive on the threads of fasteners listed as torqued with adhesive Do not use anti seize compound on any fasteners unless otherwise noted FASTENER TORQUE CHART M35 MAIN FRAME ASSEMBLY BOLT LOCATION BOLT SIZE BOLT TORQUE ADHESIVE ft lb Nm OR LUBED CYLINDER ROD END PIVOT PIN KEEPER M14 145 200 LUBED CYL BARREL END PIVOT PI...

Page 91: ...ee B000 9601 booster manual FASTENER TORQUE CHART M35 ROTATION COMPONENTS BOLT LOCATION BOLT BOLT TORQUE ADHESIVE SIZE ft lb Nm OR LUBED SLEWING RING M24 700 950 LUBED ASSEMBLY TO FRAME TOP PLATE TO M16 260 350 ADHESIVE SLEWING RING SLEWING RING M12 93 125 ADHESIVE COVER ROTATION MOTOR M16 260 350 ADHESIVE MOTOR PINION M12 93 125 ADHESIVE GEAR COUNTERBALANCE M12 95 130 LUBED VALVE COUNTERBALANCE M...

Page 92: ...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 93: ... the NPK M35 Material Processor or the carrier s hydraulic system hydraulic installation kit for the M35 Material Processor Checking the hydraulic pressure and flow will determine if the problem is in the M35 Material Processor or the carrier If the pressure and flow to the Processor are correct the problem is in the M35 Material Processor LOSS OF POWER Loss of power can be caused by a low carrier...

Page 94: ...e jaws fully open and fully closed Setting should be 3 700 psi 255 bar Check relief cartridges for tightness Tighten the relief valve cartridges Check relief cartridges for mis adjustment Reset to 3 700 psi 255 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 ch...

Page 95: ...at 3 700 psi 255 bar but the intensifier does not click 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 Dis assemble the main valve and inspect the piston assembly seals poppets and seats Polish or replace as necessary ...

Page 96: ...e 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 97: ...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 M35 Material Processor operating pressure Note If the excavator relief setting is less than 200 psi 14 bar above the M35 Material Process...

Page 98: ...l D If the intensifier is clicking rapidly pressure may not reach the relief valve setting due to severe intensifier or cylinder leakage E Open the M35 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 M35 Material Processor relief valve setting If it is not the same reset the M35 Material Processor relie...

Page 99: ...ESSOR MINIMUM CARRIER MODEL SERIAL NO RELIEF VALVE RELIEF VALVE SETTING SETTING psi bar psi bar M35 ALL 3 700 255 3 900 270 RELIEF VALVE LOCATION The M35 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 100: ...si 255 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 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 Check poppets and seats Replace poppet...

Page 101: ... cartridges 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 backup rings Main cylinder assemblies Check main cylinder piston rings for by passing oil Replace pi...

Page 102: ...owing will continue until the material is either cut crushed or the M35 Material Processor meets full resistance At full resistance the clicking will slow dramatically or sometimes stop completely PRESSURE INTENSIFIER BOOSTER The control valve bs10 and booster assembly bs27 make up the pressure intensifier assembly RAPID CONTINUOUS CLICKING IS HEARD AND THE MATERIAL IS NOT BEING CRUSHED SHEARED AS...

Page 103: ...l the gauge and swivel adapter onto the male adapter No thread sealant required 4 Close the jaws all the way Pressure will rise to the the full boosted pressure of approximately 10 870 psi 750 bar which is a ratio of 2 938 1 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 slow down there may be a pr...

Page 104: ... 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 in the test port of the jaw close circuit left shut off valve as seen from the operator s position Fully stroke the M35 Material Processor cylinders Measure the attachment operating pressure SLOW CYLINDER SPEED PROBLEM CAUSE C...

Page 105: ...ar minimum above the M35 Processor operating pressure M35 Processor relief valves Measure the relief valves with the shut off valves on the carrier in the ON position Check pressure with the jaws fully open and fully closed Setting should be 3 700 psi 255 bar Check relief cartridges for tightness Tighten the relief valve cartridges Check relief cartridges for mis adjustment Reset to 3 700 psi 255 ...

Page 106: ...ll the flow meter t36 between the M35 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 M35 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 M35 Material Processor close switch Measure the pressure on the flow m...

Page 107: ...to zero restriction fully open Set the engine throttle to the maximum full position Energize the M35 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 sec...

Page 108: ... 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 M35 Material Processor GX IF NO DRIFT OC...

Page 109: ... required for your M35 Material Processor MODEL ROTATION APPROXIMATE CARRIER RELIEF SPEED FLOW VALVE SETTING rpm gpm lpm psi bar M35 6 5 10 2 5 4 10 15 3 000 205 Adjust the rotation flow so that the rpm is within the guidelines shown for the M35 Material Processor Flows are checked at a normal operating pressure of 1000 psi 70 bar The relief listed in the above chart is only necessary to protect t...

Page 110: ...alve 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 M35 Processor rotation counterbalance valves Check counterbalance valve pressure settings for both directio...

Page 111: ...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 112: ...EMBLY BT SLEWING RING BT1 SLEWING RING COVER c11 CYLINDER ASSEMBLY c13 CYLINDER PIN LOCKING PLATE c29 CYLINDER ASSEMBLY COVER c32 PIVOT PIN NUT c36 CYLINDER PIN COVER PLATE CH TOP PLATE DN MAIN FRAME DP LOCK PIN GD HOOK PIN GE JAW FRAME PIN GF WEDGE PLATE GH STOP PLATE m 7 TOP BRACKET m14 BUSHING m18 JOINT FITTING m28 CYLINDER ROD PIN s 9 COVER PLATE ...

Page 113: ... M35 PROCESSOR K JAW COMPONENTS BD MALE JAW BG PRIMARY BLADE BG1 SECONDARY BLADE BI FEMALE JAW BJ PIN c32 PIVOT PIN NUT DB TUNNEL BLADE DF GUIDE BLADE DG1 PIERCING TIP bolt on DG2 PIERCING TIP bolt on GB JAW FRAME m14 BUSHING ...

Page 114: ...OR COMMON M35 PROCESSOR CYLINDER COMPONENTS bs 1 CONNECTOR PIPE bs35 BOOSTER ASSEMBLY 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 115: ... 115 WARRANTY STATEMENTS ...

Page 116: ... 116 WARRANTY STATEMENTS ...

Page 117: ...RIAL PROCESSOR MODEL NUMBER SERIAL 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 ...

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