Table of Contents
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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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Table of Contents
Related Manuals for NPK U31JR
Summarization of Contents
Safety Information
Safety Notice Definitions
Explains DANGER, WARNING, CAUTION, and ATTENTION notice types.
Operational Safety Precautions
Lists essential safety rules for operating the NPK Crusher.
Maintenance Safety Precautions
Details safety measures to be followed during maintenance and repair.
Standard Maintenance Practices
Reviews common standard practices for hydraulic equipment maintenance.
Introduction and Compatibility
Product and Manual Overview
Welcome message and purpose of the operation and maintenance manual.
Excavator Compatibility Guidelines
Recommends matching crusher size to excavator weight for stability.
Model Specifications
U21J Secondary Crusher Specs
Details weight, jaw opening, oil flow, and cycle time for the U21J model.
U21JA Secondary Crusher Specs
Provides specifications for the U21JA model.
U21JR Secondary Crusher Specs
Provides specifications for the U21JR model.
U31J Secondary Crusher Specs
Provides specifications for the U31J model.
U31JA Secondary Crusher Specs
Provides specifications for the U31JA model.
U31JR Secondary Crusher Specs
Provides specifications for the U31JR model.
U45J Secondary Crusher Specs
Provides specifications for the U45J model.
U45JR Secondary Crusher Specs
Provides specifications for the U45JR model.
G7 Secondary Crusher Specs
Provides specifications for the G7 model.
G18J Secondary Crusher Specs
Provides specifications for the G18J model.
G26J Secondary Crusher Specs
Provides specifications for the G26J model.
G30JR Secondary Crusher Specs
Provides specifications for the G30JR model.
Serial Number Locations
U/UJR/U45J/JR Serial Number Location
Illustrates serial number placement for specific U-series models.
G7/G18J/G26J Serial Number Location
Illustrates serial number placement for specific G-series models.
G30JR Serial Number Location
Illustrates serial number placement for the G30JR model.
Crusher Booster and Cylinder System
Booster System Introduction
Explains the hydraulic booster's role in increasing cylinder pressure.
Boosted Cylinder Structure
Details the components that make up the boosted cylinder assembly.
Operating Principles
Describes the system's operation under no load and during booster actuation.
Hydraulic Installation Procedures
Hydraulic Installation Kits
Information on available hydraulic installation kits for NPK crushers.
Flow Direction and Shut-Off Valves
Explains hydraulic flow direction and the operation of shut-off valves.
Test Port Locations
Identifies locations for pressure testing ports on the hydraulic system.
Preventing Hydraulic Contamination
Guidelines to prevent contamination in the hydraulic system.
Hydraulic Quick Disconnects
Recommendations and warnings regarding the use of quick disconnects.
Mounting and Installation
Mounting Kit Components
Lists parts included in NPK mounting kits for crusher installation.
Rotating Top Bracket Features
Describes the U and G Series rotating top bracket's functionality.
Mounting and Removal Procedures
Step-by-step instructions for mounting and removing the crusher.
Crusher Storage Guidelines
Procedures for storing the crusher when it is not in use.
Hose Installation Tips
Whip Hose Installation Best Practices
Best practices for installing and torquing hydraulic hoses, including bend radius.
Operating Instructions and Techniques
General Operating Instructions
Essential instructions and warnings before operating the crusher.
Intended Application and Techniques
Specifies the intended use and proper operating techniques for the crushers.
Prohibited Operations
Lists operations that should not be performed with the crusher to prevent damage.
General Maintenance
Daily Inspection and Maintenance
Daily checks and maintenance tasks to ensure proper crusher function.
Lubrication Points and Schedule
Identifies all lubrication points and their recommended service intervals.
Cutter Blade Maintenance
Instructions for grinding, flipping, and replacing cutter blades for optimal performance.
Shim Kits Information
Details on available shim kits for model adjustments and maintenance.
Jaw Inspection and Maintenance
Weekly Jaw Inspection
Weekly checks for jaw wear and minimum gap maintenance.
Teeth Maintenance and Replacement
Procedures for maintaining, building up, and replacing jaw teeth.
Jaw and Tooth Rebuild Procedure
Detailed steps for rebuilding worn jaws and teeth using welding.
Frame Maintenance and Repair
Main Frame Rework Guide
Procedures for main frame rework based on wear levels.
Frame Crack Repair Procedure
Instructions for inspecting and repairing frame cracks using welding techniques.
Booster Cylinder Maintenance
Booster Cylinder Disassembly
Step-by-step guide for disassembling the booster cylinder.
Cylinder Components Inspection and Assembly
Procedures for inspecting, cleaning, and reassembling cylinder components.
Top Bracket Conversion
"U" Series Conversion Packages
Lists conversion packages for changing top bracket types on "U" series crushers.
Slewing Ring Maintenance
Measuring Axial Movement
Procedure for measuring axial movement in the slewing ring to check wear.
Rotation Bearing Outer Dirt Seal Replacement
Steps for replacing the outer dirt seal on the rotation bearing.
Swivel Manifold Maintenance
Swivel Manifold Assembly and Function
Describes the swivel manifold's structure and role in crusher operation.
Seal Leakage Testing and Replacement
Procedures for testing and replacing seals within the swivel manifold.
Torque Specifications
Fastener Torque Charts
Torque values for fasteners in main frame, cylinder, and rotation assemblies.
Hose Torque Specifications
Torque values for JIC and ORFS hose connections.
Troubleshooting Guide
Troubleshooting: Power and Speed Issues
Classifies problems and guides on initial diagnosis of power or speed loss.
Troubleshooting: Relief Valve Checks
Guides on checking and setting relief valves for low power conditions.
Troubleshooting: Intensifier Issues
Diagnosing problems related to the pressure intensifier's operation.
Troubleshooting: Slow Cycle Speed
Steps for diagnosing slow cylinder speed by checking hydraulic flow.
Troubleshooting: Jaw Drift and Rotation
Diagnosing jaw drift causes and resolving rotation issues.
Component Information and Warranty
Crusher Component Keywords
Glossary of common crusher part names and their labels.
Warranty Statements
Outlines NPK's warranty terms and conditions for the crushers.
Notes and Service Record
User Notes Section
Space for recording important crusher and excavator details.
Service Record Log
Log for recording maintenance and inspection dates.
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