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NPK M20S Instruction Manual

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MATERIAL PROCESSOR
INSTRUCTION MANUAL
MODELS:
M20S M20G M20C M20K
M28S M28G M28C M28K
M38S M38G M38C M38K
© Copyright 2018 NPK Construction Equipment, Inc.
Material Processor Instruction Manual
"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
M000-9600I 10-18

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  • Page 1 M28S M28G M28C M28K M38S M38G M38C M38K “Use Genuine NPK Parts” 7550 Independence Drive Walton Hills, OH 44146-5541 Phone (440) 232-7900 Toll-free (800) 225-4379 Fax (440) 232-6294 © Copyright 2018 NPK Construction Equipment, Inc. www.npkce.com M000-9600I 10-18 Material Processor Instruction Manual...

  • Page 2: Table Of Contents

    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 ................
  • Page 3 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 –...
  • Page 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 ........................

  • Page 5: Safety

    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.

  • Page 6: 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 MATERIAL PROCESSOR while in operation.

  • Page 7: Maintenance

    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.
  • Page 8 SAFETY MAINTENANCE STANDARD PRACTICES ATTENTION 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.

  • Page 9: 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 10: M-Series Specifications

    M-SERIES SPECIFICATIONS M20C MATERIAL PROCESSOR MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening seconds (kg) (mm) (lpm) open close M20C 4,440 (2,015) 34.5 (876) 26-53 (100-200) MODEL Maximum Crushing Force Operating Pressure at Tip (Metric (bar) Ton) M20C 3,625 (250) (71) Specifications subject to change without notice.

  • Page 11: M20G Material Processor

    M-SERIES SPECIFICATIONS M20G MATERIAL PROCESSOR MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening seconds (kg) (mm) (lpm) open close M20G 4,520 (2,055) 30.3 (770) 26-53 (100-200) MODEL Maximum Crushing Force Operating Pressure at Tip (Metric (bar) Ton) M20G 3,625 (250) (76) Specifications subject to change without notice.

  • Page 12: M20K Material Processor

    M-SERIES SPECIFICATIONS M20K MATERIAL PROCESSOR MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening seconds (kg) (mm) (lpm) open close M20K 4,530 (2,060) 21.1 (535) 26-53 (100-200) MODEL Maximum Crushing Force Operating Pressure at Tip (Metric (bar) Ton) M20K 3,625 (250) (82) Specifications subject to change without notice.

  • Page 13: M20S Material Processor

    M-SERIES SPECIFICATIONS M20S MATERIAL PROCESSOR MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening seconds (kg) (mm) (lpm) open close M20S 4,355 (1,980) (940) 26-53 (100-200) MODEL Maximum Crushing Force Operating Pressure at Tip (Metric (bar) Ton) M20S 3,625 (250) (71) Specifications subject to change without notice.

  • Page 14: M28C Material Processor

    M-SERIES SPECIFICATIONS M28C MATERIAL PROCESSOR MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening seconds (kg) (mm) (lpm) open close M28C 6,500 (2,950) 36.2 (920) 50-80 (190-300) MODEL Maximum Crushing Force Operating Pressure at Tip (Metric (bar) Ton) M28C 3,625 (250) (105) Specifications subject to change without notice.

  • Page 15: M28G Material Processor

    M-SERIES SPECIFICATIONS M28G MATERIAL PROCESSOR MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening seconds (kg) (mm) (lpm) open close M28G 6,850 (3,107) 35.8 (910) 50-80 (190-300) MODEL Maximum Crushing Force at Tip Operating Pressure (Metric (bar) Ton) M28G 3,625 (250) (114) Specifications subject to change without notice.

  • Page 16: M28K Material Processor

    M-SERIES SPECIFICATIONS M28K MATERIAL PROCESSOR MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening seconds (kg) (mm) (lpm) open close M28K 6,900 (3,130) 25.1 (637) 50-80 (190-300) MODEL Maximum Crushing Force Operating Pressure at Tip (Metric (bar) Ton) M28K 3,625 (250) (121) Specifications subject to change without notice.

  • Page 17: M28S Material Processor

    M-SERIES SPECIFICATIONS M28S MATERIAL PROCESSOR MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening seconds (kg) (mm) (lpm) open close M28S 6,400 (2,915) (1,067) 50-80 (190-300) MODEL Maximum Crushing Force Operating Pressure at Tip (Metric (bar) Ton) M28S 3,625 (250) (105) Specifications subject to change without notice.

  • Page 18: M38C Material Processor

    M-SERIES SPECIFICATIONS M38C MATERIAL PROCESSOR MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening seconds (kg) (mm) (lpm) open close M38C 8,590 (3,900) 48.4 (1,230) 60-100 (225-380) MODEL Maximum Crushing Force Operating Pressure at Tip (Metric (bar) Ton) M38C 3,625 (250) (130) Specifications subject to change without notice.

  • Page 19: M38G Material Processor

    M-SERIES SPECIFICATIONS M38G MATERIAL PROCESSOR MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening seconds (kg) (mm) (lpm) open close M38G 9,100 (4,140) (1,142) 60-100 (225-380) MODEL Maximum Crushing Force Operating Pressure at Tip (Metric (bar) Ton) M38G 3,625 (250) (138) Specifications subject to change without notice.

  • Page 20: M38K Material Processor

    M-SERIES SPECIFICATIONS M38K MATERIAL PROCESSOR MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening seconds (kg) (mm) (lpm) open close M38K 9,370 (4,260) 30.2 (766) (225-380) MODEL Maximum Crushing Force Operating Pressure at Tip (Metric (bar) Ton) M38K 3,625 (250) (154) Specifications subject to change without notice.

  • Page 21: M38S Material Processor

    M-SERIES SPECIFICATIONS M38S MATERIAL PROCESSOR MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening seconds (kg) (mm) (lpm) open close M38S 8,450 (3,840) 48.6 (1,234) 60-100 (225-380) MODEL Maximum Crushing Force Operating Pressure at Tip (Metric (bar) Ton) M38S 3,625 (250) (134) Specifications subject to change without notice.

  • Page 22: K Jaw Cutting Capacity

    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 (mm) (mm) (mm) (mm) M20K (305) (305) (12.7) (12.7) M28K (406) (406) (15.9)

  • Page 23: Serial Number Location

    SERIAL NUMBER LOCATION...
  • Page 24 SERIAL NUMBER LOCATION...
  • Page 25 SERIAL NUMBER LOCATION...

  • Page 26: M-Series Jaw Identification

    M-SERIES JAW IDENTIFICATION All M-Series Material Processor jaws are shipped from NPK with the following information welded on them: Letter designating jaw type, i.e., C, G, K, S. Number denoting male or female jaw. NOTE: Even numbers indicate male jaws, odd numbers indicate female jaws.
  • Page 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.
  • Page 28 JAW SET IDENTIFICATION  G Jaw Set (Pulverizer/Secondary Concrete Crusher) for the downsizing of concrete and the separation of concrete and rebar.
  • Page 29 JAW SET IDENTIFICATION  K Jaw Set (Shear) for the demolition of steel structures, such as buildings and bridges, as well as for processing of scrap, including steel, wood, rubber and plastics.

  • Page 30: Jaw Set Identification

    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”...

  • Page 31: Processor - Booster And Cylinder

    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.
  • Page 32 PROCESSOR – BOOSTER AND CYLINDER II 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 33 PROCESSOR – BOOSTER AND CYLINDER III OPERATING PRINCIPLE 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.
  • Page 34 PROCESSOR – BOOSTER AND CYLINDER III OPERATING PRINCIPLE 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...
  • Page 35 PROCESSOR – BOOSTER AND CYLINDER III OPERATING PRINCIPLE 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 Because the area of the booster piston in oil chamber v1 is greater than the area in chamber v4, the pressure in...
  • Page 36 PROCESSOR – BOOSTER AND CYLINDER III OPERATING PRINCIPLE 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.
  • Page 37 PROCESSOR – BOOSTER AND CYLINDER III OPERATING PRINCIPLE 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).
  • Page 38 PROCESSOR – BOOSTER AND CYLINDER III OPERATING PRINCIPLE 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. main control valve spring moves the main control valve spool toward the plunger.
  • Page 39 PROCESSOR – BOOSTER AND CYLINDER III OPERATING PRINCIPLE 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...

  • Page 40: Hydraulic Installation

    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.

  • Page 41: 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 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...

  • Page 43: Hydraulic Quick Disconnects

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

  • Page 45: 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 46: Mounting Installation

    Boom Pin Bushing 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. 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.

  • Page 47: Mounting To The Carrier

    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.

  • Page 48: Storage Of The Material Processor

    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”.

  • Page 49: Hose Installation

    HOSE INSTALLATION 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 50 HOSE INSTALLATION 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 51: Operating Instructions

    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. OPERATE MATERIAL PROCESSOR WITHOUT DEMOLITION GUARDS IN PLACE! DO NOT LIFT OR LOAD BEYOND THE CAPACITY OF THE MATERIAL...
  • Page 52 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.
  • Page 53 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.
  • Page 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.
  • Page 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.
  • Page 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.
  • Page 57 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.
  • Page 58 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).

  • Page 59: General Maintenance

    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”.
  • Page 60  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”.

  • Page 61: Lubrication Points

    GENERAL MAINTENANCE LUBRICATION POINTS M20, M28, M38 CYLINDER ROD PINS One lubrication point per 10 strokes from a cylinder located at the grease gun every 4 jaw attachment end. hours. JAW PIVOT PIN One lubrication point on 15 strokes from a each end of the main grease gun per fitting pivot pin (M20), two...

  • Page 62: Cutter Blade Maintenance

    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.
  • Page 63 A blade-to-blade (A-A) clearance of .010” to .040” (0.25 to 1.00 mm) should be maintained for optimum performance. Install shims (BH) under blade (BG) as necessary, see fig. 1. SHIM KITS MODEL/ NPK SHIM JAW TYPE KIT PART NUMBER M20 - S, G & C M2000-7000 M28 - S, G &...

  • Page 64: 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 cutter blades.

  • Page 65: Cutter Blade Maintenance - K Jaws

    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...

  • Page 66: K Jaw Blade Set Up Procedure

    GENERAL MAINTENANCE PIERCING TIP TO TUNNEL GAP M20K, M28K, and M38K PRIMARY CUTTING BLADE SECONDARY CUTTING BLADE SHIM PACK (drive arm only) DRIVE ARM TUNNEL BLADE SPACER SPACER PLATE GUIDE BLADE (not shown) Fig. 3 PIERCING TIP (bolt-on) (With bolt-on piercing tip) K JAW BLADE SET UP PROCEDURE M20K, M28K, and M38K Install the primary blades in the arm second.

  • Page 67: Component Description

    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).

  • Page 68: K Jaw Blade Maintenance And Adjustment

    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”).
  • Page 69 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).
  • Page 70 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)
  • Page 71 (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”...
  • Page 72 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.

  • Page 73: Piercing Tip Maintenance And Replacement

    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.

  • Page 74: Taper Liner For M Series Processor "K" Jaw

    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.

  • Page 75: Build-Up Of The Piercing Tip

    GENERAL MAINTENANCE 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.

  • Page 76: Joining And Build-Up

    GENERAL MAINTENANCE 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. Fig.

  • Page 77: Determining Replacement Or Build Up

    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.
  • Page 78 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”).
  • Page 79 .005” (.127 mm), see Fig. D. Fig. D Apply thread adhesive to the socket head cap screws for the guide blade. Then torque to NPK specifications (see “FASTENER TORQUE CHART”). STEP 7a After completing all welding maintenance, allow the jaw (BD) to cool slowly.

  • Page 80: Jaw Inspection And Maintenance

    .75” (19 mm) compared to the template or the cylinder will bottom out. JAW BUILD-UP AND HARDFACING (M38S, M28S, and M20S) For build-up and hard facing of jaw, use the NPK template to check jaws so that they are to the original profile. Contact NPK for the correct templates, drawing no. M3803- 9501 and M3803-9502 (M38S), M2803-9500 and M2803-9501 (M28S), and M2003- 9500 and M2003-9501 (M20S).

  • Page 81: Jaw Build-Up And Hardfacing (M38C, M28C, And M20C)

    .75” (19 mm) compared to the template or the cylinder will bottom out. JAW BUILD-UP AND HARDFACING (M38C, M28C, and M20C) For build-up and hard facing of jaw, use the NPK template to check jaws so that they are to the original profile. Contact NPK for the correct templates, drawing no. M2804- 9501 (M28C) and M2004-9500 (M20C).

  • Page 82: Teeth Replacement

    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.

  • Page 83: Replaceable Tooth Plates - G Jaws

    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.
  • Page 84 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.
  • Page 85 JAW INSPECTION AND MAINTENANCE 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+). ...

  • Page 86: Jaw Contact Areas

    JAW INSPECTION AND MAINTENANCE 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”.

  • Page 87: Hardfacing: K Jaws

    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.

  • Page 88: 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 89 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...

  • Page 90: Cylinder Inspection And Maintenance

    CYLINDER INSPECTION AND MAINTENANCE BOOSTER CYLINDER DISASSEMBLY 1. Remove the Booster Assembly (bs35) from the cylinder assembly (c11). See the Booster Manual NOTE: (B000-9600) for booster maintenance. 2. Remove the spacers (bs23), o-rings (RR), and backup rings (SS) from the cylinder assembly (c11).
  • Page 91 CYLINDER INSPECTION AND MAINTENANCE BOOSTER CYLINDER DISASSEMBLY 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 polishing wheel p/n 25026030) and...
  • Page 92 CYLINDER 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 93: Inspecting And Cleaning Cylinder Components

    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.
  • Page 94 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.

  • Page 95: Repair Tools And Equipment

    CYLINDER INSPECTION AND MAINTENANCE 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) Emery cloth (200 grit) Cleaning solvent ASSEMBLY 1. Install the dirt seal (QQ), backup ring (SS) and piston seal (PP) into the seal grooves on the inner side of the cylinder end cap (c5).
  • Page 96 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.
  • Page 97 CYLINDER INSPECTION AND MAINTENANCE 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.
  • Page 98 CYLINDER INSPECTION AND MAINTENANCE ASSEMBLY 7. Install cylinder rod nut (c1) onto cylinder rod (c3) and torque to the listed value below. MODEL THREAD TORQUE SOCKET ROD NUT PART NUMBER SIZE ft. lb. (Nm) SIZE STYLE "A" STYLE "B" STYLE "C" (4,400) M65 x 3.0 3,250...
  • Page 99 CYLINDER INSPECTION AND MAINTENANCE 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 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).
  • Page 101 CYLINDER INSPECTION AND MAINTENANCE ASSEMBLY 15. With the aid of an assistant, carefully orient and align the eight mounting flange fastening holes of the booster assembly (bs35) with the corresponding eight threaded bores of the cylinder assembly (c11). If necessary, install two eye-bolts in the threaded bores on top of the booster assembly.

  • Page 102: 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.

  • Page 103: Rotation Bearing Outer Dirt Seal Replacement

    SLEWING RING INSPECTION AND MAINTENANCE ROTATION BEARING OUTER DIRT SEAL REPLACEMENT MODEL SLEWING RING DIRT SEAL PART NUMBER PART NUMBER Additional items needed: 25309550 25309273 25309660 High strength adhesive 25309270 Brake clean/solvent 25309670 25309680 25309353 1. Remove old seal (QQ) from the bottom side (72) of the slewing ring (BT).

  • Page 104: 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 processor frame that rotates. Hydraulic oil for both the open and close operations of the processor passes through this manifold. The swivel manifold assembly consists of two main parts, the “Spindle Case”...

  • Page 105: Testing The Swivel Seals For Internal Leakage

    Fig. 3 Test Procedure Install 0 to 5,000 psi (0 to 350 bar) gauges in the NPK stop valves (located on the stick of the carrier) or in gauge ports in the open and close circuits located near the end of the stick (for carriers without an NPK hydraulic kit).

  • Page 106: Replacement Of The Seals In The Swivel

    SWIVEL MANIFOLD MAINTENANCE REPLACEMENT OF THE SEALS IN THE SWIVEL Tools needed: 19 and 22 mm open end wrenches 41 and 46 mm open end wrenches External snap ring pliers The jaws of the material processor should be closed and the frame supported or the shipping pins (t80), as shown in Fig.
  • Page 107 SWIVEL MANIFOLD MAINTENANCE REPLACEMENT OF THE SEALS IN THE SWIVEL STEP 2 (Fig. 6) Remove the snap ring (AJ) and washer (U) from the top of the swivel assembly. Pull the “Spindle Case” off of the “Spindle” (the cylinder hoses can be used for this). Fig.
  • Page 108 SWIVEL MANIFOLD MAINTENANCE REPLACEMENT OF THE SEALS IN THE SWIVEL STEP 4 (Fig. 8) Seal removal and replacement: Sealing is accomplished with a combination of o-rings and back-up rings, which ride against the “Spindle”. Remove the o-rings and back-up rings with a seal pick (note the order of placement).
  • Page 109 SWIVEL MANIFOLD MAINTENANCE REPLACEMENT OF THE SEALS IN THE SWIVEL 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 cartridges (c17/c18). Install the washer (U) and snap ring (AJ).

  • Page 110: Jaw Set Interchange

     Dead blow hammer or non-metallic rod or hammer (such as nylon or wood).  Ball peen hammer.  Sledge hammer.  NPK assembly tube, p/n 35027310 for the M20 and 35027200 for the M28 and M38 models.  Spanner wrench.

  • Page 111: Procedure For Jaw Set Interchange

    JAW SET INTERCHANGE PROCEDURE FOR JAW SET INTERCHANGE 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 Processor model or jaw set. UNIT POSITIONING For ease of pin removal or installation, it is recommended that the unit be positioned with the pins parallel to the ground.
  • Page 112 JAW SET INTERCHANGE UNIT POSITIONING 3. While maintaining crane or lifting device engagement (t34), place two wood blocks (t20) under each side of the main frame toward the top bracket (m27) end. Also place a wood block under the cylinder rod cover near the cylinder rod pin. 4.

  • Page 113: Detachment Of The Jaws From The Cylinder Sub-Assemblies

    JAW SET INTERCHANGE DETACHMENT OF THE JAWS FROM THE CYLINDER SUB- ASSEMBLIES 5. Support the top cylinder sub-assembly (c11) with a wood block (t20) to prevent it from falling and potential damage when the cylinder jaw pin (c9) is removed. 6.
  • Page 114 JAW SET INTERCHANGE DETACHMENT OF THE JAWS FROM THE CYLINDER SUB- ASSEMBLIES 7. Early units: Manually remove the cylinder pin lock plate (c30). Later units: Using a socket, remove the cylinder pin locking plate (c31). NOTE: Left hand thread (c57). LATER UNITS EARLY UNITS 8.

  • Page 115: Detachment Of The Jaw Set From The Main Frame

    JAW SET INTERCHANGE DETACHMENT OF THE JAW SET FROM THE MAIN FRAME 10. Locate the socket head cap screw (OO) on the pivot pin nut (c32). 11. Using a hex key socket (t42), remove the socket head cap screw (OO). 12.
  • Page 116 1” (25 mm) on the side shown. It is at this stage that the assembly tube, NPK part no. 35027310 (for M20 units) or part no. 35027200 (for M28/M38 units), is used to keep the jaws united as the jaw pivot pin is removed.

  • Page 117: Jaw Set Removal

    JAW SET INTERCHANGE DETACHMENT OF THE JAW SET FROM THE MAIN FRAME 17. Support the jaw pivot pin (BJ) to prevent its free fall upon total removal, such as with a lifting strap (t27) attached to a crane or lift truck. 18.

  • Page 118: Jaw Set Storage

    Jaw sets that have been used and removed from a Material Processor will be equipped with an assembly tube from a removal operation. If this is not the case, contact the NPK Service Department for assistance. 1. For easier installation of the jaw set...
  • Page 119 JAW SET INTERCHANGE ATTACHMENT OF JAW SET TO THE MAIN FRAME 4. Drive the jaw pivot pin (BJ) in until the assembly tube (t44) extends out about 10” (250 mm) on the other side. Remove the assembly tube. Continue driving the jaw pivot pin (BJ) in until the head plate is flush with the main frame (DN).

  • Page 120: Attachment Of The Jaws To The Cylinder Sub-Assemblies

    JAW SET INTERCHANGE ATTACHMENT OF JAW SET TO THE MAIN FRAME 6. Using a hex key socket (t42), install the socket head cap screw (OO) securing the pivot pin nut (c32). See the “FASTENER TORQUE CHART” section of this manual for the correct torque.
  • Page 121 JAW SET INTERCHANGE ATTACHMENT OF THE JAWS TO THE CYLINDER SUB- ASSEMBLIES 10. Early units: Using a hex key socket (t42), install the two socket head cap screws (OO) securing the cylinder pin lock plate. See the “FASTENER TORQUE CHART” section of this manual for the correct torque. Later units: Using a hex key socket (t42), install the socket head cap screw (OO) securing the cylinder pin lock plate.

  • Page 122: Fastener Torque Specifications

    FASTENER TORQUE SPECIFICATIONS These torque charts are to be used with the specific “M” Series processor parts manual for the unit being repaired. 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 123 FASTENER TORQUE SPECIFICATIONS FASTENER TORQUE CHART - MAIN FRAME ASSEMBLY BOLT LOCATION MODEL BOLT SIZE BOLT TORQUE ADHESIVE ft. lb. LUBED (Nm) CYLINDER ROD END (255) LUBED PIVOT PIN KEEPER (255) LUBED (490) LUBED CYL. BARREL END (720) LUBED PIVOT PIN KEEPER (720) LUBED (720)
  • Page 124 FASTENER TORQUE SPECIFICATIONS FASTENER TORQUE CHART - CYLINDER ASSEMBLY w/BOOSTER BOLT LOCATION MODEL BOLT SIZE BOLT TORQUE ADHESIVE ft. lb. OR LUBED (Nm) CYLINDER END CAP (350) LUBED (350) LUBED (350) LUBED CYLINDER ROD NUT 1500 (2000) ADHESIVE 3200 (4300) ADHESIVE 4100 (5500)
  • Page 125 FASTENER TORQUE SPECIFICATIONS FASTENER TORQUE CHART - CYLINDER ASSEMBLY w/o BOOSTER BOLT LOCATION MODEL BOLT SIZE BOLT TORQUE ADHESIVE ft. lb. OR LUBED (Nm) CYLINDER END CAP (350) LUBED (350) LUBED (350) LUBED CYLINDER ROD NUT 1500 (2000) ADHESIVE 3200 (4300) ADHESIVE 4100...
  • Page 126 FASTENER TORQUE SPECIFICATIONS FASTENER TORQUE CHART - ROTATION COMPONENTS BOLT LOCATION MODEL BOLT BOLT TORQUE ADHESIVE SIZE ft. lb. OR LUBED (Nm) SLEWING RING (720) LUBED ASSEMBLY TO (720) LUBED (720) LUBED FRAME TOP PLATE TO (350) ADHESIVE SLEWING RING (350) ADHESIVE (350)

  • Page 127: Hose Torque Specifications

    HOSE TORQUE SPECIFICATIONS JIC ENDS NOMINAL FITTING THREAD SIZE NUMBER OF TORQUE SIZE DASH FLATS FROM SIZE FINGER TIGHT ft. lb. (Nm) 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 128: Troubleshooting

    NPK pressure intensifier performance. 2. LOSS OF CYCLE SPEED NPK Material Processor cycle speed is determined by oil flow to the unit. The hydraulic installation circuit for the Material Processor must be set to provide the correct flow.

  • Page 129: Troubleshooting Guide For Low Power

    TROUBLESHOOTING TROUBLESHOOTING GUIDE FOR LOW POWER RELIEF VALVE CHECKS PROBLEM CAUSE CHECK REMEDY Operating Pressure Carrier hydraulic Measure the carrier Adjust or replace the is less than 3,625 circuit relief valve. circuit relief valve with carrier circuit relief psi (250 bar). the pressure to close valve.
  • Page 130 TROUBLESHOOTING TROUBLESHOOTING GUIDE FOR LOW POWER RELIEF VALVE CHECKS PROBLEM CAUSE CHECK REMEDY Operating pressure Booster sequence Observe sequence Replace the is at 3,625 psi (250 valve cartridge. valve operation. sequence valve (See "PRESSURE bar), but the cartridge. (NOTE: intensifier does not INTENSIFIER The sequence valve click.

  • Page 131: Measuring Operating Pressures

    (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 132 TROUBLESHOOTING 1. CARRIER CIRCUIT RELIEF VALVE CHECK Verify that the hydraulic system of the carrier meets the requirements of the Material Processor. 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 133: Pressure Intensifier Sequence Valve And Relief Valve Actuation

    TROUBLESHOOTING 2. MATERIAL PROCESSOR RELIEF VALVE After the Material Processor hydraulic circuit has been verified, check the Material Processor 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 134: Material Processor Sequence, Relief Valve And Carrier Relief Valve Settings

    TROUBLESHOOTING MATERIAL PROCESSOR SEQUENCE, RELIEF VALVE AND CARRIER RELIEF VALVE SETTINGS MODEL SERIAL NO. PROCESSOR PROCESSOR MINIMUM CARRIER SEQUENCE RELIEF VALVE RELIEF VALVE VALVE SETTING SETTING SETTING (bar) (bar) (bar) 2,950 (205) 3,625 (250) 3,825 (265) (205) (250) (265) 2,950 3,625 3,825 (205)
  • Page 135 TROUBLESHOOTING INTENSIFIER CHECKS (unit does not click) INTENSIFIER CHECKS PROBLEM CAUSE CHECK REMEDY Intensifier does not Material Processor Check relief Tighten the relief click relief valves cartridges for valve cartridges. tightness. Check relief Reset to 3,625 psi cartridges for mis- (250 bar).
  • Page 136 TROUBLESHOOTING INTENSIFIER CHECKS (unit clicks – does not slow down) INTENSIFIER CHECKS PROBLEM CAUSE CHECK REMEDY Intensifier clicks but Material Processor Check relief Tighten the relief does not slow down relief valves cartridges for valve cartridges. tightness. Main valve orifice. Check the orifice, o- Clean the orifice and rings and backup...

  • Page 137: Pressure Intensifier Operation

    TROUBLESHOOTING PRESSURE INTENSIFIER OPERATION NPK’s exclusive pressure intensifier system is used in NPK Material Processors to boost cylinder pressure to increase the jaw closing forces. When the intensifier is working properly, a rapid clicking sound will be heard, indicating that the pressure intensifier is being actuated as the jaws begin to close against resistance.

  • Page 138: Checking Boosted Pressure

    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 Material Processors. The pressure intensifier’s have three test ports as shown. L017-8000 GAUGE ASSEMBLY guage: 0 - 15,000 psi...

  • Page 139: Slow Cycle Speed

    (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 140 TROUBLESHOOTING TEST PROCEDURE SLOW CYLINDER SPEED PROBLEM CAUSE CHECK REMEDY Operating Pressure Carrier hydraulic Measure the carrier Adjust or replace the is less than 3,625 circuit relief valve. circuit relief valve with carrier circuit relief psi (250 bar).) the pressure to close valve.

  • Page 141: Checking The Hydraulic Flow At Rated Pressure

    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 Material Processor close (m3) and open lines (m4) as shown.
  • Page 142 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 143: Jaw Drift

    TROUBLESHOOTING JAW DRIFT  Some jaw drift may be experienced depending on the Material Processor’s position.  Acceptable drift may occur over a number of minutes.  Rapid drift may indicate a problem with the Material Processor’s cylinder, booster, or swivel manifold. The problem could also be in the carrier’s hydraulic circuit.

  • Page 144: Rotation

    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 Material Processor. MODEL ROTATION APPROXIMATE...
  • Page 145 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 Material hydraulic circuit flow setting.
  • Page 146 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 147: Keywords For Common Processor Components

    KEYWORDS FOR COMMON PROCESSOR COMPONENTS M38G SHOWN MALE JAW TOOTH PLATE (male jaw) PRIMARY BLADE SECONDARY BLADE ROTARY JOINT ASSEMBLY ROTATION VALVE HYDRAULIC MOTOR BOOSTER bs35 ASSEMBLY SLEWING RING CYLINDER ASSEMBLY PIVOT PIN NUT MANIFOLD BLOCK MAIN FRAME LOCK PIN TOP BRACKET JOINT FITTING...

  • Page 148: Keywords For Common Processor Cylinder Components

    KEYWORDS FOR COMMON PROCESSOR CYLINDER COMPONENTS bs35 BOOSTER ASSEMBLY bs38 SWIVEL BLOCK bs41 MANIFOLD BLOCK CYLINDER ROD NUT PISTON CYLINDER ROD CYLINDER MAIN BARREL CYLINDER END CAP PISTON RING...

  • Page 149: Warranty Statements

    WARRANTY STATEMENTS...
  • Page 150 WARRANTY STATEMENTS...

  • Page 151: Notes

    NOTES NPK MATERIAL PROCESSOR MODEL NUMBER ______________ SERIAL NUMBER ______________ NPK INSTALLATION KIT NUMBER ___________________________ EXCAVATOR MANUFACTURER MODEL NUMBER SERIES SERIAL NUMBER DATE OF INSTALLATION __________________ DATE OF 20 HOUR INSPECTION ___________WARRANTY REGISTRATION SENT  SERVICE RECORD DATE...
  • Page 152 © Copyright 2018 NPK Construction Equipment, Inc. www.npkce.com M000-9600I 10-18 Material Processor Instruction Manual...

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