NPK M20S, M20C, M20K, M20G, M28S Instruction Manual

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M38K

MATERIAL PROCESSOR

INSTRUCTION MANUAL

MODELS:

“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

- 2 -

CONTENTS

SAFETY ............................................................................................................................ 5

OPERATION ............................................................................................................... 6

MAINTENANCE .......................................................................................................... 7

INTRODUCTION ............................................................................................................... 9

CARRIER COMPATIBILITY .............................................................................................. 9

M-SERIES SPECIFICATIONS .......................................................................................... 10

M20C MATERIAL PROCESSOR ................................................................................ 10

M20G MATERIAL PROCESSOR ............................................................................... 11

M20K MATERIAL PROCESSOR ................................................................................ 12

M20S MATERIAL PROCESSOR ................................................................................ 13

M28C MATERIAL PROCESSOR ................................................................................ 14

M28G MATERIAL PROCESSOR ............................................................................... 15

M28K MATERIAL PROCESSOR ................................................................................ 16

M28S MATERIAL PROCESSOR ................................................................................ 17

M38C MATERIAL PROCESSOR ................................................................................ 18

M38G MATERIAL PROCESSOR ............................................................................... 19

M38K MATERIAL PROCESSOR ................................................................................ 20

M38S MATERIAL PROCESSOR ................................................................................ 21

K JAW CUTTING CAPACITY ........................................................................................... 22

SERIAL NUMBER LOCATION .......................................................................................... 23

M-SERIES JAW IDENTIFICATION ................................................................................... 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

HOSE INSTALLATION TIPS ...................................................................................... 49

OPERATING INSTRUCTIONS ......................................................................................... 51

GENERAL MAINTENANCE .............................................................................................. 59

DAILY INSPECTION AND MAINTENANCE ............................................................... 59

LUBRICATION POINTS ............................................................................................. 61

CUTTER BLADE MAINTENANCE .............................................................................. 62

M20K, M28K, M38K JAW MAINTENANCE ................................................................ 64

DAILY MAINTENANCE............................................................................................... 64

CUTTER BLADE MAINTENANCE – K JAWS ............................................................ 65

BLADE-TO-BLADE CLEARANCE ........................................................................ 65

PIERCING TIP TO TUNNEL GAP .............................................................................. 65

- 3 -

CONTENTS

K JAW BLADE SET UP PROCEDURE ...................................................................... 66

COMPONENT DESCRIPTION ................................................................................... 67

K JAW BLADE MAINTENANCE AND ADJUSTMENT ................................................ 68

PIERCING TIP MAINTENANCE AND REPLACEMENT ............................................. 73

MAINTENANCE .......................................................................................................... 73

TAPER LINER FOR M SERIES PROCESSOR “K” JAW ............................................ 74

BUILD-UP OF THE PIERCING TIP ............................................................................ 75

REPLACING THE PIERCING TIP .............................................................................. 75

JOINING AND BUILD-UP ........................................................................................... 76

DETERMINING REPLACEMENT OR BUILD UP ....................................................... 77

JAW INSPECTION AND MAINTENANCE ........................................................................ 80

JAW INSPECTION: S, C, and G JAWS ..................................................................... 80

WEEKLY INSPECTION ....................................................................................... 80

JAW PROFILES: S, C, AND G JAWS ....................................................................... 80

JAW BUILD-UP AND HARDFACING (M38S, M28S, and M20S) ............................... 80

JAW BUILD-UP AND HARDFACING (M38C, M28C, and M20C) .............................. 81

TEETH REPLACEMENT ............................................................................................ 82

REPLACEABLE TOOTH PLATES – G JAWS ............................................................ 83

JAW AND TOOTH REBUILD PROCEDURE: S, C, and G JAWS ............................. 83

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 OUTER DIRT SEAL REPLACEMENT .................................... 103

SWIVEL MANIFOLD MAINTENANCE .............................................................................. 104

SWIVEL MANIFOLD ASSEMBLY............................................................................... 104

LEAKAGE OF THE SEALS......................................................................................... 104

TESTING THE SWIVEL SEALS FOR INTERNAL LEAKAGE .................................... 105

REPLACEMENT OF THE SEALS IN THE SWIVEL ................................................... 106

JAW SET INTERCHANGE................................................................................................ 110

TOOL AND SUPPLIES ............................................................................................... 110

PROCEDURE FOR JAW SET INTERCHANGE ......................................................... 111

UNIT POSITIONING ................................................................................................... 111

DETACHMENT OF THE JAWS FROM THE CYLINDER SUB-ASSEMBLIES ........... 113

DETACHMENT OF THE JAW SET FROM THE MAIN FRAME ................................. 115

JAW SET REMOVAL .................................................................................................. 117

JAW SET STORAGE .................................................................................................. 118

- 4 -

CONTENTS

JAW SET INSTALLATION INTO THE MAIN FRAME ................................................. 118

ATTACHMENT OF JAW SET TO THE MAIN FRAME ............................................... 118

ATTACHMENT OF THE JAWS TO THE CYLINDER SUB-ASSEMBLIES ................. 120

FASTENER TORQUE SPECIFICATIONS ........................................................................ 122

HOSE TORQUE SPECIFICATIONS ................................................................................. 127

JIC ENDS ................................................................................................................... 127

ORFS ENDS ............................................................................................................... 127

TROUBLESHOOTING ...................................................................................................... 128

DETERMINE THE TYPE OF PROBLEM .................................................................... 128

DETERMINE THE CAUSE OF THE PROBLEM ......................................................... 128

LOSS OF POWER...................................................................................................... 128

TROUBLESHOOTING GUIDE FOR LOW POWER ................................................... 129

RELIEF VALVE CHECKS..................................................................................... 129

MEASURING OPERATING PRESSURES ................................................................. 131

RELIEF VALVE CHECKING AND SETTING PROCEDURE ...................................... 131

PRESSURE 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 ................................................................................................... 139

CHECKING THE HYDRAULIC FLOW AT RATED PRESSURE ................................ 141

JAW DRIFT ................................................................................................................ 143

TO DETERMINE IF THE JAW DRIFT IS WITH THE MATERIAL PROCESSOR OR

THE CARRIER............................................................................................................ 143

ROTATION ................................................................................................................. 144

KEYWORDS FOR COMMON PROCESSOR COMPONENTS ......................................... 147

KEYWORDS FOR COMMON PROCESSOR CYLINDER COMPONENTS ...................... 148

WARRANTY STATEMENTS ............................................................................................. 149

NOTES .............................................................................................................................. 151

SERVICE RECORD .......................................................................................................... 151

- 5 -

SAFETY

Safety notices in NPK Instruction Manuals follow ISO and ANSI standards for safety warnings:

DANGER (red) notices indicate an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING (orange) notices indicate a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION (yellow) notices indicate a potentially 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 operator.

WARNING – STAY CLEAR decal (part number H100-

7200) is installed on all NPK Crushers, Shears, and

MATERIAL PROCESSORS. Keep them clean and visible. NPK will provide decals free of charge as needed.

- 6 -

Warning Decal for Cab Installation

SAFETY

OPERATION

1. Operator personnel must read and understand the NPK INSTRUCTION MANUAL

to prevent serious or fatal injury.

2. FLYING OR FALLING DEBRIS CAN CAUSE SERIOUS OR FATAL INJURY.

Keep personnel and bystanders clear of the MATERIAL PROCESSOR while in operation.

3. Do not operate MATERIAL PROCESSOR without an impact resistant shield between the MATERIAL PROCESSOR and operator. Operate with extreme caution near walls or columns that may collapse and near concrete debris that may fall.

4. Operate the MATERIAL PROCESSOR from the operator’s seat only.

5. Use two people whenever operator visibility is limited, one to operate the MATERIAL PROCESSOR, the other to guide operations.

6. Do not leave a load suspended in air.

7. Do not pass a load over people, vehicles, etc.

8. Do not operate the MATERIAL PROCESSOR

within reach of power lines.

9. Do not climb, sit, or ride on the MATERIAL PROCESSOR.

10. Match the MATERIAL PROCESSOR size to excavator according to NPK recommendations, 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 can penetrate the skin, causing serious injury. Avoid the hazard by relieving pressure before disconnecting any lines. Search for leaks with a piece of

cardboard, or other object. If an accident occurs, see a doctor immediately!

Hydraulic fluid injected into the skin must be surgically removed immediately or gangrene may result!

14. The pressure generated by the power intensifier on the MATERIAL PROCESSOR exceeds 10,000 psi (690 bar), which is higher than commonly encountered on hydraulic equipment. To avoid bodily harm and/or injury when conducting inspection checks, use gauges, hoses and fittings rated at 15,000 psi (1035 bar). For parts replacement, use only genuine NPK replacement parts. Contact NPK

Service Department at 1-800-225-4379.

15. When removing or installing mounting pins, beware of flying metal chips.

- 7 -

SAFETY

MAINTENANCE

1. Use only NPK supplied replacement parts. NPK specifically disclaims any responsibility for bodily injury or MATERIAL PROCESSOR damage that results from the use of parts not sold or approved by NPK.

2. Use extreme caution in handling. A fully assembled MATERIAL PROCESSOR can weigh up to 5 tons. Sub-assemblies range in weight from hundreds to thousands of pounds. To avoid bodily harm, use lifting and securing mechanisms of adequate capacity to support loads. Seek the aid of an assistant as much as possible, and always when handling heavier sub-assemblies.

3. Use extreme caution when changing jaw sets, particularly in the field. Employ lifting and securing mechanisms of adequate capacity to support the jaw sets. At least

two people are required to change a jaw set safely in the field.

4. Wear safety glasses and protective clothing when working on the MATERIAL PROCESSOR. Wear thermal-protective gloves when handling heated parts.

5. Prevent exposure 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. Avoid the hazard by relieving pressure before disconnecting any lines. Search for leaks with a piece of

cardboard, or other object. If an accident occurs, see a doctor immediately!

Hydraulic fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

8. The pressure generated by the power intensifier on the MATERIAL PROCESSOR exceeds 10,000 psi (690 bar), which is higher than commonly encountered on hydraulic equipment. To avoid bodily harm and/or injury when conducting inspection checks, use gauges, hoses and fittings rated at 15,000 psi (1035 bar). For parts replacement, use only genuine NPK replacement parts. Contact NPK Service Department at 1-800-225-4379.

9. When removing or installing mounting pins, beware of flying metal chips.

- 8 -

SAFETY

ATTENTION

MAINTENANCE

STANDARD PRACTICES

Maintenance of and repairs to the MATERIAL PROCESSOR should be performed by an experienced service technician, thoroughly familiar with all standard practices and procedures, and most importantly, all safety precautions. The following is a review of common standard practices to be followed when working with hydraulic equipment, and is not meant to be all-inclusive. Rather, this review is presented as a reminder as to some of the unique characteristics of hydraulic equipment.

 The prevention of foreign contaminant damage is critical when working with

hydraulic equipment. Protect exposed holes and parts to guard against entry of contaminants.

 Mark the location and position of mating parts as an aid to re-assembly. Mark

corresponding parts uniquely 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-assembly.

 Always inspect threaded areas on components. Repair or replace as required.

 Use care to avoid scratches, nicks, dents, or other damage to machined surfaces of

mating components.

 When securing a component, always tighten cap screws gradually in an opposing

pattern, applying the specified torque.

 Grease can be used to temporarily hold a part in place while the abutting part is

placed into position.

 Always use common sense and exercise standard safety precautions when working

with all tools and equipment required to maintain, repair or troubleshoot the MATERIAL PROCESSOR.

- 9 -

INTRODUCTION

PROCESSOR

RECOMMENDED CARRIER WEIGHT RANGE

MODEL

3rd member mounting

US ton

(Metric ton)

M20

20 - 25

(18 - 23)

M28

25 - 40

(23 - 36)

M38

33 - 55

(30 - 50)

Specifications subject to change without notice.

Thank you for your purchase of an NPK attachment. NPK prides itself in the design and manufacture of high quality attachments. The quality workmanship and materials, which go into all of our attachments, will provide maximum service life. With proper care and use, your NPK attachment should provide you with many years of productive service.

The purpose of this manual is to provide you with information and instructions required to properly operate and maintain the M20, M28, or M38 MATERIAL PROCESSOR. This will result in maximum ATTACHMENT reliability and productivity.

Read this manual thoroughly before attempting to operate, remove, disassemble, repair, or troubleshoot the MATERIAL PROCESSOR or any of its components. For additional information or help with any problem encountered, please contact your authorized NPK dealer.

Follow all the 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.

CARRIER COMPATIBILITY

These carrier weight ranges are intended as a guideline only. Other factors, such as stick length, counterweights, undercarriage, etc., must be taken into consideration.

Mounting a MATERIAL PROCESSOR that is too heavy for the carrier can be dangerous and damage the carrier. Verify carrier stability with the MATERIAL PROCESSOR before transport or operation.

Mounting a MATERIAL PROCESSOR that is too small for the carrier can damage the MATERIAL PROCESSOR and void warranties. Please consult NPK Service or Engineering for specific detailed information.

- 10 -

M-SERIES SPECIFICATIONS

MODEL

Weight

Maximum Jaw

Oil Flow

Cycle Time

Opening

seconds

lb.

(kg)

in.

(mm)

gpm

(lpm)

open

M20C

4,440

(2,015)

34.5

(876)

26-53

(100-200)

1.4

2.8

MODEL

Maximum

Crushing Force

Operating Pressure

at Tip

(Metric

psi

(bar)

Ton

Ton)

M20C

3,625

(250)

(71)

M20C MATERIAL PROCESSOR

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.

- 11 -

M-SERIES SPECIFICATIONS

MODEL

Weight

Maximum Jaw

Oil Flow

Cycle Time

Opening

seconds

lb.

(kg)

in.

(mm)

gpm

(lpm)

open

M20G

4,520

(2,055)

30.3

(770)

26-53

(100-200)

1.4

2.8

MODEL

Maximum

Crushing Force

Operating Pressure

at Tip

(Metric

psi

(bar)

Ton

Ton)

M20G

3,625

(250)

(76)

M20G MATERIAL PROCESSOR

- 12 -

M-SERIES SPECIFICATIONS

MODEL

Weight

Maximum Jaw

Oil Flow

Cycle Time

Opening

seconds

lb.

(kg)

in.

(mm)

gpm

(lpm)

open

M20K

4,530

(2,060)

21.1

(535)

26-53

(100-200)

1.4

2.8

MODEL

Maximum

Crushing Force

Operating Pressure

at Tip

(Metric

psi

(bar)

Ton

Ton)

M20K

3,625

(250)

(82)

M20K MATERIAL PROCESSOR

- 13 -

M-SERIES SPECIFICATIONS

MODEL

Weight

Maximum Jaw

Oil Flow

Cycle Time

Opening

seconds

lb.

(kg)

in.

(mm)

gpm

(lpm)

open

M20S

4,355

(1,980)

(940)

26-53

(100-200)

1.4

2.8

MODEL

Maximum

Crushing Force

Operating Pressure

at Tip

(Metric

psi

(bar)

Ton

Ton)

M20S

3,625

(250)

(71)

M20S MATERIAL PROCESSOR

- 14 -

M-SERIES SPECIFICATIONS

MODEL

Weight

Maximum Jaw

Oil Flow

Cycle Time

Opening

seconds

lb.

(kg)

in.

(mm)

gpm

(lpm)

open

M28C

6,500

(2,950)

36.2

(920)

50-80

(190-300)

1.7

3.1

MODEL

Maximum

Crushing Force

Operating Pressure

at Tip

(Metric

psi

(bar)

Ton

Ton)

M28C

3,625

(250)

116

(105)

M28C MATERIAL PROCESSOR

- 15 -

M-SERIES SPECIFICATIONS

MODEL

Weight

Maximum Jaw

Oil Flow

Cycle Time

Opening

seconds

lb.

(kg)

in.

(mm)

gpm

(lpm)

open

M28G

6,850

(3,107)

35.8

(910)

50-80

(190-300)

1.7

3.1

MODEL

Maximum

Crushing Force

Operating Pressure

at Tip

(Metric

psi

(bar)

Ton

Ton)

M28G

3,625

(250)

125

(114)

M28G MATERIAL PROCESSOR

- 16 -

M-SERIES SPECIFICATIONS

MODEL

Weight

Maximum Jaw

Oil Flow

Cycle Time

Opening

seconds

lb.

(kg)

in.

(mm)

gpm

(lpm)

open

M28K

6,900

(3,130)

25.1

(637)

50-80

(190-300)

1.7

3.1

MODEL

Maximum

Crushing Force

Operating

Pressure

at Tip

(Metric

psi

(bar)

Ton

Ton)

M28K

3,625

(250)

133

(121)

M28K MATERIAL PROCESSOR

- 17 -

M-SERIES SPECIFICATIONS

MODEL

Weight

Maximum Jaw

Oil Flow

Cycle Time

Opening

seconds

lb.

(kg)

in.

(mm)

gpm

(lpm)

open

M28S

6,400

(2,915)

(1,067)

50-80

(190-300)

1.7

3.1

MODEL

Maximum

Crushing Force

Operating Pressure

at Tip

(Metric

psi

(bar)

Ton

Ton)

M28S

3,625

(250)

115

(105)

M28S MATERIAL PROCESSOR

- 18 -

M-SERIES SPECIFICATIONS

MODEL

Weight

Maximum Jaw

Oil Flow

Cycle Time

Opening

seconds

lb.

(kg)

in.

(mm)

gpm

(lpm)

open

M38C

8,590

(3,900)

48.4

(1,230)

60-100

(225-380)

2.1

3.8

MODEL

Maximum

Crushing Force

Operating Pressure

at Tip

(Metric

psi

(bar)

Ton

Ton)

M38C

3,625

(250)

143

(130)

M38C MATERIAL PROCESSOR

- 19 -

M-SERIES SPECIFICATIONS

MODEL

Weight

Maximum Jaw

Oil Flow

Cycle Time

Opening

seconds

lb.

(kg)

in.

(mm)

gpm

(lpm)

open

M38G

9,100

(4,140)

(1,142)

60-100

(225-380)

2.1

3.8

MODEL

Maximum

Crushing Force

Operating Pressure

at Tip

(Metric

psi

(bar)

Ton

Ton)

M38G

3,625

(250)

152

(138)

M38G MATERIAL PROCESSOR

- 20 -

M-SERIES SPECIFICATIONS

MODEL

Weight

Maximum Jaw

Oil Flow

Cycle Time

Opening

seconds

lb.

(kg)

in.

(mm)

gpm

(lpm)

open

M38K

9,370

(4,260)

30.2

(766)

60-

100

(225-380)

2.1

3.8

MODEL

Maximum

Crushing Force

Operating Pressure

at Tip

(Metric

psi

(bar)

Ton

Ton)

M38K

3,625

(250)

170

(154)

M38K MATERIAL PROCESSOR

- 21 -

M-SERIES SPECIFICATIONS

MODEL

Weight

Maximum Jaw

Oil Flow

Cycle Time

Opening

seconds

lb.

(kg)

in.

(mm)

gpm

(lpm)

open

M38S

8,450

(3,840)

48.6

(1,234)

60-100

(225-380)

2.1

3.8

MODEL

Maximum

Crushing Force

Operating Pressure

at Tip

(Metric

psi

(bar)

Ton

Ton)

M38S

3,625

(250)

147

(134)

M38S MATERIAL PROCESSOR

- 22 -

K JAW CUTTING CAPACITY

NOTE: Cutting capacities 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

(mm)

M20K

(305)

1/2

(12.7)

1/2

(12.7)

M28K

(406)

5/8

(15.9)

5/8

(15.9)

M38K

(483)

3/4

(19.1)

3/4

(19.1)

MODEL E F

(mm)

M20K

(50.8)

1/2

(12.7)

M28K

2-1/2

(63.5)

3/4

(19.1)

M38K

(76.2)

(25.4)

- 23 -

SERIAL NUMBER LOCATION

M20

- 24 -

SERIAL NUMBER LOCATION

M28

- 25 -

SERIAL NUMBER LOCATION

M38

- 26 -

M-SERIES JAW IDENTIFICATION

“C” STYLE

COMBO CUTTER

“G” STYLE

SECONDARY/PRIMARY

DEMOLITION

“K” STYLE

DEMOLITION

SCRAP PROCESSING

“S” STYLE

PRIMARY DEMOLITION

All M-Series Material Processor jaws are shipped from NPK with the following information welded on them:

1. Letter designating jaw type, i.e., C, G, K, S.

2. Number denoting male or female jaw.

NOTE: Even numbers indicate male jaws, odd numbers indicate female jaws.

This information is welded onto the jaws in the location shown below:

These two items will aid in identifying the exact required parts when ordering. For questions, please contact the NPK Service Department at 1-800-225-4379.

- 27 -

JAW SET IDENTIFICATION

 C Jaw Set (Primary Breaker) 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.

- 28 -

JAW SET IDENTIFICATION

 G Jaw Set (Pulverizer/Secondary Concrete Crusher) for the downsizing of concrete

and the separation of concrete and rebar.

- 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.

- 30 -

JAW SET IDENTIFICATION

The following jaw sets are available for the Material Processor:

 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.

- 31 -

PROCESSOR – BOOSTER AND CYLINDER

c11

Jaw Cylinder

c14

Booster Piston

c15

Main Valve Assembly

c16

Sequence Valve Cartridge

c17

Relief Valve (close)

c18

Relief Valve (open)

c44

Swivel Manifold

Carrier Hydraulic Pump

Carrier Control Valve

I INTRODUCTION

The hydraulic cylinders used on the NPK Material Processor are equipped with a shared hydraulic booster. To close the jaws of the processor, hydraulic oil from the carrier is directed to the base end of the cylinders, which extends the cylinder rods. Under no load, no boost is applied and this results in a rapid cycle time as compared to large, non-boosted cylinders.

When a load (material to be crushed or sheared) is encountered, pressure builds and shifts the sequence valve of the booster. This directs oil into the booster section, which intensifies 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 Processor. To open the jaws of the NPK Material Processor, oil is directed to the rod ends of the cylinders. This retracts the rods and pulls the jaws open. No boost is provided in the jaw open mode.

- 32 -

PROCESSOR – BOOSTER AND CYLINDER

Fig. 1

As shown in Fig. 1, the booster cylinder consists of:

c11

Jaw Cylinder

c14

Booster Piston

c15

Main Valve Assembly

c16

Sequence Valve Cartridge

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

c44

Swivel Manifold

Carrier Hydraulic Pump

Carrier Control Valve

Oil Chamber - 1

Oil Chamber - 2

Oil Chamber - 3

Oil Chamber - 4

II STRUCTURE OF THE BOOSTED CYLINDER

For a complete breakdown of parts in the booster cylinder assembly, see the parts manual for each unit by serial number.

- 33 -

PROCESSOR – BOOSTER AND CYLINDER

Fig. 2

CYLINDER EXTEND (NO LOAD)

When the cylinders (c11) are extended (jaw close) and no load (material to 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 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

Carrier Control Valve

fl1

High Pressure Hydraulic Flow

fl2

Low Pressure Hydraulic Flow

fl3

Intensified Hydraulic Flow

III OPERATING PRINCIPLE

- 34 -

PROCESSOR – BOOSTER AND CYLINDER

Fig. 3

BOOSTER ACTUATION

When a load (material to be crushed or sheared) in encountered on jaw close, the hydraulic pressure in the booster unit starts to rise. When the hydraulic pressure 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 Hydraulic Flow

fl3

Intensified Hydraulic Flow

III OPERATING PRINCIPLE

- 35 -

PROCESSOR – BOOSTER AND CYLINDER

Fig. 4

FORWARD PISTON STROKE

The hydraulic oil that has passed through the sequence valve (c16) and booster valve (c15), flows into rear oil chambers v1 and v2 of the booster piston (c14) and strokes it toward oil chamber v4. Because the area of the booster piston in oil 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"

Oil Chamber - 1

Oil Chamber - 2

Oil Chamber - 4

fl1

High Pressure Hydraulic Oil

fl2

Low Pressure Hydraulic Oil

fl3

Intensified Hydraulic Oil

III OPERATING PRINCIPLE

- 36 -

PROCESSOR – BOOSTER AND CYLINDER

Fig. 5

MAIN VALVE REVERSE SHIFT

When the booster piston (c14) reaches its full stroke, oil entering 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

III OPERATING PRINCIPLE

- 37 -

PROCESSOR – BOOSTER AND CYLINDER

Fig. 6

REVERSE PISTON STROKE

When the main valve assembly (c15) has been shifted, oil is directed through the main valve assembly to oil chambers (v3) and (v4) of the booster piston (c14). This strokes the booster piston toward oil chamber (v2). 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"

Oil Chamber - 2

Oil Chamber - 3

Oil Chamber - 4

fl1

High Pressure Hydraulic Flow

fl2

Low Preuusre Hydraulic Flow

fl3

Intensified Hydraulic Flow

III OPERATING PRINCIPLE

- 38 -

PROCESSOR – BOOSTER AND CYLINDER

Fig. 7

VALVE SHIFT TO FORWARD STROKE

When the booster piston (c14) reaches full reverse stroke, oil drains out of the plunger (c19) end of the main control valve (c15) through ports C2 (c27) and C3 (c28) of the booster piston. The main control valve spring moves the main control valve spool toward the plunger. This places 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

Plunger

c27

Port C2 Piston

c28

Port C3 Piston

Carrier Control Valve

fl1

High Pressure Hydraulic Flow

fl2

Low Pressure Hydraulic Flow

fl3

Intensified Hydraulic Flow

III OPERATING PRINCIPLE

- 39 -

PROCESSOR – BOOSTER AND CYLINDER

Fig. 8

CYLINDER RETRACT (JAW OPEN)

When the crusher jaws are opened, oil from the excavator’s control valve (k7) is directed through the booster to the rod ends 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

Carrier Control Valve

fl1

High pressure Hydraulic Flow

fl2

Low Pressure Hydraulic Flow

fl3

Intensified Hydraulic Flow

III OPERATING PRINCIPLE

- 40 -

HYDRAULIC INSTALLATION

HYDRAULIC KITS

NPK Hydraulic Installation Kits are available for virtually all compatible backhoe loaders, excavators, and skid steers. Complete parts and instructions for the hydraulic installation of the NPK Material Processor, including valves, 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 (looking from the operator’s seat) and to open (m4) the jaws is on the right.

- 41 -

HYDRAULIC INSTALLATION

SHUT-OFF VALVES

Most NPK Hydraulic Installation Kits use two shut-off 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).

- 42 -

HYDRAULIC INSTALLATION

TEST PORT LOCATIONS

B. NPK also provides pressure test (gauge) ports (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).

- 43 -

HYDRAULIC INSTALLATION

HYDRAULIC QUICK DISCONNECTS

NPK prefers the use of a straight JIC connection (39) when installing its Material Processor onto a carrier.

NOTE: Care should be given when removing the Material Processor to make sure that the hoses are plugged and the tube ends are capped to prevent contamination from entering the hydraulic system.

NPK recommends against the use of non-NPK hydraulic quick disconnects on fluid circuits operating NPK products, including Material Processors, for the following reasons:

1. The hydraulic pulsations caused by the Material Processor can cause internal

pieces of the non-NPK quick disconnect (32) to disintegrate. These pieces can migrate into the Material Processor, causing damage 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 restriction in the hydraulic circuit. NPK Material

Processors are not pressure sensitive, but the restrictions cause unnecessary heating of the oil. Also, the pressure required to operate the Material Processor, plus the restriction of the quick disconnects, may push an older, lower pressure carrier to the limit of its hydraulic system. This would interfere with the proper operation of the Material Processor. However, the NPK approved quick disconnects are properly sized so that the Material Processor operation is not affected.

- 44 -

HYDRAULIC INSTALLATION

ROFLEX COUPLING

STUCCI COUPLING

HYDRAULIC QUICK DISCONNECTS

NPK has approved quick disconnects. Contact your NPK dealer or NPK direct at 1800-225-4379 for proper sizing of approved NPK quick disconnects for your unit.

- 45 -

HYDRAULIC INSTALLATION

PREVENTION OF CONTAMINATION

1. Neglect of the hydraulic oil will cause many problems in all of the hydraulic

components, including the attachment. Care should be taken to check for

contamination of the oil and to change the oil if contamination is found. Routine oil

sampling is recommended once per month.

 When the hydraulic oil shows low viscosity and bubbles, this indicates that the

oil is deteriorated. If the oil is dark brown and gives off an offensive odor, it is

severely deteriorated. Change the oil immediately!

 When the oil is clouded, or the oil filter becomes clogged, it indicates that the oil

is contaminated. Change the oil immediately!

 To change the contaminated hydraulic oil, drain the hydraulic system as

completely as possible. Try to minimize the amount of old oil that will be mixed with the new oil.

NOTE: It is suggested to change the oil in the system with all of the cylinders retracted.

NOTE: If a catastrophic failure has occurred and the system is found to have metal mixed with the hydraulic 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 ready.

3. Low oil level will cause heat buildup, resulting in deterioration of the hydraulic oil.

Also, it may cause pump cavitation due to air mixing with the oil, leading to damage to the attachment or the carrier components. Keep the oil at the proper level at all times.

4. Do not use the hammer at an operating temperature higher than 180 °F (80°C). The

proper operating oil temperature range is between 120°F (50°C) and 180°F (80°C). Since contaminated cooler fins cause reduced efficiency of the cooler, keep them clean at all times. The use of a heat gun is the best way to evaluate if the cooler is working properly.

5. Water in the hydraulic oil will lead to damage of the attachment and the carrier.

Drain off water and foreign matter from the hydraulic tank at specified intervals.

When out of service, the attachment should be stored indoors.

- 46 -

MOUNTING INSTALLATION

Stick Pin

Link Pin

Main Whip Hose (jaw close)

Main Whip Hose (jaw open)

Top Bracket

m24

Boom Pin Collar

m39

Rotation Whip Hose

m40

Motor Drain Whip hose

m41

Boom Pin Bushing

m42

Stover Nut

m43

Hex head Cap Screw

ITEM

DESCRIPTION

Holding Valve

BQ2

Rotation Motor

Rotation Hose

Motor Drain Line

m18a

Main Connection (close)

- #20 JIC male

m18b

Main Connection (open)

- #20 JIC male

m20

Rotation Connections

- #8 JIC male

m21

Motor Drain Connection

- #6 JIC male

m22

Optional Rotation Ports

m23

Optional Drain Port

NPK Mounting Installation Kits include the parts required to adapt the NPK Material Processor to the arm of your carrier. The kits include all necessary boom pins, bushings, spacers, etc.

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.

- 47 -

MOUNTING INSTALLATION

MOUNTING TO THE CARRIER

1. Position the Material Processor horizontal on wood blocks (t20) as shown.

2. Align the stick pin bore (m26). Install stick pin (m1).

3. Align the link pin bore (m25). Install the link pin (m2).

4. Clean away any dirt found on the hose connections, then connect the whip hoses

(m3 and m4).

5. Connect the rotation whip hoses (m39) and hydraulic motor case drain whip hose

(m40).

6. Open 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 Processor down. Install

metal plugs in the hydraulic hoses and metal caps on the stick tubes to keep out contamination.

5. Position the Material Processor horizontal on wood blocks (t20), as shown in

“MOUNTING TO THE CARRIER”.

- 48 -

STORAGE OF THE MATERIAL PROCESSOR

1. Make sure all whip hoses (m38) that connect the Material Processor 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.

- 49 -

HOSE INSTALLATION

NOMINAL

THREAD

TORQUE

HOSE SIZE

SIZE

ft. lbs.

(Nm)

1/2"

3/4 - 10

(52)

3/4"

1-1/16 - 12

(119)

1-5/16 - 12

113

(153)

1-1/4"

1-5/8 - 12

133

(180)

HOSE INSTALLATION TIPS

1. Connect larger diameter hoses first. Larger hoses are more difficult to bend and

maneuver, while the smaller lines are usually more flexible and easier to install.

2. Do not twist the hose during 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.

- 50 -

HOSE INSTALLATION

HOSE

MINIMUM

SIZE

BEND RADIUS

(mm)

1/2"

(177.8)

3/4"

9.5

(241.3)

(304.8)

1-1/4"

16.5

(419.1)

TEMPERATURE RANGE

°F

(°C)

HYDRAULIC FLUID

14 to 176

(-10 to +80)

ATMOSPHERIC

14 to 122

(-10 to +50)

HOSE INSTALLATION TIPS

5. All hoses change in length slightly when pressure is applied. Hoses must have

enough slack to relieve stressing the connections.

6. Make sure the hose being installed is routed with the proper bend ra dius to prevent

kinking, flow restrictions or hose failures at the hose connection.

7. Hoses should be used within the following ranges of temperature.

- 51 -

OPERATING INSTRUCTIONS

Before operating the NPK Material Processor, 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.

- 52 -

OPERATING INSTRUCTIONS

USE THE MATERIAL PROCESSOR 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

- 53 -

OPERATING INSTRUCTIONS

USE THE MATERIAL PROCESSOR ONLY FOR 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

- 54 -

OPERATING INSTRUCTIONS

USE THE MATERIAL 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

- 55 -

OPERATING INSTRUCTIONS

USE THE MATERIAL PROCESSOR ONLY FOR THE APPLICATION FOR WHICH IT IS INTENDED:

 NPK Material Processors 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

- 56 -

OPERATING TECHNIQUES AND PRECAUTIONS

1. Do not use 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.

- 57 -

OPERATING TECHNIQUES AND PRECAUTIONS

3. For 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 Material Processor as possible. Do not force the material into the jaw.

If you have any 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 positioning the processor and supplying hydraulic power to the processor.

- 58 -

OPERATING TECHNIQUES AND PRECAUTIONS

5. Do not use the rebar cutters on the “S” and “G” jaw sets to cut rod over 1-1/4” in

diameter.

6. Do not operate the 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 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 what your carrier is equipped with.

- 59 -

GENERAL MAINTENANCE

REFER TO IMPORTANT SAFETY INFORMATION SECTION

DAILY INSPECTION AND MAINTENANCE

The functions the Material Processor performs are demanding in tough environments. Therefore, 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).

- 60 -

GENERAL MAINTENANCE

REFER TO IMPORTANT SAFETY INFORMATION SECTION

DAILY INSPECTION AND MAINTENANCE

 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 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 “CUTTER BLADE MAINTENANCE”.

- 61 -

GENERAL MAINTENANCE

GR1

CYLINDER ROD PINS

One lubrication point per cylinder located at the jaw attachment end.

10 strokes from a grease gun every 4 hours.

GR3

JAW PIVOT PIN

One lubrication point on each end of the main pivot pin (M20), two lubrication points at one end, one 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

One lubrication point located at the main frame attachment end.

10 strokes from a grease gun every 4 hours.

LUBRICATION POINTS

M20, M28, M38

- 62 -

GENERAL MAINTENANCE

CUTTER BLADE MAINTENANCE

C, G, AND S JAWS

When cutter blades become damaged or rounded due to abrasion, grind the rounded 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.

- 63 -

GENERAL MAINTENANCE

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

CUTTER BLADE MAINTENANCE

C, G, AND S JAWS

DO NOT WELD CUTTER BLADES!

Torque the cutter blade bolts (AF) to specification; see the “FASTENER TORQUE” section of this manual.

BLADE-TO-BLADE CLEARANCE

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

Fig. 1

- 64 -

GENERAL MAINTENANCE

M20K, M28K, M38K JAW MAINTENANCE

The following information is to be used as a general guide for maintaining the K Jaw and cutter blades on the NPK M Series Processor. Failure to maintain the jaws and cutter blades will result in poor performance, and eventual failure to the jaws and cutte r blades. These failures are not covered under the standard NPK warranty.

Use care when handling the blades.

Do not over grind the cutter blades.

Do not weld on the cutter blades.

During normal use of a processor, the jaws and cutter blades will become worn. Regular maintenance must be performed to 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 of the cutting blades. If the edge is rounded and dull, grind the

edges back to 90°. Rotate the blades if extreme wear or chipping on the cutting edge is noted. If the blades are replaced or rotated, they must be shimmed. Blades should be shimmed from .005” (0.127 mm) to a maximum of .010” (0.254 mm). Replace the blades if they are cracked.

 See “BLADE MAINTENANCE AND ADJUSTMENT” for piercing tip and blade

maintenance.

- 65 -

GENERAL MAINTENANCE

Fig. 2

(With weld-on piercing tip)

ARM

PRIMARY CUTTING BLADE

BG1

SECONDARY CUTTING BLADE

SHIM PACK (drive arm only)

DRIVE ARM

PIERCING TIP (weld-on)

TUNNEL BLADE

SPACER

SPACER PLATE

GUIDE BLADE (not shown)

CUTTER BLADE MAINTENANCE – K JAWS

BLADE-TO-BLADE CLEARANCE

M20K, M28K, and M38K

A blade-to-blade clearance of .000” to .010” (.00 to 0.25 mm) should be maintained for optimum performance.

See Fig. 2 and 3 for cutting blade and shim arrangement. Refer to the NPK Parts Manual for part numbers.

PIERCING TIP TO TUNNEL GAP

M20K, M28K, and M38K

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 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).

- 66 -

GENERAL MAINTENANCE

Fig. 3

(With bolt-on piercing tip)

ARM

PRIMARY CUTTING BLADE

BG1

SECONDARY CUTTING BLADE

SHIM PACK (drive arm only)

DRIVE ARM

TUNNEL BLADE

SPACER

SPACER PLATE

GUIDE BLADE (not shown)

PIERCING TIP (bolt-on)

ST1.

Install the primary blades in the arm second. Check to ensure that the primary blade faces are parallel. See “COMPONENT 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 ADJUSTMENT”, Step 4.

ST4.

Install the tunnel blade in the drive arm. See “COMPONENT DESCRIPTION” and “BLADE MAINTENANCE and ADJUSTMENT”, Step 5.

ST5.

Install the piercing tip on the arm (if needed) first. See “COMPONENT DESCRIPTION” and “PIECING TIP MAINTENANCE AND REPLACEMENT”.

PIERCING TIP TO TUNNEL GAP

M20K, M28K, and M38K

K JAW BLADE SET UP PROCEDURE

M20K, M28K, and M38K

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GENERAL MAINTENANCE

COMPONENT 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).

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GENERAL MAINTENANCE

K JAW BLADE MAINTENANCE AND ADJUSTMENT

Each cutting blade and the tunnel blade can be turned four times. The guide blade can only be turned twice. The piercing tip is a weld-in style and can be built up via a weld procedure (see “PIERCING TIP MAINTENANCE AND REPLACEMENT”). The piercing tip can also be replaced (see “REPLACING 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 from the pockets using a grinder (t1).

If existing blades (BG) are being turned, the face must also be free of scars. Remove the scars using a grinder (t1).

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GENERAL MAINTENANCE

K JAW BLADE MAINTENANCE AND ADJUSTMENT

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 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 difference between the primary blades is

excessive, install new primary blades. DO NOT ADD SHIMS BEHIND THE PRIMARY

BLADES!

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GENERAL MAINTENANCE

K JAW BLADE MAINTENANCE AND ADJUSTMENT

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, 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.

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GENERAL MAINTENANCE

K JAW BLADE MAINTENANCE AND ADJUSTMENT

Begin closing the processor jaws until the first primary blade (BG) begins 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 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 socket head cap screws (OO) for each secondary blade and apply thread adhesive. Then torque to NPK specifications (see the “FASTENER TORQUE CHART”).

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GENERAL MAINTENANCE

K JAW BLADE MAINTENANCE AND ADJUSTMENT

STEP 4:

The female jaw (BI) also has a guide blade (DF) and a spacer plate (DE). This blade is located directly across from the first secondary blade (BG1).

The guide blade (DF) must also be shimmed as close as possible to the side of the piercing 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 Note:

The guide blade clearance will have to be checked after any weld build-up of the piercing tip.

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GENERAL MAINTENANCE

K JAW BLADE MAINTENANCE AND ADJUSTMENT

STEP 5:

Inspect the tunnel blade (DB), located in the bottom of the female jaw (BI). If the lead edge is worn or rounded off, remove and turn the blade. This blade can be turned four times. There is a spacer plate (DE) between the blade and pocket wall, be sure to install this spacer. The tunnel blade does not require shimming. Apply thread adhesive to the socket head cap screws (OO) for the tunnel blade. Then torque to NPK specifications (see “FASTENER TORQUE CHART”).

PIERCING TIP MAINTENANCE AND REPLACEMENT

Before maintenance is performed on the piercing tip, it is recommended that the fixed female jaw tunnel be repaired first. (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 enter the female jaw (tunnel). The piercing tip should fit squarely in the female jaw tunnel. The piercing tip will require attention if a large gap is noted and the tip is rounded. Also, if it is noted that the material is being drug through the tunnel and not efficiently pierced by the tip, is also an indication that the tip is in need of attention. The length of time between piercing tip maintenance will greatly influence if a tip can be repaired or if the tip must be replaced.

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GENERAL MAINTENANCE

ts1

ts2

M20K

19011029

19011030

M28K

19011031

19011032

M38K

19011033

19011034

TAPER LINER FOR M SERIES PROCESSOR “K” JAW

NPK provides a taper 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.

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GENERAL MAINTENANCE

Fig. A

Fig. B

BUILD-UP OF THE PIERCING TIP

Before beginning the build-up of the existing piercing tip, it is necessary to first grind off all remaining hardface material. After determining the amount of build-up required, preheat the tip and surrounding area to 300° - 400°F (150° - 200°C). Using a suitable underlay rod, build up the areas in question by using stringer welds. Peen after each pass. Continue to build the areas by overlaying weld stringers. Stop periodically and cycle the piercing tip through the female jaw tunnel to check the 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 new tip, carbon arc (t12) or torch cut (t13) off the old tip approximately the dimension of your model piercing tip, please note that a seat for the top is present in the male jaw, see Fig. A. The surface must be prepared by chamfering the male jaw, see Fig. B. NOTE: Be sure the area is free from all carbon residue, leaving it flat and smooth.

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GENERAL MAINTENANCE

Fig. C

Fig. D

REPLACING THE PIERCING TIP

Place the new tip into the seat area. Use a straight edge to position the tip before tacking it into place. Place the straight edge against the face of the cutting blade and maintain the alignment to the side edge of the replaceable tip.

Move tip squarely against the edge, making sure it is level, see Fig. C. Tack firmly in place, see Fig. D, cycle the processor jaws to check the clearance of the new tip. The leading edge 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.

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 to 300°F - 400°F (150° - 200°C).

JOINING AND BUILD-UP

For joining, stringer beads are the 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, and Stoody 2110.

Fig. E

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GENERAL MAINTENANCE

DETERMINING REPLACEMENT OR BUILD UP

The piercing tip profile must be maintained for piercing efficiency. Piercing tip build up and/or replacement should be completed after all cutting blade, guide blade, and tunnel blade maintenance has been completed (see “K JAW BLADE MAINTENANCE AND ADJUSTMENT”, STEPS 1 through 5.) Perform the following steps to determine 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 female jaw (BI) tunnel. Note the wear on the corners of the piercing tip and also the gap (d66) between the lead edge of the piercing tip and the tunnel blade (DB), see Fig. B.

Fig. B

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GENERAL MAINTENANCE

DETERMINING REPLACEMENT OR BUILD UP

STEP 3a

If the gap between the straight edge and the piercing tip is minor and the wear on the lead edge and corners of the tip is not excessive, weld build-up of the tip is recommended, (see “BUILD-UP OF THE PIERCING TIP”). If tip wear is excessive, replace the piercing tip, (see “REPLACING THE PIERCING TIP”).

STEP 4a

After completing the welding and grinding of the tip, place the 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). Additional welding or grinding may be required to achieve the desired clearance, see Fig. C.

When installing a new piercing tip, the clearance between the piercing tip and tunnel blade can be set when placing the new tip in the male jaw.

Fig. C

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GENERAL MAINTENANCE

DETERMINING REPLACEMENT OR BUILD UP

STEP 6a

Close the processor jaws until the side of the piercing tip (DA) is 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.

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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. M38039501 and M3803-9502 (M38S), M2803-9500 and M2803-9501 (M28S), and M20039500 and M2003-9501 (M20S). Then, refer to JAW and TOOTH REBUILD

PROCEDURE.

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JAW INSPECTION AND MAINTENANCE

C 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 (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. M28049501 (M28C) and M2004-9500 (M20C). Then, refer to JAW and TOOTH REBUILD

PROCEDURE.

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JAW INSPECTION AND MAINTENANCE

TEETH REPLACEMENT

The M20G/M28G/M38G Material Processors have three types of jaw teeth (mp1, mp2, and mp8). All three types can be cut off and replaced when worn beyond rebuild ability.

Following is the procedure for teeth replacement:

1. Remove worn teeth by carbon arc (t12) or acetylene cutting torch (t13).

2. Prepare surface for new teeth.

3. Place new teeth into proper location.

4. Heat dry welding rod to 300°F+ (150°C+).

5. Pre-heat weld area to 300°F - 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 (or wire equivalent) or equal: Airco Hardcraft CR-70, Cronatron 7350, Eutectic Eutectrode N70, Hobart Smooth Arc 16, McKay Hardalloy 40 Tic, Stoody 19, 21, or 77.

8. Adjust weld current to rod manufacturer’s specification.

9. Peen each layer.

10. Cool slowly. Cover weld in cold environments.

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JAW INSPECTION AND MAINTENANCE

REPLACEABLE TOOTH PLATES – G JAWS

Another alternative is to replace the entire bolt-on plates.

The male jaw tooth plate (BE) is part number M3802-9500 (M38G), M2802-9500 (M28G) and M2002-9500 (M20G)

JAW AND TOOTH REBUILD PROCEDURE: S, C, and G JAWS

Due to the abrasive nature of the material being crushed, jaw wear will occur on the M20, M28, and 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. Hard Face Weld.

1. SURFACE PREPARATION

Grind the entire worn area until it is smooth and clean. Remove all paint, grease, oil, dirt, and old hard facing material before welding.

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JAW INSPECTION AND MAINTENANCE

JAW AND TOOTH REBUILD PROCEDURE: S, C, and G JAWS

2. UNDERLAYMENT

Underlayment weld is necessary to build-up the base material (DH) to match the original jaw or tooth profile before hard facing. You cannot hard face over old hard facing.

 Welding rod: Airco Austex 361, Cronatron 7770, 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 cold environments.

3. HARDFACE

Hardface (we3) can only be applied over base material (DH) or underlayment weld (we2). NEVER HARDFACE OVER EXISTING HARDFACE!

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JAW INSPECTION AND MAINTENANCE

1. BEFORE WELD

2. AFTER WELD

CORRECT

BD/BI

MALE OR FEMALE

CRUSHER JAW

WORN AREA

we2

UNDERLAYMENT

we3

HARDFACE

CORRECT

BD/BI

MALE OR FEMALE

CRUSHER JAW

we2

UNDERLAYMENT

we3

HARDFACE

we5

END OF NEW WELD

we6

OLD WELD

FINISH GRIND TO BLEND

INCORRECT

BD/BI

MALE OR FEMALE

CRUSHER JAW

we4

OVERFLOW

we5

END OF NEW WELD

JAW AND TOOTH REBUILD PROCEDURE: S, C, and G JAWS

Welding Rod: Airco Tubecraft 1A, Cronatron 7355, Eutectic N6006, Postalloy 214, Stoody 31 or equal. In Canada: NCH Canada Inc. Wear-X #176 or equal.

 Dry welding rod at 300°F+ (150°C+).  Pre-heat the jaw weld area to 350°F (177°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. 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.

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JAW INSPECTION AND MAINTENANCE

S JAW

C JAW

G JAW

JAW CONTACT AREAS

S, C, and G JAW CONTACT AREAS

In contact areas of jaws, hard facing (we3) may be added to increase the wear life of these surfaces for hard facing instructions, see the “JAW and TOOTH REBUILD

PROCEDURE”.

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 adjoining blades, see “HARDFACING K JAWS”.

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JAW INSPECTION AND MAINTENANCE

HARDFACING: K JAWS

If hard facing is to be performed, the jaw must be preheated to 300° - 400°F (150° 200°C) before hard facing is applied. Failure to preheat the tip area will cause the hard

facing to crack and chip off prematurely. Using a suitable hard face rod, apply the material in stringer beads vertically on the front and sides of the piercing tip and parallel to the moveable jaw on the 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 process takes approximately twelve hours. It is recommended that the tip area is covered with a heat blanket, covered with dry sand, floor dry, or other suitable material. Refer to the “HARDFACE” section and use the same procedure.

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FRAME MAINTENANCE – REPAIR OF MAIN FRAME

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 plate, grind the bevel in halfway from both sides. Remove all slag and grinding residue.

4. Consult the “JAW and TOOTH REBUILD PROCEDURE, HARDFACE” section for pre-heat and welding instructions.

5. Peen or stress relieve after each pass. Maintain pre-heat.

6. After welding, grind area flush.

DIRECTION OF GRINDING

DIRECTION OF PRINCIPLE STRESS

Inspect frame for cracks periodically. Crushing or shearing is an abusive operation and eventually frame cracking may occur. If the attachment has been overstressed due to improper operation or has been used for many hours of operation, the steel components may develop fatigue cracks. If cracking is found in any of the steel components of the processor, photos of the crack or cracks must be emailed to NPK immediately so that the crack can be evaluated and a repair option recommended.

ROUTINE WELD REPAIR

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FRAME MAINTENANCE – REPAIR OF MAIN FRAME

ROUTINE WELD REPAIR

7. Allow area to cool slowly (eight hours minimum). Cover with a heat blanket or other suitable insulation. FAILURE TO DO SO MAY CAUSE 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.

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CYLINDER INSPECTION AND MAINTENANCE

1. Remove the Booster Assembly (bs35) 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).

BOOSTER CYLINDER

DISASSEMBLY

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CYLINDER INSPECTION AND MAINTENANCE

5. Check the piston rings (c8). The rings should be free in their grooves. If the rings are found to be stuck in their grooves, use a die grinder with a soft polishing stone (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 rod (c3). Remove the cylinder end cap (c5).

BOOSTER CYLINDER

DISASSEMBLY

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CYLINDER INSPECTION AND MAINTENANCE

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.

BOOSTER CYLINDER

DISASSEMBLY

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CYLINDER INSPECTION AND MAINTENANCE

INSPECTING AND CLEANING CYLINDER COMPONENTS

The prevention of foreign contaminant damage is critical when working with hydraulic equipment. Keep the work area clean. Using masking tape, cover all exposed holes and parts which may allow entry of foreign contaminants. Habitually clean the work area by wiping with a lint-free dry cloth.

Mating surfaces are machined to a smooth surface. Use care to avoid scratches, nicks, dents, or other damage to machined surfaces. If damaged, the component must be repaired or replaced as required.

1. Inspect the 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. Inspect drained and residual hydraulic fluid for evidence of contamination. If contaminated, inspect all components, seal, etc., to determine the cause.

4. Inspect the cylinder housing (c4) bore. Lightly hone using a ball hone (t17). If there is heavy scoring, the cylinder housing will need to be replaced.

5. Inspect the bronze guide (c10) found in the cylinder end cap (c5) for damage or excessive wear.

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CYLINDER INSPECTION AND MAINTENANCE

INSPECTING AND CLEANING CYLINDER COMPONENTS

6. Using a die grinder with a soft polishing stone (t8), preferably NPK polishing wheel p/n 25026030, polish the leading edges of the piston ring grooves (25) to remove damage to the piston and allow free movement of the piston rings.

7. Using a straight edge (t15), check the cylinder rod (c3) for straightness.

NOTE: The cylinder rod is a forged, high 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 current at other people within the work area.

9. Remove all thread sealant from threads using an appropriate thread sealant solvent. Remove old thread sealant residue with a maximum of 30 psi (2 bars) of compressed air.

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CYLINDER INSPECTION AND MAINTENANCE

Air or electric handheld grinder (NPK model NHG-65LD recommended)

Polishing wheel for grinder (NPK p/n 25026030)

NPK Assembly Lube (p/n H010-5010)

Emery cloth (200 grit)

Cleaning solvent

REPAIR TOOLS AND EQUIPMENT

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.

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CYLINDER INSPECTION AND MAINTENANCE

ASSEMBLY

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 (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).

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CYLINDER INSPECTION AND MAINTENANCE

Style “A”

Style “B”

Style “C”

ASSEMBLY

5. Apply high strength thread adhesive (t41) to the clean dry threads (th1) of the cylinder rod.

NOTE: New style cylinder 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.

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CYLINDER INSPECTION AND MAINTENANCE

MODEL

THREAD

TORQUE

SOCKET

ROD NUT PART NUMBER

SIZE

ft. lb.

(Nm)

SIZE

STYLE "A"

STYLE "B"

STYLE "C"

M20

M65 x 3.0

3,250

(4,400)

90 mm

16032575

16084717

M28

M70 x 3.0

4,100

(5,500)

120 mm

16039992

16084683

G180-1000

M38

M70 x 3.0

4,100

(5,500)

120 mm

16039992

16084683

G180-1000

ASSEMBLY

7. Install cylinder rod nut (c1) onto cylinder rod (c3) and torque to the listed value below.

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 1/64th 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 (Style “C” type), the replacement will have a nylon patch and will not require a set screw.

9. Using a ring expander (t16), install the piston rings with the splits in the piston rings opposing each other.

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CYLINDER INSPECTION AND MAINTENANCE

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)

ASSEMBLY

10. 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.

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.

- 100 -

CYLINDER INSPECTION AND MAINTENANCE

ASSEMBLY

13. Apply a light coat of oil or NPK Assembly Lube to four (quantity of six 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.

NPK M20S, M20C, M20K, M20G, M28S Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual