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NPK M35G Instruction Manual

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MATERIAL PROCESSOR
INSTRUCTION MANUAL
MODELS:
M35G M35K
M35S
"Use Genuine NPK Parts"
7550 Independence Drive
Walton Hills, OH 44146-5541
Phone (440) 232-7900
Toll-free (800) 225-4379
Fax (440) 232-6294
© Copyright 2018 NPK Construction Equipment, Inc.
www.npkce.com
M000-9601B M35 Material
Processor Instruction Manual 10-18

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  • Page 1 INSTRUCTION MANUAL MODELS: M35G M35K M35S “Use Genuine NPK Parts” 7550 Independence Drive Walton Hills, OH 44146-5541 Phone (440) 232-7900 Toll-free (800) 225-4379 Fax (440) 232-6294 © Copyright 2018 NPK Construction Equipment, Inc. www.npkce.com M000-9601B M35 Material Processor Instruction Manual 10-18...

  • Page 2: Table Of Contents

    JAW PROFILES: G and S JAWS ......................60 JAW BUILD-UP AND HARDFACING (M35S) .................... 60 TEETH BUILD-UP AND HARDFACING (M35G) ..................61 REPLACEABLE TOOTH PLATES – G JAWS .................... 62 JAW AND TOOTH REBUILD PROCEDURE: S and G JAWS ..............62...
  • Page 3 CONTENTS JAW CONTACT AREAS ..........................65 S and G JAW CONTACT AREAS ....................65 FRAME MAINTENANCE ........................... 66 REPAIR OF MAIN FRAME ........................66 ROUTINE WELD REPAIR ......................66 INSPECTION AND MAINTENANCE ......................68 BOOSTER CYLINDER ..........................68 DISASSEMBLY .......................... 68 INSPECTING AND CLEANING CYLINDER COMPONENTS ..............

  • Page 4: Safety

    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.

  • 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 MATERIAL PROCESSOR while in operation.

  • Page 6: 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 7 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 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: M-Series Specifications

    M-SERIES SPECIFICATIONS M35G MATERIAL PROCESSOR MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening seconds (kg) (mm) (lpm) open close M35G 7,590 (3,450) 38.6 (981) 50-80 (190-300) MODEL Maximum Crushing Force Operating Pressure at Tip (Metric (bar) Ton) M35G 3,700...

  • Page 10: M35K Material Processor

    M-SERIES SPECIFICATIONS M35K MATERIAL PROCESSOR MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening seconds (kg) (mm) (lpm) open close M35K 7,370 (3,350) (559) 50-80 (190-300) MODEL Maximum Crushing Force Operating Pressure at Tip (Metric (bar) Ton) M35K 3,700 (255) (113) Specifications subject to change without notice.

  • Page 11: M35S Material Processor

    M-SERIES SPECIFICATIONS M35S MATERIAL PROCESSOR MODEL Weight Maximum Jaw Oil Flow Cycle Time Opening seconds (kg) (mm) (lpm) open close M35S 7,535 (3,425) (1,092) 50-80 (190-300) MODEL Maximum Crushing Force Operating Pressure at Tip (Metric (bar) Ton) M35S 3,700 (255) (100) Specifications subject to change without notice.

  • Page 12: 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) M35K (406) (406) (15.9) (15.9) MODEL (mm) (mm) M35K...

  • Page 13: Serial Number Location

    SERIAL NUMBER LOCATION...

  • Page 14: Jaw Set Identification

    JAW SET IDENTIFICATION  G Jaw Set (Pulverizer/Secondary Concrete Crusher) for the downsizing of concrete and the separation of concrete and rebar.
  • Page 15 JAW SET IDENTIFICATION  K Jaw Set (Shear) for the demolition of steel structures, such as buildings and bridges, as well as for processing of scrap, including steel, wood, rubber and plastics.
  • Page 16 JAW SET IDENTIFICATION  S Jaw Set (Primary Breaker) for the demolition of concrete pillars, buildings, retaining walls, bridges, and highway barriers. Jaw sets can easily be removed from and installed onto the Material Processor at the job site, see the “JAW SET INTERCHANGE” section, page 78, of this manual.

  • Page 17: Processor Booster & 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 end of the cylinder. This retracts the rod and pulls the jaw open.

  • Page 18: Structure Of The Boosted Cylinder

    PROCESSOR BOOSTER & CYLINDER STRUCTURE OF THE BOOSTED CYLINDER As shown in Fig. 1, the booster cylinder consists of: bs34 Inlet Check Valve Jaw Cylinder Booster Piston Main Valve Assembly Relief Valve (close) Relief Valve (open) Plunger Pilot Check Valve Assembly Check Valve 1 - booster piston inner "B"...

  • Page 19: Operating Principle

    PROCESSOR BOOSTER & CYLINDER OPERATING PRINCIPLE Jaw Cylinder Pilot Check Valve Assembly Carrier Control Valve 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 valves (c20) in the booster assemblies.
  • Page 20 PROCESSOR BOOSTER & CYLINDER OPERATING PRINCIPLE Booster Piston Main valve Assembly Fig. 3 BOOSTER ACTUATION When a load (material to be crushed or sheared) is encountered on jaw close, the hydraulic pressure in the booster unit starts to rise, which redirects the hydraulic oil through the control valve (c15) of the booster, then to the booster piston (c14).
  • Page 21 PROCESSOR BOOSTER & CYLINDER OPERATING PRINCIPLE Jaw Cylinder Booster Piston Main Valve Assembly Check Valve 3 - booster sleeve "B" Check Valve 4 - booster sleeve "A" Oil Chamber - 1 Oil Chamber - 2 Oil Chamber - 4 Fig. 4 FORWARD PISTON STROKE The hydraulic oil that has passed through the booster valves (c15), flows into rear oil chambers v1 and v2 of the booster pistons (c14) and strokes it...
  • Page 22 PROCESSOR BOOSTER & CYLINDER OPERATING PRINCIPLE Booster Piston Main Valve Assembly Plunger Port C1 Piston Port C2 Piston Fig. 5 MAIN VALVE REVERSE SHIFT When the booster pistons (c14) reaches their full stroke, oil entering port “C1” (c26) transfers to port “C2”...
  • Page 23 PROCESSOR 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 Fig.
  • Page 24 PROCESSOR BOOSTER & CYLINDER OPERATING PRINCIPLE Booster Piston Main Valve Assembly Plunger Port C2 Piston Port C3 Piston Carrier Control Valve Fig. 7 VALVE SHIFT TO FORWARD STROKE When the booster pistons (c14) reach full reverse stroke, oil drains out of the plunger (c19) ends of the main control valves (c15) through ports C2 (c27) and C3 (c28) of the booster pistons.
  • Page 25 PROCESSOR BOOSTER & CYLINDER OPERATING PRINCIPLE Jaw Cylinder Pilot check valve assembly Carrier Control Valve Fig. 8 CYLINDER RETRACT (JAW OPEN) When the crusher jaws are opened, oil from the excavator’s control valve (k7) is directed through the boosters to the rod ends of the cylinders (c11). A pilot signal from this flow is sent to open the pilot check valve assemblies (c20) which allows oil to be pushed out of the base end of the cylinders as the...

  • Page 26: 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 Material Processor, including valves, electrical or manual controls, hoses and fittings, boom and stick piping and clamps are provided.

  • Page 27: Test Port Locations

    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...

  • Page 28: 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 29: 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 30 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. STUCCI COUPLING ROFLEX COUPLING...

  • Page 31: 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. M35 SERIES TOP BRACKET The M35 Series top bracket is ported for right or left side hose access for rotation and motor case drain line connections.

  • Page 32: Mounting To The Carrier

    MOUNTING INSTALLATION MOUNTING TO THE CARRIER 1. Position the M35 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 33: Storage Of The M35 Material Processor

    STORAGE OF THE M35 MATERIAL PROCESSOR 1. Make sure all whip hoses (m38) that connect the M35 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.

  • Page 34: 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 35 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 36: Operating Instructions

    OPERATING INSTRUCTIONS Before operating the NPK M35 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 M35 MATERIAL PROCESSOR WITHOUT DEMOLITION GUARDS IN PLACE! DO NOT LIFT OR LOAD BEYOND THE CAPACITY OF THE M35 MATERIAL PROCESSOR OR THE CARRIER.
  • Page 37 OPERATING INSTRUCTIONS MATERIAL PROCESSOR ONLY APPLICATION FOR WHICH IT IS INTENDED:  NPK M35 Material Processors equipped with “G” style jaws are designed for the downsizing of concrete, the separation of concrete and rebar and some primary demolition. “G” JAW APPLICATION...
  • Page 38 USE THE NPK M35 MATERIAL PROCESSOR ONLY FOR THE APPLICATION FOR WHICH IT IS INTENDED:  NPK M35 Material Processors equipped with “K” style jaws are designed for the demolition of steel structures and for processing of steel, wood, rubber and plastic scrap.
  • Page 39 MATERIAL PROCESSOR ONLY APPLICATION FOR WHICH IT IS INTENDED:  NPK M35 Material Processors equipped with “S” style jaws are designed for the primary breakup of concrete, such as pillars, buildings, retaining walls, bridges and highway barriers. “S” JAW APPLICATION...

  • Page 40: Operating Techniques And Precautions

    M35 Material Processor as possible. Do not force the material into the jaw. If you have any questions on operating the M35 Material Processor, please contact your local NPK dealer or call the NPK Service Department at 1-800-225-4379.
  • Page 41 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 M35 Material Processor on an excavator with an NPK combination Hydraulic Hammer/Crusher hydraulic installation kit without first isolating the line mounted accumulators (k23).

  • Page 42: General Maintenance

     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 43: Lubrication Points

    GENERAL MAINTENANCE LUBRICATION POINTS CYLINDER ROD PINS One lubrication point per 10 strokes from a grease cylinder located at the jaw gun every 4 hours. attachment end. JAW PIVOT PIN One lubrication point on each 15 strokes from a grease end of pin ("S", early "K"...

  • Page 44: 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 45 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 46: Cutter Blade Maintenance

    GENERAL MAINTENANCE CUTTER BLADE MAINTENANCE 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 47 A blade-to-blade (‘A’-‘A’) clearance of .010” to .040” (0.25 to 1.00 mm) should be maintained for optimum performance. Install shims (BH) under blade (BG) as necessary, see fig. 1. SHIM KITS MODEL/ NPK SHIM JAW TYPE KIT PART NUMBER M35, S & G 1618210...

  • Page 48: M35K Jaw Maintenance

    The following information is to be used as a general guide for maintaining the jaws and cutter blades on the NPK M35 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 49: Cutter Blade Maintenance

    A blade to blade clearance of .000” to .010” (.00 to 0.25 mm) should be maintained for optimum performance. See Fig. 2 for cutting blade and shim arrangement. Refer to the NPK Parts Manual for part numbers. PIERCING TIP TO TUNNEL BLADE GAP...

  • Page 50: K Jaw Blade Set Up Procedure

    GENERAL MAINTENANCE K JAW BLADE SET UP PROCEDURE M35K Install the piercing tip on the arm (if needed) first. Check to ensure that the ST1. piercing tip blades are parallel. See “COMPONENT DESCRIPTION”, “PIERCING TIP MAINTENANCE AND REPLACEMENT” and “BLADE MAINTENANCE AND ADJUSTMENT”, Steps 1 and 2.

  • Page 51: Component Description

    GENERAL MAINTENANCE COMPONENT DESCRIPTION M35K The arm (BD) contains the primary cutting blades (BG), spacer plates (DE) and a two piece bolt-on piercing tip (DA). The drive arm (BI) contains the secondary blades (BG1), tunnel blade (DB), spacer (DC), guide blade (DF) and spacer plate (DE).

  • Page 52: 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 bolt in style and cannot be turned. The piercing tip also cannot be built up via a weld procedure.
  • Page 53 GENERAL MAINTENANCE K JAW BLADE MAINTENANCE AND ADJUSTMENT Install and tighten the piercing tip blades (DG) into the male jaw (BD) first using the three socket head cap screws (OO) provided. Use thread adhesive (t41) when installing the cap screws. Each primary blade (BG) will have a spacer plate (DE) placed between the blade and blade pocket.
  • Page 54 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”).
  • Page 55 Continue closing the jaws stopping to record the clearance (d61) at the second secondary blade. NPK shim packs have a variety of shims (i.e., .005, .010, .024, .060, and .120). Install the required amount of shims behind each secondary blade until a clearance of .005”...
  • Page 56 K JAW BLADE MAINTENANCE AND ADJUSTMENT STEP 3: 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”). STEP 4: Install either a reconditioned (used) or new tunnel blade (DB) into the female jaw tunnel blade pocket (DM).
  • Page 57 Install tunnel blade shims if necessary to achieve the above clearances. After blade shimming is complete, remove the socket head cap screws (OO) for the tunnel blade and apply thread adhesive. Then torque to NPK specifications (see the “FASTENER TORQUE CHART”).
  • Page 58 Install the required amount of shims to reduce these gaps to .005” (.127 mm). After blade shimming is complete, remove the socket head cap screws (OO) for the guide blades and apply thread adhesive. Then torque to NPK specifications (see the “FASTENER TORQUE CHART”).

  • Page 59: Piercing Tip Maintenance And Replacement

    GENERAL MAINTENANCE PIERCING TIP MAINTENANCE AND REPLACEMENT Before maintenance is performed on the piercing tip, it is recommended that the drive arm (tunnel) be repaired first. MAINTENANCE To maintain maximum piercing efficiency, the piercing tip (DG) should be checked daily for wear.

  • Page 60: Jaw Inspection And Maintenance

    .75” (19 mm) compared to the template or the cylinder will bottom out. JAW BUILD-UP AND HARDFACING (M35S) For build-up and hardfacing 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. M3500-9501...

  • Page 61: Teeth Build-Up And Hardfacing (M35G)

    TEETH BUILD-UP AND HARDFACING (M35G) For build-up and hardfacing of teeth, use the NPK template (t72) to check teeth so that they are to the original profile (CY). Contact NPK for the correct template, drawing no.

  • Page 62: Replaceable Tooth Plates - G Jaws

    Due to the abrasive nature of the material being crushed, jaw wear will occur on the M35S and M35G Processors. The jaws must be built up with hard face weld when the clearance between the tip of the jaws in the closed position is worn to the extent that the material can no longer be crushed efficiently.
  • Page 63 JAW INSPECTION AND MAINTENANCE JAW INSPECTION: G and S JAWS WEEKLY INSPECTION JAW AND TOOTH REBUILD PROCEDURE: S 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 hardfacing. You cannot hard face over old hardfacing. ...
  • Page 64 JAW INSPECTION AND MAINTENANCE JAW INSPECTION: G and S JAWS WEEKLY INSPECTION JAW AND TOOTH REBUILD PROCEDURE: S 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. ...

  • Page 65: Jaw Contact Areas

    JAW INSPECTION AND MAINTENANCE JAW CONTACT AREAS S and G JAW CONTACT AREAS In contact areas of jaws, hardfacing (we3) may be added to increase the wear life of these surfaces for hardfacing instructions, see the JAW and TOOTH REBUILD PROCEDURE.

  • Page 66: Frame Maintenance

    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 assembly (c11). NOTE: See the Booster Manual (B000- 9601 for Booster maintenance. 2. Remove the spacers (bs23), o-rings (RR) and backup rings (SS) from the cylinder assembly (c11).
  • Page 69 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 polish the rings until they spring out of...
  • 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 and discard.

  • Page 71: Inspecting And Cleaning Cylinder Components

    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 72 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 73: Suggested Repair Tools And Equipment

    (c5). Install the o-ring and backup ring into the outer groove. 2. Apply hydraulic oil or NPK Assembly Lube to the inner surface coating the previously installed dirt seal, backup ring and piston seal. Install the cylinder end cap onto the...
  • Page 74 SUGGESTED REPAIR TOOLS AND EQUIPMENT 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) onto the cylinder rod (c3).
  • Page 75 8. Using a ring expander (t16), install the piston rings with the splits in the piston rings opposing each other. 9. Apply hydraulic oil or NPK Assembly Lube to the inner surface of the cylinder housing and to the outside diameter of the piston and piston rings.
  • Page 76 (bs23), then install in the corresponding counter bores of the main cylinder (c11). 13. Apply a light coat of oil or NPK Assembly Lube to the mating surfaces of the booster main body. 14. With the aid of an assistant, carefully...
  • Page 77 INSPECTION AND MAINTENANCE SUGGESTED REPAIR TOOLS AND EQUIPMENT 16. Secure the main booster assembly to the cylinder housing using the eight cap screws and washers. Tighten the cap screws in an opposing pattern. Torque to value listed below. MODEL BOLT TORQUE SIZE ft.

  • Page 78: Jaw Set Interchange

     Three wood blocks, 4” x 4” x 24” (100 x 100 x 610 mm) or larger.  12 mm hex key socket.  17 mm hex key socket (available as NPK part no. 35004600).  12 mm hex key wrench (available as NPK part no. 25004120).

  • Page 79: 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 or jaw set. UNIT POSITIONING All processor positioning will be done with the excavator.

  • Page 80: Removal Of The Jaw Set Assembly From The Main Frame

    JAW SET INTERCHANGE DETACHMENT OF THE EYE AND FORKED JAWS FROM THE CYLINDER SUB-ASSEMBLIES 3. Manually remove the cylinder lock plates. 4. Remove the cylinder pins (c9). Once the cylinder jaw pins are removed, the jaws may rock forward. REMOVAL OF THE JAW SET ASSEMBLY FROM THE MAIN FRAME 5.

  • Page 81: Jaw Set Storage

    JAW SET INTERCHANGE REMOVAL OF THE JAW SET ASSEMBLY FROM THE MAIN FRAME 7. Using a non-metallic (e.g., nylon, wood) rod (t3), drive the four jaw frame pins (c41) in until they hit the pin stop (131) or through the jaw frame (GB) and flush with the processor frame.

  • Page 82: Jaw Set Installation Into The Main Frame

    JAW SET INTERCHANGE JAW SET INSTALLATION INTO THE MAIN FRAME 1. Using the excavator, hook the main frame assembly (DN1) at the hook pin (c46) to the jaw set assembly (DO1). 2. Using a 17 mm hex key socket or wrench, install the four retaining pin bolts (c42) to secure the four lock plates (c43) to the four jaw frame pins (c41).

  • Page 83: 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 84: 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 M35 processor frame that rotates. Hydraulic oil for both the open and close operations of the M35 processor pass through this manifold. The swivel manifold assembly consists of two main parts, the “Spindle Case”...

  • Page 85: 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 86: 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 M35 material processor should be closed and the frame supported or the shipping pins (t80), as shown in Fig.
  • Page 87 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 88 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 89 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 90: Fastener Torque Specifications

    FASTENER TORQUE SPECIFICATIONS These torque charts are to be used with the specific “M35” Series processor parts manual for the unit being repaired. All fasteners will be used with lube or medium strength 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 91 FASTENER TORQUE SPECIFICATIONS FASTENER TORQUE CHART - M35 CYLINDER ASSEMBLY BOLT LOCATION BOLT SIZE BOLT TORQUE ADHESIVE ft. lb. OR LUBED (Nm) CYLINDER END CAP (495) LUBED CYLINDER ROD NUT 3200 (4300) ADHESIVE GUIDE PLATE (300) ADHESIVE BOOSTER ASSEMBLY (300) ADHESIVE MANIFOLD BLOCK (200)

  • Page 92: Hose Torque Specifications

    HOSE TORQUE SPECIFICATIONS JIC ENDS NUMBER OF NOMINAL FITTING THREAD FLATS FROM TORQUE SIZE DASH SIZE 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 93: Troubleshooting

    NPK pressure intensifier performance. 2. LOSS OF CYCLE SPEED NPK M35 Material Processor cycle speed is determined by oil flow to the unit. The hydraulic installation circuit for the M35 Material Processor must be set to provide the correct flow.

  • Page 94: Troubleshooting Guide For Low Power

    TROUBLESHOOTING TROUBLESHOOTING GUIDE FOR LOW POWER RELIEF VALVE CHECKS LOW POWER CHECKS PROBLEM CAUSE CHECK REMEDY Operating Pressure Carrier hydraulic Measure the carrier Adjust or replace the is less than 3,700 circuit relief valve. circuit relief valve with carrier circuit relief psi (255 bar).
  • Page 95 TROUBLESHOOTING TROUBLESHOOTING GUIDE FOR LOW POWER RELIEF VALVE CHECKS LOW POWER CHECKS PROBLEM CAUSE CHECK REMEDY Operating pressure Booster control Dis-assemble the Polish or replace as is at 3,700 psi (255 valve assembly. main valve and necessary. bar), but the inspect the spring, intensifier does not plungers and for...

  • Page 96: 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 97 TROUBLESHOOTING 1. CARRIER CIRCUIT RELIEF VALVE CHECK Verify that the hydraulic system of the carrier meets the requirements of the M35 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 98: Pressure Intensifier Sequence Valve And Relief Valve Actuation

    TROUBLESHOOTING 2. M35 MATERIAL PROCESSOR RELIEF VALVE After the M35 Material Processor hydraulic circuit has been verified, check the M35 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 99: M35 Material Processor Relief Valve And Carrier Relief Valve Settings

    TROUBLESHOOTING M35 MATERIAL PROCESSOR RELIEF VALVE AND CARRIER RELIEF VALVE SETTINGS M35 PROCESSOR MINIMUM CARRIER MODEL SERIAL NO. RELIEF VALVE RELIEF VALVE SETTING SETTING (bar) (bar) 3,700 (255) 3,900 (270) RELIEF VALVE LOCATION The M35 Material Processor relief valve cartridges, close (c17) and open (c18) are located in the relief blocks (bs24) that are bolted to the rotary joint assembly (BN).
  • Page 100 TROUBLESHOOTING INTENSIFIER CHECKS (unit does not click) INTENSIFIER CHECKS PROBLEM CAUSE CHECK REMEDY Intensifier does not M35 Processor Check relief Tighten the relief click relief valves cartridges for valve cartridges. tightness. Check relief Reset to 3,700 psi (255 bar). If unable cartridges for mis- adjustment.
  • Page 101 TROUBLESHOOTING INTENSIFIER CHECKS (unit clicks – does not slow down) INTENSIFIER CHECKS PROBLEM CAUSE CHECK REMEDY Intensifier clicks but M35 Processor Check relief Tighten the relief does not slow down relief valves cartridges for valve cartridges. tightness. Pilot check valve Inspect the booster Replace the inlet pilot assemblies.

  • Page 102: Pressure Intensifier Operation

    TROUBLESHOOTING PRESSURE INTENSIFIER OPERATION NPK’s exclusive pressure intensifier system is used in NPK M35 Material Processors to boost cylinder pressure to increase the jaw closing forces. When the intensifier is working properly, a rapid clicking sound will be heard, indicating that the pressure intensifier is being actuated as the jaws begin to close against resistance.

  • Page 103: 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 M35 Material Processors. The pressure intensifier’s have three test ports as shown. L017-8000 GAUGE ASSEMBLY gauge: 0 - 15,000 psi...

  • Page 104: 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 105 TROUBLESHOOTING TEST PROCEDURE SLOW CYLINDER SPEED PROBLEM CAUSE CHECK REMEDY Operating Pressure Carrier hydraulic Measure the carrier Adjust or replace the is less than 3,700 circuit relief valve. circuit relief valve with carrier circuit relief psi (255 bar).) the pressure to close valve.

  • Page 106: 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 M35 Material Processor close (m3) and open lines (m4) as shown.
  • Page 107 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 108: 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 109: 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 M35 Material Processor. MODEL ROTATION APPROXIMATE...
  • Page 110 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 M35 hydraulic circuit flow Processor rotation setting.
  • Page 111 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 112: Keywords For Common M35 Processor Components

    KEYWORDS FOR COMMON M35 PROCESSOR COMPONENTS ROTARY JOINT ASSEMBLY ROTATION VALVE HYDRAULIC MOTOR PINION GEAR bs35 BOOSTER ASSEMBLY SLEWING RING SLEWING RING COVER CYLINDER ASSEMBLY CYLINDER PIN LOCKING PLATE CYLINDER ASSEMBLY COVER PIVOT PIN NUT CYLINDER PIN COVER PLATE TOP PLATE MAIN FRAME LOCK PIN HOOK PIN...

  • Page 113: Keywords For Common M35 Processor "K" Jaw Components

    KEYWORDS FOR COMMON M35 PROCESSOR “K” JAW COMPONENTS MALE JAW PRIMARY BLADE SECONDARY BLADE FEMALE JAW PIVOT PIN NUT TUNNEL BLADE GUIDE BLADE PIERCING TIP (bolt on) PIERCING TIP (bolt on) JAW FRAME BUSHING...

  • Page 114: Keywords For Common M35 Processor Cylinder Components

    KEYWORDS FOR COMMON M35 PROCESSOR CYLINDER COMPONENTS bs 1 CONNECTOR PIPE bs35 BOOSTER ASSEMBLY bs41 MANIFOLD BLOCK CYLINDER ROD NUT PISTON CYLINDER ROD CYLINDER MAIN BARREL CYLINDER END CAP PISTON RING...

  • Page 115: Warranty Statements

    WARRANTY STATEMENTS...
  • Page 116 WARRANTY STATEMENTS...

  • Page 117: 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 118 © Copyright 2018 NPK Construction Equipment, Inc. www.npkce.com M000-9601B M35 Material Processor Instruction Manual 10-18...

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