NPK U Series Operation And Maintenance Manual
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NPK U Series Operation And Maintenance Manual

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U and G-SERIES SECONDARY
CONCRETE CRUSHERS
MODELS U21J, U21JR, U31J, U31JR
OPERATION AND MAINTENANCE MANUAL
© Copyright 2018 NPK Construction Equipment, Inc.
G Series Crushers Operation Manual 10-18
U45J, U45JR, G7, G18J, G26J, G30JR
"Use Genuine NPK Parts"
"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
www.npkce.com
U000-9600B U and

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  • Page 1 "Use Genuine NPK Parts” "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 U000-9600B U and G Series Crushers Operation Manual 10-18...

  • Page 2: Table Of Contents

    CONTENTS SAFETY ..............................3 OPERATION ............................4 MAINTENANCE ..........................5 INTRODUCTION ............................. 7 EXCAVATOR COMPATIBILITY ....................... 7 MODEL SPECIFICATIONS ........................8 SERIAL NUMBER LOCATION ......................20 U21J/JR, U31J/JR, U45J/JR ......................20 G7, G18J, G26J ..........................21 G30JR .............................. 22 CRUSHER BOOSTER & CYLINDER ..................... 23 INTRODUCTION ..........................
  • Page 3 CONTENTS U21J, U21JR, U31J, U31JR, U45J, U45JR, G30JR ................82 G7, G18J, G26J ..........................82 SWIVEL MANIFOLD MAINTENANCE ....................84 SWIVEL MANIFOLD ASSEMBLY ..................... 84 LEAKAGE OF THE SEALS ....................... 84 TESTING THE SWIVEL SEALS FOR INTERNAL LEAKAGE ............. 84 REPLACEMENT OF THE SEALS IN THE SWIVEL ................

  • Page 4: Safety

    CONCRETE CRUSHER. The decal must be installed in the cab, visible to the operator. WARNING - STAY CLEAR decals are installed on all NPK CONCRETE CRUSHERS. Keep them clean and visible. NPK will provide decals free of charge as needed. FALLING OR FLYING DEBRIS decal is included with each NPK CONCRETE CRUSHER.

  • Page 5: Operation

    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 CONCRETE CRUSHER while in operation.

  • Page 6: Maintenance

    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.
  • Page 7 SAFETY MAINTENANCE STANDARD PRACTICES ATTENTION Maintenance of and repairs to the CONCRETE CRUSHER 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.

  • Page 8: Introduction

    INTRODUCTION 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.

  • Page 9: Model Specifications

    MODEL SPECIFICATIONS U21J SECONDARY CONCRETE CRUSHER MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening (seconds) (kg) (mm) (lpm) open close U21J 4,650 (2,110) 31.6 (802.4) 26-53 (98-200) MODEL Maximum Crushing Force Crushing Force Operating Pressure at d86 at d87 (Metric (Metric (bar)
  • Page 10 MODEL SPECIFICATIONS U21JA SECONDARY CONCRETE CRUSHER MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening (seconds) (kg) (mm) (lpm) open close U21JA 4,650 (2,110) 31.6 (802.4) 26-53 (98-200) MODEL Maximum Crushing Force Crushing Force Operating Pressure at d86 at d87 (Metric (Metric (bar)
  • Page 11 MODEL SPECIFICATIONS U21JR SECONDARY CONCRETE CRUSHER MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening (seconds) (kg) (mm) (lpm) open close U21JR 5,400 (2,500) 31.6 (802.4) 26-53 (98-200) MODEL Maximum Crushing Force Crushing Force Operating Pressure at d86 at d87 (Metric (Metric (bar)
  • Page 12 MODEL SPECIFICATIONS U31J SECONDARY CONCRETE CRUSHER MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening (seconds) (kg) (mm) (lpm) open close U31J 7,000 (3,175) 38.6 (980) 26-66 (98-250) MODEL Maximum Crushing Force Crushing Force Operating Pressure at d86 at d87 (Metric (Metric (bar)
  • Page 13 MODEL SPECIFICATIONS U31JA SECONDARY CONCRETE CRUSHER MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening (seconds) (kg) (mm) (lpm) open close U31JA 7,000 (3,175) 38.6 (980) 26-66 (98-250) MODEL Maximum Crushing Force Crushing Force Operating Pressure at d86 at d87 (Metric (Metric (bar)
  • Page 14 MODEL SPECIFICATIONS U31JR SECONDARY CONCRETE CRUSHER MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening (seconds) (kg) (mm) (lpm) open close U31JR 8,000 (3,630) 38.6 (980) 26-66 (98-250) MODEL Maximum Crushing Force Crushing Force Operating Pressure at d86 at d87 (Metric (Metric (bar)
  • Page 15 MODEL SPECIFICATIONS U45J SECONDARY CONCRETE CRUSHER MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening (seconds) (kg) (mm) (lpm) open close U45J 9,000 (4,080) 44.5 (1130) 46-73 (175-275) MODEL Maximum Crushing Force Crushing Force Operating Pressure at d86 at d87 (Metric (Metric (bar)
  • Page 16 MODEL SPECIFICATIONS U45JR SECONDARY CONCRETE CRUSHER MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening (seconds) (kg) (mm) (lpm) open close U45JR 9,920 (4,500) 44.5 (1130) 46-73 (175-275) MODEL Maximum Crushing Force Crushing Force Operating Pressure at d86 at d87 (Metric (Metric (bar)
  • Page 17 MODEL SPECIFICATIONS G7 SECONDARY CONCRETE CRUSHER MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening (seconds) (kg) (mm) (lpm) open close 1,650 (750) (533.4) 13-21 (49-80) MODEL Maximum Crushing Force Crushing Force Operating Pressure at d86 at d87 (Metric (Metric (bar) Ton) Ton)
  • Page 18 MODEL SPECIFICATIONS G18J SECONDARY CONCRETE CRUSHER MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening (seconds) (kg) (mm) (lpm) open close G18J 4,400 (2000) (838.2) 26-52 (98-197) MODEL Maximum Crushing Force Crushing Force Operating Pressure at d86 at d87 (Metric (Metric (bar) Ton)
  • Page 19 MODEL SPECIFICATIONS G26J SECONDARY CONCRETE CRUSHER MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening (seconds) (kg) (mm) (lpm) open close G26J 6,050 (2745) (965.2) 26-66 (98-250) MODEL Maximum Crushing Force Crushing Force Operating Pressure at d86 at d87 (Metric (Metric (bar) Ton)
  • Page 20 MODEL SPECIFICATIONS G30JR SECONDARY CONCRETE CRUSHER MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening (seconds) (kg) (mm) (lpm) open close G30JR 7,000 (3175) (965.2) 26-66 (98-250) MODEL Maximum Crushing Force Crushing Force Operating Pressure at d86 at d87 (Metric (Metric (bar) Ton)

  • Page 21: Serial Number Location

    SERIAL NUMBER LOCATION U21J/JR, U31J/JR, U45J/JR...

  • Page 22: G7, G18J, G26J

    SERIAL NUMBER LOCATION G7, G18J, G26J...

  • Page 23: G30Jr

    SERIAL NUMBER LOCATION G30JR...

  • Page 24: Crusher Booster & Cylinder

    This reduces cycle time for the NPK Crusher. To open the jaws of the NPK Crusher, oil is directed to the rod end of the cylinder. This retracts the rod and pulls the jaw open. No boost is provided in the jaw open mode.

  • Page 25: Structure Of The Boosted Cylinder

    CRUSHER BOOSTER & CYLINDER STRUCTURE OF THE BOOSTED CYLINDER As shown in Fig. 1, the booster cylinder consists of: Jaw Cylinder Booster Piston Main Valve Assembly Sequence Valve Cartridge Relief Valve (close) Relief Valve (open) Plunger Pilot Check Valve Assembly Check Valve 1 - booster piston inner "B"...

  • Page 26: Operating Principle

    CRUSHER BOOSTER & CYLINDER OPERATING PRINCIPLE Jaw Cylinder Pilot Check Valve Assembly Carrier Control Valve High Pressure Hydraulic Flow Low Pressure Hydraulic Flow Intensified Hydraulic Flow When the cylinder (c11) is extended (jaw close) and no load (material to be crushed) is encountered, oil is directed from the carrier control valve (k7) to the base end of the cylinder by way of the pilot check valve...
  • Page 27 CRUSHER BOOSTER & CYLINDER OPERATING PRINCIPLE Booster Piston Main valve Assembly Sequence Valve Cartridge High pressure Hydraulic Flow Low Pressure Hydraulic Flow Intensified Hydraulic Flow When a load (material to be crushed) is 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...
  • Page 28 CRUSHER BOOSTER & CYLINDER OPERATING PRINCIPLE Jaw Cylinder Booster Piston Main Valve Assembly Sequence Valve Cartridge Check Valve 3 - booster sleeve "B" Check Valve 4 - booster sleeve "A" Oil Chamber - 1 Oil Chamber - 2 Oil Chamber - 4 High Pressure Hydraulic Oil Low Pressure Hydraulic Oil Intensified Hydraulic Oil...
  • Page 29 CRUSHER BOOSTER & CYLINDER OPERATING PRINCIPLE Booster Piston Main Valve Assembly Plunger Port C1 Piston Port C2 Piston High Pressure Hydraulic Flow Low Pressure Hydraulic Flow Intensified Hydraulic Flow When the booster piston (c14) reaches its full stroke, oil entering port “C1” (c26) transfers to port “C2”...
  • Page 30 CRUSHER BOOSTER & CYLINDER OPERATING PRINCIPLE Jaw Cylinder Booster Piston Main Valve Assembly Pilot Check Valve Assembly Check Valve 3 - booster sleeve "B" Check Valve 4 - booster sleeve "A" Oil Chamber - 2 Oil Chamber - 3 Oil Chamber - 4 High Pressure Hydraulic Flow Low Preuusre Hydraulic Flow Intensified Hydraulic Flow...
  • Page 31 CRUSHER BOOSTER & CYLINDER OPERATING PRINCIPLE Booster Piston Main Valve Assembly Plunger Port C2 Piston Port C3 Piston Carrier Control Valve High Pressure Hydraulic Flow Low Pressure Hydraulic Flow Intensified Hydraulic Flow 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.
  • Page 32 CRUSHER BOOSTER & CYLINDER OPERATING PRINCIPLE Jaw Cylinder Pilot check valve assembly Carrier Control Valve High pressure Hydraulic Flow Low Pressure Hydraulic Flow Intensified Hydraulic Flow When the crusher jaw is opened, oil from the excavator’s control valve (k7) is directed through the booster to the rod end of the cylinder (c11).

  • Page 33: Hydraulic Installation

    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 Crusher, including valves, electrical or manual controls, hoses and fittings, boom and stick piping and clamps are provided.

  • Page 34: Shut-Off Valves

    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.
  • Page 35 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...

  • Page 36: Prevention Of Contamination

    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.

  • Page 37: Hydraulic Quick Disconnects

    HYDRAULIC INSTALLATION HYDRAULIC QUICK DISCONNECTS NPK prefers the use of a straight JIC connection (39) when installing its crusher onto a carrier. NOTE: Care should be given when removing the crusher to make sure that the hoses are plugged and the tube ends are capped to prevent contamination from entering the hydraulic system.
  • Page 38 NPK approved quick disconnects are properly sized so that the crusher operation is not affected. 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.

  • Page 39: Mounting Installation

    Stover Nut 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. “U” AND “G” SERIES ROTATING TOP BRACKET The “U”...

  • Page 40: Mounting To The Carrier

    MOUNTING INSTALLATION MOUNTING TO THE CARRIER 1. Position the crusher horizontal on a wood block (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.

  • Page 41: Removal From The Carrier

    MOUNTING INSTALLATION REMOVAL FROM THE CARRIER 1. Retract the cylinder 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 crusher down. Install metal plugs in the hydraulic hoses and metal caps on the stick tubes to keep out contamination.

  • Page 42: Hose Installation

    HOSE INSTALLATION WHIP 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.
  • Page 43 HOSE INSTALLATION WHIP 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 radius to prevent kinking, flow restrictions, or hose failures at the hose connection.

  • Page 44: Operating Instructions

    OPERATING INSTRUCTIONS Before operating the NPK Crusher, be sure to read the safety information and perform the daily and weekly maintenance as specified in this manual. DO NOT OPERATE THE CRUSHER WITHOUT DEMOLITION GUARDS IN PLACE! DO NOT LIFT OR LOAD BEYOND THE CAPACITY OF THE CRUSHER OR THE...
  • Page 45 OPERATING INSTRUCTIONS USE THE CRUSHER ONLY FOR THE APPLICATION FOR WHICH IT IS INTENDED:  NPK “U” and “G” Series Crushers are designed for the downsizing of concrete, the separation of concrete and rebar and some primary demolition.

  • Page 46: Operating Techniques And Precautions

    OPERATING TECHNIQUES AND PRECAUTIONS 1. Do not use the NPK Crusher with the excavator cylinders fully extended or retracted. 2. Do not strike the material with the crusher main body (DN1) or outer surface of the jaw set (DO1). Do not push, pull, or scrape material with the crusher.
  • Page 47 OPERATING TECHNIQUES AND PRECAUTIONS 4. Do not pry, twist, or pull with the excavator. Allow the hydraulic crushing forces of the crusher 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 and supplying hydraulic power to the crusher.
  • Page 48 OPERATING TECHNIQUES AND PRECAUTIONS 7. Do not operate the crusher 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.

  • Page 49: General Maintenance

     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 jaw and main frame for cracks. See the “FRAME CRACK AND JAW REPAIR”...

  • Page 50: Lubrication Points

    GENERAL MAINTENANCE LUBRICATION POINTS U21J(R), U31J(R), U45J(R), G30JR CYLINDER ROD PIN One lubrication point 10 strokes from a located at the jaw grease gun every 4 attachment end. hours. CYLINDER PIVOT PIN One lubrication point per 10 strokes from a side located at the grease gun once per cylinder trunnion flanges.
  • Page 51 GENERAL MAINTENANCE LUBRICATION POINTS G7, G18J, G26J CYLINDER ROD PIN lubrication point 10 strokes from grease located gun per shift. attachment end. CYLINDER PIVOT PIN One lubrication point per strokes from side located grease gun once per cylinder trunnion flanges. shift.

  • Page 52: Hose Installation Tips

    GENERAL MAINTENANCE HOSE INSTALLATION TIPS 1. Connect larger diameter hoses first. Larger hoses are more difficult to bend and maneuver, while 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.
  • Page 53 GENERAL MAINTENANCE HOSE INSTALLATION TIPS 5. Make sure the hose being installed 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 ⁰F ⁰C...

  • Page 54: Cutter Blade Maintenance

    GENERAL MAINTENANCE CUTTER BLADE MAINTENANCE 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.
  • Page 55 GENERAL MAINTENANCE CUTTER BLADE MAINTENANCE DO NOT WELD CUTTER BLADES! Torque the cutter blade bolts (OO) to specification; see the “FASTENER TORQUE” section of this manual. BLADE-TO-BLADE CLEARANCE Fig. 1 A blade-to-blade (A-A) clearance of .010” to .040” (0.25 to 1.00 mm) should be maintained for optimum performance.
  • Page 56 GENERAL MAINTENANCE SHIM KITS MODEL NPK SHIM KIT PART NUMBER U21J, U21JR U2100-1063 U31J, U31JR S1850-7000 U45J,U45JR 1615250 1609371 G18J S1850-7000 G26J S1850-7000 G30JR S1850-7000...

  • Page 57: Jaw Inspection And Maintenance

    MINIMUM DISTANCE BETWEEN FIXED AND MOVEABLE The distance between the fixed and moveable jaw must be maintained on U and G Series Crushers so that the crusher cylinder will not reach full stroke and become bottomed during operation. G SERIES U SERIES...
  • Page 58 JAW INSPECTION AND MAINTENANCE WEEKLY INSPECTION If the cylinder reaches full stroke and becomes bottomed out, damage to the cylinder head cap (c5) and retaining cap screws (OO) can occur. When the jaw teeth on moveable (BD) and fixed (BI) jaws become worn, allowing the gap to become less than the minimum (d3a) shown in TABLE 1, the teeth must be replaced or builtup by welding to reach the...

  • Page 59: Teeth Maintenance And Replacement

    NPK specification. MOVEABLE JAW BUILDUP and HARDFACING For buildup and hard facing, use NPK templates (t72) to check teeth so that they are to the original profile. Contact NPK for the correct templates for each model. Then, refer to JAW and TOOTH REBUILD PROCEDURE.

  • Page 60: Teeth Replacement

    JAW INSPECTION AND MAINTENANCE MOVEABLE JAWS: Wear on the small outside side teeth (mp5) determines when the cylinders are approaching full extension. The large center teeth (mp6) are for crushing purposes only. TEETH REPLACEMENT Following is the procedure for teeth replacement: 1.

  • Page 61: Replaceable Tooth Plates - Moveable Jaws

    Another alternative is to replace the entire bolt on plates (BE). The male jaw (BD) tooth plate (BE) is replaceable on all U21J, U21JR, U31J, U31JR, U45J, U45JR, G18J, G26J, and G30JR models. Contact NPK for part numbers. REPLACEABLE TOOTH PLATES – MAIN FRAME The main frame (BI) tooth plate (BE1) is replaceable on all U21JA and U31JA models.

  • Page 62: Jaw And Tooth Rebuild Procedure: All Models

    JAW INSPECTION AND MAINTENANCE JAW AND TOOTH REBUILD PROCEDURE: ALL MODELS Due to the abrasive nature of the material being crushed, jaw wear will occur on the U and G Series Crushers. 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.
  • Page 63 JAW INSPECTION AND MAINTENANCE JAW AND TOOTH REBUILD PROCEDURE: ALL MODELS 3. HARD FACE Hard face (we3) can only be applied over base material (DH) or underlayment weld (we2). NEVER HARD FACE OVER EXISTING HARD FACE! Welding Rod: Airco Tubecraft 1A, Cronatron 7355, Eutectic N6006, Postalloy 214, Stoody 31 or equal.

  • Page 64: Jaw Contact Areas

    JAW INSPECTION AND MAINTENANCE JAW AND TOOTH REBUILD PROCEDURE: ALL MODELS DO NOT WELD OVER OLD HARD FACING! Remove all old hard facing before applying new underlay weld. 1. BEFORE WELD 2. AFTER WELD CORRECT CORRECT INCORRECT BD/BI BD/BI BD/BI MALE OR FEMALE MALE OR FEMALE MALE OR FEMALE...

  • Page 65: Main Frame Rework Guide

    MAIN FRAME REWORK GUIDE Consult with the NPK Service Department to determine which rework procedure is required. U21J-5206 (U21J), U31J-5200 (U31J), and U45J-5202 (U45J) are the procedures to be followed for normal main frame rework. NORMAL WEAR U21J-5207 (U21J), U31J-5201 (U31J), and U45J-5201 (U45J) are the procedures to be followed for excessive main frame rework.

  • Page 66: Frame Maintenance - Repair Of Main Frame

    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.
  • Page 67 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...

  • Page 68: Inspection And Maintenance

    INSPECTION AND MAINTENANCE BOOSTER CYLINDER DISASSEMBLY 1. Remove the Booster Assembly (bs35) from the cylinder (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.
  • Page 69 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.
  • Page 70 INSPECTION AND MAINTENANCE BOOSTER CYLINDER DISASSEMBLY 9. Remove the dirt seal (QQ), rod seal (PP), o-ring (RR), and backup rings (SS) from the cylinder end cap (c5) and discard. 10. Remove the o-ring (RR) and backup rings (SS) from the inside of the piston (c2) and discard.

  • Page 71: Cylinder Components

    INSPECTION AND MAINTENANCE CYLINDER COMPONENTS INSPECTING AND CLEANING 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 cloth.
  • Page 72 CYLINDER COMPONENTS INSPECTING AND CLEANING 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.

  • Page 73: Repair Tools And Equipment

    Remove old thread sealant residue with a maximum of 30 psi (2 bars) of compressed air. REPAIR TOOLS AND EQUIPMENT 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)
  • Page 74 2. Apply hydraulic oil or NPK Assembly Lube (p/n H010-5010) 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.
  • Page 75 INSPECTION AND MAINTENANCE CYLINDER COMPONENTS ASSEMBLY 4. Install the piston (c2), with the dimple (24) facing away from the rod eye, onto the cylinder rod. 5. Apply high strength thread adhesive (t41) to the clean dry threads (th1) of the cylinder rod (c3). NOTE: New style cylinder rod nuts (without set screws) have a nylon...
  • Page 76 INSPECTION AND MAINTENANCE CYLINDER COMPONENTS ASSEMBLY 7. Thread cylinder rod nut (c1) onto the cylinder rod (c3) and torque to the listed value below. MODEL THREAD TORQUE SOCKET ROD NUT PART NUMBER STYLE STYLE STYLE SIZE ft. lb. (Nm) SIZE "A"...
  • Page 77 INSPECTION AND MAINTENANCE CYLINDER COMPONENTS 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).
  • Page 78 INSPECTION AND MAINTENANCE CYLINDER COMPONENTS ASSEMBLY 13. Apply a light coat of oil or NPK Assembly Lube to four new backup rings (SS), four new o-rings (RR) and the two spacers (bs23), then install in the corresponding counter bores of the main cylinder assembly (c11).
  • Page 79 INSPECTION AND MAINTENANCE CYLINDER COMPONENTS ASSEMBLY 16. Apply high-strength thread sealant to the clean, dry threads of the eight previously removed cap screws. MODEL BOLT TORQUE SIZE ft. lb. (Nm) U21J M16-2 (300) 17. Secure the main booster assembly U21JR M16-2 (300) to the cylinder housing using the...

  • Page 80: Top Bracket Conversion

    TOP BRACKET CONVERSION CONVERSION PACKAGES OFFERED FOR “U” SERIES CRUSHERS A. Safe handling procedures must be followed to avoid personal injury. B. Lifting and securing mechanisms must be of adequate capacity to safely support the particular crusher. Swivel Top Fixed Top CRUSHER PART FUNCTION...

  • Page 81: Slewing Ring Inspection And Maintenance

    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 MAXIMUM MODEL...

  • Page 82: Rotation Bearing Outer Dirt Seal Replacement

    SLEWING RING INSPECTION AND MAINTENANCE ROTATION BEARING OUTER DIRT SEAL REPLACEMENT Additional items needed: MODEL SLEWING RING DIRT SEAL PART NUMBER PART NUMBER High strength adhesive U21JR 25309660 25309273 Brake clean/solvent U31JR 25309680 25309353 U45JR 25309840 25309843 1. Remove old seal (QQ) from the bottom side (72) of the slewing ring (BT).

  • Page 83: Crusher Relief Locations

    CRUSHER RELIEF LOCATIONS U21J, U21JR, U31J, U31JR, U45J, U45JR, G30JR Relief valve cartridges (c17/c18) for the “U” Series and the G30JR are located on the swivel manifold on rotating units (see Fig. 1) and below the joint assembly on fixed units (see Fig.
  • Page 84 (operating) pressure. The test ports on the NPK shut-off valves provided with NPK hydraulic kits are used for checking the carrier relief settings and to test and set the crusher relief cartridges. If not using an NPK hydraulic kit, a similar provision must be made to check pressures.

  • Page 85: Swivel Manifold Maintenance

    SWIVEL MANIFOLD MAINTENANCE SWIVEL MANIFOLD ASSEMBLY The swivel manifold assembly is located between the top bracket, which is pinned to the carrier, and the crusher frame that rotates. Hydraulic oil for both the open and close operations of the crusher pass through this manifold. The swivel manifold assembly consists of two main parts, the “Spindle Case”...

  • Page 86: Replacement Of The Seals In The Swivel

    TESTING THE SWIVEL SEALS FOR INTERNAL LEAKAGE 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).
  • Page 87 SWIVEL MANIFOLD MAINTENANCE REPLACEMENT OF THE SEALS IN THE SWIVEL STEP 1 (Fig. 4) Disconnect the rotation hoses (m39) at the counterbalance valve (BO). Remove the rotation motor hoses and motor fittings (f1) from the hydraulic motor. Disconnect the cylinder hoses (AO) at the side plates of the top bracket.
  • Page 88 Install the o-ring. Refer to the illustration for o-ring and back-up ring placement. Fig. 8 Spray the “Spindle” (CA) with NPK assembly lube (P/N H010-5010). Install the hoses onto the “Spindle Case” (BZ). Slide the “Spindle Case” over the “Spindle”, which includes the relief valve...

  • Page 89: Fastener Torque Specifications

    FASTENER TORQUE SPECIFICATIONS These torque charts are to be used with the specific “U” or “G” Series Crusher parts manual for the unit being paired. All fasteners will be used with lube or medium strength thread adhesive. Bolts must have their threads wire brushed or cleaned with a thread die, then cleaned with solvent and finally cleaned with compressed air.
  • Page 90 FASTENER TORQUE SPECIFICATIONS FASTENER TORQUE CHART - MAIN FRAME ASSEMBLY BOLT LOCATION MODEL BOLT BOLT TORQUE ADHESIVE SIZE ft. lb. OR LUBED (Nm) CYLINDER ROD END U21J/JR (350) LUBED PIVOT PIN KEEPER U31J/JR (350) LUBED U45J/JR (450) LUBED CYLINDER PIVOT U21J/JR (450) LUBED...
  • Page 91 FASTENER TORQUE SPECIFICATIONS FASTENER TORQUE CHART - MAIN FRAME ASSEMBLY BOLT LOCATION MODEL BOLT SIZE BOLT TORQUE ADHESIVE ft. lb. OR LUBED (Nm) CYLINDER ROD END (255) LUBED PIVOT PIN KEEPER G18J (350) LUBED G26J (350) LUBED G30JR (350) LUBED CYLINDER PIVOT (165) LUBED...
  • Page 92 FASTENER TORQUE SPECIFICATIONS FASTENER TORQUE CHART - CYLINDER ASSEMBLY BOLT LOCATION MODEL BOLT SIZE BOLT TORQUE ADHESIVE ft. lb. OR LUBED (Nm) CYLINDER END CAP U21J/JR (350) LUBED U31J/JR (500) LUBED U45J/JR (500) LUBED CYLINDER ROD NUT U21J/JR (1900) 1400 ADHESIVE U31J/JR 3200...
  • Page 93 FASTENER TORQUE SPECIFICATIONS FASTENER TORQUE CHART - CYLINDER ASSEMBLY BOLT LOCATION MODEL BOLT SIZE BOLT TORQUE ADHESIVE ft. lb. OR LUBED (Nm) CYLINDER END CAP (255) LUBED G18J (350) LUBED (See NOTE₁) G18J (500) LUBED G26J (350) LUBED G26J (500) LUBED G26J (550)
  • Page 94 FASTENER TORQUE SPECIFICATIONS FASTENER TORQUE CHART - ROTATION COMPONENTS BOLT LOCATION MODEL BOLT BOLT TORQUE ADHESIVE SIZE ft. lb. OR LUBED (Nm) SLEWING RING U21JR (950) LUBED ASSEMBLY TO U31JR (1050) LUBED FRAME U45JR (1050) LUBED (1400) 1035 LUBED TOP PLATE TO U21JR (350) ADHESIVE...
  • Page 95 FASTENER TORQUE SPECIFICATIONS FASTENER TORQUE CHART - G30JR ROTATION COMPONENTS BOLT LOCATION BOLT BOLT TORQUE ADHESIVE SIZE ft. lb. OR LUBED (Nm) SLEWING RING (950) LUBED ASSEMBLY TO FRAME SLEWING RING (125) ADHESIVE COVER ROTATION MOTOR (350) ADHESIVE MOTOR PINION (125) ADHESIVE GEAR...

  • Page 96: Hose Torque Specifications

    HOSE TORQUE SPECIFICATIONS JIC ENDS NOMINAL FITTING THREAD NUMBER OF TORQUE SIZE DASH SIZE FLATS FROM SIZE FINGER TIGHT (Nm) ft. lb. 1/2" 3/4-16 36 - 39 (49 - 53) 3/4" 1-1/16-12 79 - 88 (107 - 119) 1" 1-5/16-12 108 - 113 (146 - 153) 1-1/4"...

  • Page 97: Troubleshooting

    NPK pressure intensifier performance. 2. LOSS OF CYCLE SPEED NPK CRUSHER cycle speed is determined by oil flow to the unit. The hydraulic installation circuit for the CRUSHER must be set to provide the correct flow. DETERMINE THE CAUSE OF THE PROBLEM Technical problems are caused by either the NPK CRUSHER or the carrier’s hydraulic...
  • Page 98 TROUBLESHOOTING TROUBLESHOOTING GUIDE FOR LOW POWER RELIEF VALVE CHECKS RELIEF VALVE CHECKS PROBLEM CAUSE CHECK REMEDY Operating Pressure Carrier hydraulic Measure the carrier Adjust or replace the is less than the circuit relief valve. circuit relief valve with carrier circuit relief pressure setting the pressure to close valve.
  • Page 99 TROUBLESHOOTING TROUBLESHOOTING GUIDE FOR LOW POWER RELIEF VALVE CHECKS LOW POWER CHECKS PROBLEM CAUSE CHECK REMEDY Operating pressure Booster sequence Observe sequence Replace the is per Crusher valve cartridge. valve operation. sequence valve (See "PRESSURE cartridge. (NOTE: specification (See MODEL INTENSIFIER The sequence valve SPECIFICATIONS"),...
  • Page 100 (For carriers with an NPK hydraulic installation kit installed). Pressure 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).
  • Page 101 TROUBLESHOOTING 1. CARRIER CIRCUIT RELIEF VALVE CHECK Verify that the hydraulic system of the carrier meets the requirements of the CRUSHER. A. Install a 0 – 5000 psi (350 bar) pressure gauge (g8f) in the #4 SAE test ports in each of the shut-off valves at the end of the stick.
  • Page 102 TROUBLESHOOTING 2. CRUSHER RELIEF VALVE After the CRUSHER hydraulic circuit has been verified, check the CRUSHER relief valve settings for both open and close. A. With a 0 – 5000 psi (350 bar) gauge installed in both the open and close side of the stick, open the shut-off valves.

  • Page 103: Relief Valve Location

    TROUBLESHOOTING CRUSHER SEQUENCE, RELIEF VALVE AND CARRIER RELIEF VALVE SETTINGS MODEL SERIAL NO. CRUSHER CRUSHER MINIMUM CARRIER SEQUENCE RELIEF VALVE RELIEF VALVE VALVE SETTING SETTING SETTING (bar) (bar) (bar) U21J/JR 2,990 (210) 3,771 (260) 4,000 (275) U31J/JR 2,990 (210) 4,061 (280) 4,250 (295)
  • Page 104 TROUBLESHOOTING RELIEF VALVE LOCATION The CRUSHER 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 105 TROUBLESHOOTING INTENSIFIER CHECKS (unit does not click) INTENSIFIER CHECKS PROBLEM CAUSE CHECK REMEDY Intensifier does not CRUSHER relief Check relief Tighten the relief click valves cartridges for valve cartridges. tightness. Check relief Reset to 3,625 psi cartridges for mis- (250 bar). If unable to adjustment.
  • Page 106 TROUBLESHOOTING INTENSIFIER CHECKS (unit clicks – does not slow down) INTENSIFIER CHECKS PROBLEM CAUSE CHECK REMEDY Intensifier clicks but CRUSHER relief Check relief Tighten the relief does not slow down valves cartridges for valve cartridges. tightness. Main valve orifice. Check the orifice, o- Clean the orifice and (NOTE: Not found rings and backup...
  • Page 107 TROUBLESHOOTING PRESSURE INTENSIFIER OPERATION NPK’s exclusive pressure intensifier system is used in NPK CRUSHERs 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.
  • Page 108 TROUBLESHOOTING CHECKING BOOSTED PRESSURE EXTREMELY HIGH PRESSURE OIL! NPK gauge assembly, P/N L017-8000 is available to directly check the boosted pressure on all CRUSHERS. The pressure intensifier’s have three test ports as shown. L017-8000 GAUGE ASSEMBLY guage: 0 - 15,000 psi...
  • Page 109 (For carriers with an NPK hydraulic installation kit installed.) Pressure 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. Loading type hydraulic flow meter (t36): 100 gpm (380 l/m) hydraulic flow capacity.
  • Page 110 TROUBLESHOOTING TEST PROCEDURE SLOW CYLINDER SPEED PROBLEM CAUSE CHECK REMEDY Operating Pressure Carrier hydraulic Measure the carrier Adjust or replace the is less than the circuit relief valve. circuit relief valve with carrier circuit relief pressure setting the pressure to close valve.
  • Page 111 TROUBLESHOOTING CHECKING THE HYDRAULIC FLOW AT RATED PRESSURE out port in port load valve flow/temperature display flow/temperature switch pressure gauge (Typical loading type flow meter) 1. Installation of the loading type flow meter. Install the flow meter (t36) between the CRUSHER close (m3) and open lines (m4) as shown.
  • Page 112 TROUBLESHOOTING CHECKING THE HYDRAULIC FLOW AT RATED PRESSURE 3. Determine the circuit relief valve pressure and oil flow. NOTE: First, warm the carrier’s hydraulic system to operating temperature. Measure the flow and pressure with the loading flow meter (t36). Adjust the load valve (f1) to zero restriction (fully open).
  • Page 113 TROUBLESHOOTING JAW DRIFT  Some jaw drift may be experienced depending on the CRUSHER’s position.  Acceptable drift may occur over a number of minutes.  Rapid drift may indicate a problem with the CRUSHER’s cylinder, booster, or swivel manifold. The problem could also be in the carrier’s hydraulic circuit. TO DETERMINE IF THE JAW DRIFT IS WITH THE CRUSHER OR THE CARRIER 1.
  • Page 114 TROUBLESHOOTING ROTATION The rotation speed is a direct result of the amount of flow (gpm – lpm) supplied by the rotation hydraulic circuit of the carrier. The chart below lists the recommended rotation speed and approximate flow required for your CRUSHER. MODEL ROTATION APPROXIMATE...
  • Page 115 TROUBLESHOOTING ROTATION Excessive rotation speed will result in damage to the hydraulic motor, pinion gear, and slewing ring. ROTATION PROBLEM CAUSE CHECK REMEDY Unit will not rotate. Low or no flow Check hydraulic Adjust rotation flow. (See hydraulic circuit CRUSHER rotation flow setting.
  • Page 116 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.

  • Page 117: Keywords For Common Crusher Components

    KEYWORDS FOR COMMON CRUSHER COMPONENTS MALE JAW TOOTH PLATE (male jaw) TOOTH PLATE (main frame) PRIMARY BLADE SECONDARY BLADE MAIN FRAME ROTARY JOINT ASSEMBLY ROTATION VALVE HYDRAULIC MOTOR PINION GEAR bs35 BOOSTER ASSEMBLY SLEWING RING SLEWING RING COVER CYLINDER ASSEMBLY PIVOT PIN NUT ARM PIN STOP PLATE...

  • Page 118: Keywords For Common Crusher Cylinder Components

    KEYWORDS FOR COMMON CRUSHER CYLINDER COMPONENTS bs 1 CONNECTOR PIPE bs35 BOOSTER ASSEMBLY bs40 BLOCK CYLINDER ROD NUT PISTON CYLINDER ROD CYLINDER MAIN BARREL CYLINDER END CAP PISTON RING...

  • Page 119: Warranty Statements

    WARRANTY STATEMENTS...
  • Page 120 WARRANTY STATEMENTS...
  • Page 121 NOTES NPK SECONDARY CONCRETE CRUSHER 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...
  • Page 122 © Copyright 2018 NPK Construction Equipment, Inc. www.npkce.com U000-9600B U and G Series Crushers Operation Manual 10-18...

This manual is also suitable for:

U31jU21jU21jrG seriesU31jrU45j ... Show all

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