MATERIAL PROCESSOR

MATERIAL PROCESSOR

INSTRUCTION MANUAL

MODELS:

M20S M20G M20C M20K 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 2015 NPK Construction Equipment, Inc. www.npkce.com M000-9600H 7-15 Material Processor Instruction Manual

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CONTENTS

SAFETY ............................................................................................................................ 4 OPERATION ............................................................................................................... 5 MAINTENANCE .......................................................................................................... 6

INTRODUCTION ............................................................................................................... 8 EXCAVATOR COMPATIBILITY ........................................................................................ 8 SERIAL NUMBER LOCATION .......................................................................................... 9 M-SERIES SPECIFICATIONS .......................................................................................... 12

M20S MATERIAL PROCESSOR ................................................................................ 12 M20C MATERIAL PROCESSOR................................................................................ 13 M20G MATERIAL PROCESSOR ............................................................................... 14 M20K MATERIAL PROCESSOR ................................................................................ 15 M28S MATERIAL PROCESSOR ................................................................................ 16 M28C MATERIAL PROCESSOR................................................................................ 17 M28G MATERIAL PROCESSOR ............................................................................... 18 M28K MATERIAL PROCESSOR ................................................................................ 19 M38S MATERIAL PROCESSOR ................................................................................ 20 M38C MATERIAL PROCESSOR................................................................................ 21 M38G MATERIAL PROCESSOR ............................................................................... 22 M38K MATERIAL PROCESSOR ................................................................................ 23

PRINCIPLE OF OPERATION ........................................................................................... 24 HYDRAULIC INSTALLATION ........................................................................................... 32

SHUT-OFF VALVES ................................................................................................... 32 HYDRAULIC QUICK DISCONNECTS ........................................................................ 33

MOUNTING INSTALLATION ............................................................................................ 34 M-SERIES TOP BRACKET ........................................................................................ 34 MOUNTING TO THE EXCAVATOR ........................................................................... 35 REMOVAL FROM THE CARRIER .............................................................................. 35

STORAGE OF MATERIAL PROCESSOR ........................................................................ 35 OPERATING INSTRUCTIONS ......................................................................................... 36

OPERATING TECHNIQUES AND PRECAUTIONS ................................................... 41 GENERAL MAINTENANCE .............................................................................................. 44

DAILY INSPECTION AND MAINTENANCE ............................................................... 44 LUBRICATION POINTS ............................................................................................. 45

CYLINDER MAINTENANCE ............................................................................................. 46 CYLINDER CAP BOLT TORQUES ............................................................................ 46 ROD NUT TORQUES ................................................................................................. 47

SLEWING RING INSPECTION AND MAINTENANCE ..................................................... 48 MEASURING MAXIMUM AXIAL MOVEMENT ........................................................... 48

SWIVEL MANIFOLD MAINTENANCE .............................................................................. 49 SWIVEL OIL MANIFOLD ASSEMBLY ........................................................................ 49 LEAKAGE OF THE SEALS ........................................................................................ 49 TESTING THE SWIVEL SEALS FOR INTERNAL LEAKAGE .................................... 49 REPLACEMENT OF THE SEALS IN THE SWIVEL ................................................... 50 SWIVEL ASSEMBLY .................................................................................................. 52

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CONTENTS M-SERIES JAW IDENTIFICATION ................................................................................... 53 JAW SET IDENTIFICATION ............................................................................................. 54 K JAW CUTTING CAPACITY ........................................................................................... 58 JAW INSPECTION AND MAINTENANCE ........................................................................ 59

JAW WEAR AND REPAIR .......................................................................................... 59 CUTTING BLADE MAINTENANCE ............................................................................ 61 CUTTING BLADE MAINTENANCE ............................................................................ 62 PIERCING TIP MAINTENANCE AND REPLACEMENT ............................................. 63 REPLACING PIERCING TIP ...................................................................................... 64

PIERCING TIP MAINTENANCE AND REPLACEMENT ................................................... 65 K-JAW BLADE SET UP PROCEDURE ............................................................................. 67 M-SERIES “K” (SHEAR) JAW MAINTENANCE ................................................................ 68

BLADE MAINTENANCE AND ADJUSTMENT ............................................................ 69 JAW INSPECTION AND MAINTENANCE ........................................................................ 74

HARDFACING ............................................................................................................ 74 JAW AND TOOTH REBUILD PROCEDURE .............................................................. 75 TEETH BUILD-UP AND HARDFACING (M20G, M28G, M38G) ................................. 77 “G” JAW CONTACT AREAS ....................................................................................... 78

TEETH REPLACEMENT ...................................................................................... 79 “C” JAW CONTACT AREAS ....................................................................................... 81

TEETH REPLACEMENT ...................................................................................... 82 JAW SET INTERCHANGE ................................................................................................ 84

TOOLS AND SUPPLIES ............................................................................................. 84 PROCEDURE FOR JAW SET INTERCHANGE ......................................................... 85

DETACHMENT OF JAWS FROM THE CYLINDER SUB-ASSEMBLIES ............. 87 DETACHMENT OF A JAW SET FROM THE MAIN FRAME ................................ 89 JAW SET REMOVAL ........................................................................................... 92 JAW SET STORAGE ........................................................................................... 92 INSTALLATION OF A JAW SET INTO THE MAIN FRAME ................................. 92 ATTACHMENT OF JAWS TO THE MAIN FRAME .............................................. 93 ATTACHMENT OF JAWS TO THE CYLINDER SUB-ASSEMBLIES ................... 94

FASTENER TORQUE CHART .......................................................................................... 97 TROUBLESHOOTING ...................................................................................................... 101

TROUBLESHOOTING FOR LOSS OF POWER ........................................................ 101 PROPER OPERATION OF BOOSTER ...................................................................... 103 CHECKING BOOSTED PRESSURE .......................................................................... 104 ROTATION ................................................................................................................. 106 TROUBLESHOOTING FOR SLOW CYCLE SPEED .................................................. 107 CHECKING THE HYDRAULIC FLOW AT RATED PRESSURE ................................. 108

KEYWORDS FOR COMMON PROCESSOR COMPONENTS ......................................... 110 WARRANTY STATEMENTS ............................................................................................. 111 NOTES .............................................................................................................................. 113 SERVICE RECORD .......................................................................................................... 113

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

DANGER (red) notices indicate an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING (orange) notices indicate a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION (yellow) notices indicate a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury.

ATTENTION (blue) notices in NPK Instruction Manuals are an NPK standard to alert the reader to situations which, if not avoided, could result in equipment damage.

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

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Warning Decal for Cab Installation

SAFETY OPERATION

1. Operator personnel must read and understand the NPK INSTRUCTION MANUAL to prevent serious or fatal injury.

2. FLYING OR FALLING DEBRIS CAN CAUSE SERIOUS OR FATAL INJURY. Keep personnel and bystanders clear of the MATERIAL PROCESSOR while in operation.

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

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

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

6. Do not leave a load suspended in air. 7. Do not pass a load over people, vehicles, etc. 8. Do not operate the MATERIAL PROCESSOR

within reach of power lines. 9. Do not climb, sit, or ride on the MATERIAL

PROCESSOR.

10. Match the MATERIAL PROCESSOR size to excavator according to NPK

recommendations, see page 8. The excavator must be stable during MATERIAL PROCESSOR operation and during transport.

11. Do not operate without inspection (access) covers in place. 12. Be especially cautious around hydraulic lines. Hydraulic oil can be extremely HOT!

Avoid skin contact with hydraulic oil. It can cause severe burns! 13. Protect hands and body from hydraulic fluids under pressure. Escaping high

pressure fluid can penetrate the skin, causing serious injury. Avoid the hazard by relieving pressure before disconnecting any lines. Search for leaks with a piece of cardboard, or other object. If an accident occurs, see a doctor immediately! Hydraulic fluid injected into the skin must be surgically removed immediately or gangrene may result!

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

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

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SAFETY MAINTENANCE

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

2. Use extreme caution in handling. A fully assembled MATERIAL PROCESSOR can

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

3. Use extreme caution when changing jaw sets, particularly in the field. Employ lifting

and securing mechanisms of adequate capacity to support the jaw sets. At least two people are required to change a jaw set safely in the field.

4. Wear safety glasses and protective clothing when working on the MATERIAL

PROCESSOR. Wear thermal-protective gloves when handling heated parts. 5. Prevent exposure to hazardous fumes. Remove all paint, grease, and oil before

heating, cutting or welding on the MATERIAL PROCESSOR. 6. Be especially cautious around hydraulic lines. Hydraulic oil can be extremely HOT!

Avoid skin contact with hydraulic oil. It can cause severe burns! 7. Protect hands and body from hydraulic fluids under pressure. Escaping fluid

under pressure can penetrate the skin, causing serious injury. Avoid the hazard by relieving pressure before disconnecting any lines. Search for leaks with a piece of cardboard, or other object. If an accident occurs, see a doctor immediately! Hydraulic fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

8. The pressure generated by the power intensifier on the MATERIAL PROCESSOR

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

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

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SAFETY MAINTENANCE

STANDARD PRACTICES

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

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

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

corresponding parts uniquely to reflect their relationship, including proper location, position, orientation, and/or alignment.

DO: During assembly, observe all markings made during disassembly, and all

corresponding features of mating parts to ensure proper location, position, orientation, and alignment.

During disassembly of a sub-assembly, place removed components on a clean, dry

surface, in proper relative position as an aid in re-assembly. Always inspect threaded areas on components. Repair or replace as required.

Use care to avoid scratches, nicks, dents, or other damage to machined surfaces of mating components.

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

pattern, applying the specified torque. Grease can be used to temporarily hold a part in place while the abutting part is

placed into position. Always use common sense and exercise standard safety precautions when working

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

ATTENTION

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INTRODUCTION NPK prides itself on the design and manufacture of high quality products. This tradition of quality workmanship and materials continues in our M20 / M28 / M38 MATERIAL PROCESSORS. Many years of productive service can be realized with proper operation and care of the MATERIAL PROCESSOR. The purpose of this manual is to provide you with the information and instructions required to properly operate and maintain the MATERIAL PROCESSOR. This will result in maximum MATERIAL PROCESSOR reliability and productivity. Read this manual thoroughly before attempting to operate, remove, disassemble, repair or troubleshoot the MATERIAL PROCESSOR or any of its components. Follow all the safety precautions contained in this manual. Failure to do so, can result in death, personal injury, injury to others, and property damage.

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

Mounting a MATERIAL PROCESSOR that is too heavy for the excavator can be dangerous and damage the machine. Verify excavator stability with the MATERIAL PROCESSOR before transport or operation. Mounting a MATERIAL PROCESSOR that is too small for the excavator can damage the MATERIAL PROCESSOR and void Warranties. Please consult NPK Engineering for specific detailed information.

MODEL RECOMMENDED EXCAVATOR CLASS 3rd member mounting

US ton Metric ton

M20 20 - 25 18 - 23

M28 25 - 40 23 - 36

M38 33 - 55 30 - 50

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SERIAL NUMBER LOCATION

M20

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M28

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M38

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M-SERIES SPECIFICATIONS M20S MATERIAL PROCESSOR

MODEL Weight

lb (kg)

Excavator Class tons

(tonnes)

Crushing Force at Tip

tons (tonnes)

Max. Jaw Opening in (mm)

Cycle Time sec

Max. Op. Pressure psi (bar)

Oil Flow

gpm (lpm)

M20S 4355 lb (1980 kg)

20 – 25 (18 – 23)

78 (71)

37.0” (940 mm)

2.8 Close 1.4 Open

3625 psi (250 bar)

26 – 53 gpm (100 – 200 lpm)

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M-SERIES SPECIFICATIONS M20C MATERIAL PROCESSOR

MODEL Weight

lb (kg)


(tonnes)


tons (tonnes)


Cycle Time sec


Oil Flow

gpm (lpm)

M20C 4440 lb (2015 kg)

20 – 25 (18 – 23)

78 (71)

34.5” (876 mm)

2.8 Close 1.4 Open

3625 psi (250 bar)

26 – 53 gpm (100 – 200 lpm)

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M-SERIES SPECIFICATIONS M20G MATERIAL PROCESSOR

MODEL Weight

lb (kg)


(tonnes)


tons (tonnes)


Cycle Time sec


Oil Flow

gpm (lpm)

M20G 4520 lb (2055 kg)

20 – 25 (18 – 23)

84 (76)

30.3” (770 mm)

2.8 Close 1.4 Open

3625 psi (250 bar)

26 – 53 gpm (100 – 200 lpm)

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M-SERIES SPECIFICATIONS M20K MATERIAL PROCESSOR

MODEL Weight

lb (kg)


(tonnes)

Piercing Force at Tip

tons (tonnes)


Cycle Time sec


Oil Flow

gpm (lpm)

M20K 4530 lb (2060 kg)

20 – 25 (18 – 23)

91 (82)

21.1” (535 mm)

2.8 Close 1.4 Open

3625 psi (250 bar)

26 – 53 gpm (100 – 200 lpm)

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MODEL Weight

lb (kg)


(tonnes)


tons (tonnes)


Cycle Time sec


Oil Flow

gpm (lpm)

M28S 6400 lb (2915 kg)

25 – 40 (23 – 36)

115 (105)

42.0” (1067 mm)

3.1 Close 1.7 Open

3625 psi (250 bar)

50 – 80 gpm (190 – 300 lpm)

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MODEL Weight

lb (kg)


(tonnes)


tons (tonnes)


Cycle Time sec


Oil Flow

gpm (lpm)

M28C 6500 lb (2950 kg)

25 – 40 (23 – 36)

116 (105)

36.2” (920 mm)

3.1 Close 1.7 Open

3625 psi (250 bar)

50 – 80 gpm (190 – 300 lpm)

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MODEL Weight

lb (kg)


(tonnes)


tons (tonnes)


Cycle Time sec


Oil Flow

gpm (lpm)

M28G 6850 lb (3107 kg)

25 – 40 (23 – 36)

125 (114)

35.8” (910 mm)

3.1 Close 1.7 Open

3625 psi (250 bar)

50 – 80 gpm (190 – 300 lpm)

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MODEL Weight

lb (kg)


(tonnes)


tons (tonnes)


Cycle Time sec


Oil Flow

gpm (lpm)

M28K 6900 lb (3130 kg)

25 – 40 (23 – 36)

133 (121)

25.1” (637 mm)

3.1 Close 1.7 Open

3625 psi (250 bar)

50 – 80 gpm (190 – 300 lpm)

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MODEL Weight

lb (kg)



tons


Cycle Time sec


Oil Flow

gpm (lpm)

M38S 8450 lb (3840 kg)

33 – 55 (30 – 50)

147 (134)

48.6” (1234 mm)

3.8 Close 2.1 Open

3625 psi (250 bar)

60 – 100 gpm (225 – 380 lpm)

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MODEL Weight

lb (kg)


(tonnes)


tons (tonnes)


Cycle Time sec


Oil Flow

gpm (lpm)

M38C 8590 lb (3900 kg)

33 – 55 (30 – 50)

143 (130)

48.4” (1230 mm)

3.8 Close 2.1 Open

3625 psi (250 bar)

60 – 100 gpm (225 – 380 lpm)

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MODEL Weight

lb (kg)


(tonnes)


tons (tonnes)


Cycle Time sec


Oil Flow

gpm (lpm)

M38G 9100 lb 4140 kg

33 – 55 (30 – 50)

152 (138)

45.0” (1142 mm)

3.8 Close 2.1 Open

3625 psi (250 bar)

60 – 100 gpm (225 – 380 lpm)

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MODEL Weight

lb (kg)


(tonnes)


tons (tonnes)


Cycle Time sec


Oil Flow

gpm (lpm)

M38K 9370 lb 4260 kg

33 – 55 (30 – 50)

170 (154)

30.2” (766 mm)

3.8 Close 2.1 Open

3625 psi (250 bar)

60 – 100 gpm (225 – 380 lpm)

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PRINCIPLE OF OPERATION 1.0 BOOSTER AND CYLINDER

1.1 DESCRIPTION The NPK Material Processor obtains its power from the hydraulic system of the excavator to which it is mounted. Two hydraulic cylinders convert hydraulic power to crushing and shearing forces. The Material Processor hydraulic cylinders work independently of each other, but share an exclusive NPK pressure intensifier (booster) mechanism. Because the boosted cylinders are relatively small diameter, less oil is required compared to conventional large diameter cylinders without a pressure booster, thus reducing cycle time. JAW CLOSE Oil from the excavator is directed to the piston end of the cylinders to close the jaws of the Material Processor. Under no load, boost pressure is not applied. When the jaws meet resistance (material to be crushed or sheared), pressure builds and shifts the sequence valve on the booster. This directs oil into the booster section. JAW OPEN To open the jaws of the NPK Material Processor, oil is directed to the rod end of the cylinders. This retracts the rods and pulls the jaws open. Pressure boost is not provided nor is it necessary to open the jaw.

c11. Jaw Cylinder c14. Pressure Intensifier c15. Main Valve c16. Sequence Valve c17. Relief Valve (Close) c18. Relief Valve (Open) k7. Control Valve k8. Hydraulic Pump

(Excavator) k9. Valve Bank (Excavator)

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1.2 STRUCTURE OF THE BOOSTER/CYLINDER ASSEMBLY

Fig. 1.1 Structure of Booster/Cylinder Assembly

The Booster/Cylinder assembly consists of: Cylinder Assemblies Booster Piston Booster Valve and Plunger Pilot Check Valve (PCV) and Check Valve 1 (CV1) thru Check Valve 5 (CV5) Sequence Valve (SV)

For a complete breakdown of the parts in the Booster/Cylinder assembly, refer to the Booster Parts Manual.

c11. Jaw Cylinder c14. Booster Piston c15. Booster Valve c16. Sequence Valve c19. Plunger c20. Pilot Check Valve c21. Check Valve (1) c22. Check Valve (2) c23. Check Valve (3) c24. Check Valve (4) c25. Check Valve (5) k7. Control Valve v1. Oil Chamber (1) v2. Oil Chamber (2) v3. Oil Chamber (3) v4. Oil Chamber (4)

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PRINCIPLE OF OPERATION 1.0 BOOSTER AND CYLINDER 1.3 OPERATING PRINCIPLE 1.3.1 Jaw Close Under No Load Oil is directed through the booster unit to the base end of the cylinders to close the jaws. If no load is encountered, hydraulic pressure developed is low, and no boost is needed.

Fig. 1.2 Cylinder Extend (Jaw Close) under no load


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1.3 OPERATING PRINCIPLE 1.3.2 Jaw Close Under Load (Booster actuated) Fig. 1.3 thru 1.7 When a load (material to be broken) is encountered as the jaws close, the hydraulic pressure starts to rise. When the hydraulic pressure reaches a pre-set pressure, the sequence valve (SV) shifts and directs oil through the control valve of the booster and to the booster piston. This starts the boosting process. The booster piston is double ended and provides boost in each direction of travel. The hydraulic oil that has passed through the sequence valve and booster control valve flows into rear chambers V1 and V2 of the booster piston and strokes it toward chamber V4. Because the area of the piston in chambers V1 and V2 is greater than the area at V4, the pressure at V4 is intensified. This higher pressure oil is directed through CV4 and to the base end of the cylinders.

Fig. 1.3 Forward Piston Stroke


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PRINCIPLE OF OPERATION 1.0 BOOSTER AND CYLINDER 1.3 OPERATING PRINCIPLE 1.3.2 Jaw Close Under Load (continued) When the booster piston reaches full stroke, oil entering port C1 of the piston transfers to port C2 and to the plunger end of the booster control valve. This shifts the valve as shown in Figure 1.4.

Fig. 1.4 Booster Valve Shift

c11. Jaw Cylinder c14. Booster Piston c15. Booster Valve c16. Sequence Valve c19. Plunger c20. Pilot Check Valve c21. Check Valve (1) c22. Check Valve (2) c23. Check Valve (3) c24. Check Valve (4) c25. Check Valve (5) c26. Port “C1” of the Piston c27. Port “C2” of the Piston c28. Port “C3” of the Piston k7. Control Valve v1. Oil Chamber (1) v2. Oil Chamber (2) v3. Oil Chamber (3) v4. Oil Chamber (4)

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PRINCIPLE OF OPERATION 1.0 BOOSTER AND CYLINDER 1.3 OPERATING PRINCIPLE 1.3.2 Jaw Close Under Load (continued) When the booster valve has been shifted, oil from the sequence valve (SV) is directed through the booster valve to chambers V3 and V4 of the booster piston. This strokes the booster piston toward chamber V2. The oil in chamber V2 is compressed and sent through CV3 to the base end of the cylinders.

Fig 1.5 Reverse Piston Stroke


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PRINCIPLE OF OPERATION 1.0 BOOSTER AND CYLINDER 1.3 OPERATING PRINCIPLE 1.3.2 Jaw Close Under Load (continued) When the booster piston reaches full reverse stroke, oil drains out of the plunger end of the booster control valve through ports C2 and C3 of the booster piston. The booster control valve spring moves the valve toward the plunger. This places the valve in position to direct oil to the piston to start the next forward piston stroke. These forward and reverse piston strokes will continue as long as the operating switch in the cab is actuated, up to maximum system pressure when the booster will automatically stop.

Fig 1.6 Valve Shift To Forward Stroke


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1.3 OPERATING PRINCIPLE 1.3.3 Jaw open (no Booster actuation) When the Material Processor jaws are opened, oil from the hydraulic circuit of the excavator is directed to the rod end of the cylinders. A pilot signal from this flow is sent to the pilot check valve. This opens the pilot check valve allowing oil to be pushed out of the base end of the cylinders as the rods retract. As the cylinder rods retract, the jaws open. There is no boost actuation on jaw opening.

Fig 1.7 Cylinder Retract (Jaw Open)


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HYDRAULIC INSTALLATION NPK Hydraulic Installation Kits are available for virtually all compatible excavator models. The kits include all parts and complete instructions for the hydraulic installation, including valving and/or controls, hoses and fittings, boom and stick tubing, and clamps.

Combination kits that can also be used for hydraulic hammer or compactor operation are available. See your NPK dealer for details or call NPK direct at 1-800-225-4379.

SHUT-OFF VALVES Most NPK Hydraulic Installation Kits use two shut-off valves (k4) on the dipper stick of the carrier. Make sure the shut-off valves (k4) are turned to the “ON” (k5) position before operating the Material Processor.

NOTE: A pressure test port (k8) is located in the shut-off valve spool.

k1. Stick k4. Shut-off Valve k5. On k6. Off k8. Test Ports m3. Pressure (Close) m4. Pressure (Open)

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HYDRAULIC INSTALLATION HYDRAULIC QUICK DISCONNECTS NPK discourages the use of quick disconnects on hydraulic circuits operating NPK products, including Material Processors, for the following reasons: 39 = JIC Connection, NPK Recommended 32 = Quick Disconnect, NPK Non-Recommended

1. The hydraulic pulsations caused by the Material Processor can cause internal pieces of the quick disconnect to disintegrate. These pieces can migrate into the Material Processor, causing damage.

2. Quick disconnects create a restriction in the circuit. NPK Material Processors are not back pressure sensitive, but restrictions cause unnecessary heating of the oil. Also, the pressure required to operate the Material Processor, plus the restriction of the disconnects may push an older, low pressure excavator to the limit of its hydraulic system. This would interfere with proper Material Processor operation.

3. If quick disconnects are not used, when the Material Processor is removed from the excavator, the tube ends and hoses should be capped to keep them clean. As this cannot be relied upon, contamination of the disconnect will be flushed into the Material Processor when re-connected. This, again, can cause damage.

NPK APPROVED CONNECTION QUICK DISCONNECTS CONTACT YOUR NPK DEALER FOR ADDITIONAL INFORMATION

ABOUT NPK QUICK DISCONNECTS

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MOUNTING INSTALLATION NPK Mounting Installation Kits include the parts required to adapt the NPK Material Processor to the stick or arm of the excavator. The kits include all necessary boom pins, bushings and spacers, etc.

NOTE: MOUNTING KITS USING LOOSE FIT BUSHINGS TO ADAPT THE PINS TO THE TOP BRACKET ARE NOT COMPATIBLE FOR USE WITH QUICK ATTACHES OR PIN GRABBER COUPLER.

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.

Main connections (m3 - near side and m4 - far side) from excavator - #20 male JIC Rotation connections (m20) - #8 JIC Motor drain (m21) - #6 JIC Rotation lines (CW) Optional rotation ports (m22) Optional drain port (m23) Motor drain line (CX) NOTE: THE CONNECTIONS FOR THE ROTATION LINES CAN BE MADE ON THE

LEFT OR RIGHT SIDE OF THE TOP BRACKET.

AF BOLT BF BUSHING CW ROTATION HOSE CX MOTOR DRAIN LINE EZ LOCK COLLAR FB STOVER NUT m1 STICK PIN m2 LINK PIN m3 CLOSE WHIP HOSE m4 OPEN WHIP HOSE m7 TOP BRACKET

AF BOLT BF BUSHING CW ROTATION HOSE CX MOTOR DRAIN LINE EZ LOCK COLLAR FB STOVER NUT m1 STICK PIN m2 LINK PIN m3 CLOSE WHIP HOSE m4 OPEN WHIP HOSE m7 TOP BRACKET

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MOUNTING INSTALLATION

MOUNTING TO THE EXCAVATOR

1. Position the Material Processor horizontal on wood blocks (t20) as shown. 2. Align the stick pin bore (m24). Install the stick pin (m1). 3. Align the link pin bore (m25). Install the link pin (m2). 4. Clean away any dirt found on the hose connections and connect the whip hoses (m3

and m4). 5. Also connect rotation hoses (CW) and motor drain hose (CX). 6. Open the shut off valves (k4).

REMOVAL FROM THE CARRIER 1. Retract the cylinders to open jaws fully. 2. Close the shut-off valves. 3. Disconnect the hydraulic hoses before laying the Material Processor down. Install

plugs in the hydraulic hoses and caps on the stick tubes to keep out contamination. 4. Position the Material Processor horizontal on wood blocks, as shown above.

STORAGE OF MATERIAL PROCESSOR 1. Make sure the hydraulic hoses are plugged and stick tubes capped. 2. Grease all lubrication points, see page 45. 3. If stored outdoors, cover with waterproof tarp.

The hydraulic lines must be handled carefully to prevent contamination from entering the Processor or the carrier hydraulic system.

ATTENTION

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OPERATING INSTRUCTIONS Before operating the NPK Material Processor, be sure to read the safety information and perform the daily and weekly maintenance as specified in this manual.

DO NOT OPERATE THE MATERIAL PROCESSOR WITHOUT DEMOLITION GUARDS IN PLACE!

DO NOT LIFT OR LOAD BEYOND THE CAPACITY OF THE MATERIAL PROCESSOR OR THE EXCAVATOR.

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OPERATING INSTRUCTIONS USE THE MATERIAL PROCESSOR ONLY FOR THE APPLICATION FOR WHICH IT IS INTENDED: NPK Material Processors equipped with “S” style jaws are designed for the primary

breakup of concrete, such as pillars, buildings, retaining walls, bridges and highway barriers.

“S” JAW APPLICATION

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OPERATING INSTRUCTIONS USE THE MATERIAL PROCESSOR ONLY FOR THE APPLICATION FOR WHICH IT IS INTENDED: NPK Material Processors equipped with “G” style jaws are designed for the

downsizing of concrete, the separation of concrete and rebar and some primary demolition.

“G” JAW APPLICATION

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

- 40 -

OPERATING INSTRUCTIONS USE THE MATERIAL PROCESSOR ONLY FOR THE APPLICATION FOR WHICH IT IS INTENDED: NPK Material Processors equipped with “K” style jaws are designed for the

demolition of steel structures and for processing of steel, wood, rubber and plastic scrap, but not concrete.

“K” JAW APPLICATION

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ATTENTION

OPERATING INSTRUCTIONS OPERATING TECHNIQUES AND PRECAUTIONS

Do not use the Material Processor with the excavator cylinders fully extended or retracted.

Do not strike the material with the Material Processor body (FP) or outer surface of the jaw (DO). Do not push, pull or scrape material with the Material Processor.

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ATTENTION

OPERATING INSTRUCTIONS OPERATING TECHNIQUES AND PRECAUTIONS

Do not pry, twist or pull with the excavator. Allow the hydraulic crushing forces of the Material Processor jaw to do the work. If the material does not crush completely at first, open the jaws and close again in a chewing action. The excavator is used as a way of positioning the processor and supplying hydraulic power to the processor.

Do not operate the Material Processor on an excavator with a combination Hydraulic Hammer/Crusher hydraulic installation kit without first isolating line-mounted accumulators.

(A) Shut-off valve (k4) must be in off (k6) position for use with processor. (B) Return line from hammer/compactor (processor open) (m4).

NOTE: ON SOME HYDRAULIC KITS, THIS LOCKOUT FEATURE IS DONE AUTOMATICALLY. CONSULT NPK IF YOU ARE UNSURE OF WHAT YOUR MACHINE IS EQUIPPED WITH.

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OPERATING INSTRUCTIONS For most efficient operation, open the jaw only wide enough to grasp the material. Grasp the material to be crushed as deep into the throat of the Material Processor as possible. Do not force the material into the jaw.

If you have any questions on operating the Material Processor, please contact your local NPK dealer or call the NPK Service Department at 1-800-225-4379.

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GENERAL MAINTENANCE REFER TO IMPORTANT SAFETY INFORMATION SECTION

DAILY INSPECTION AND MAINTENANCE The functions that the Material Processor performs are demanding jobs 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. Lubrication

points are at the following locations as shown on page 45. Check for oil leaks at the Cylinder Piston Rods and all of the Material Processor’s

hoses and fittings. Check all fasteners for looseness. Retighten if necessary.

Inspect all welds and repair as necessary.

Inspect the hydraulic hoses for wear, damage or oil leakage.

Check the condition of the cutting blades. Rotate, or repair as necessary (See Cutter Blade Maintenance Section for instructions).

Check to ensure that C, S, & G Jaw blade-to-blade clearance is .010 to .040 inch

(0.25 to 1.00 mm). Shim if necessary (See Cutter Blade Maintenance Section for instructions).

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GENERAL MAINTENANCE LUBRICATION POINTS

A Cylinder base end pins: one lubrication point per cylinder located at main frame attachment end. 10 strokes from grease gun every 4 hours.

B Cylinder rod pins: one lubrication point per cylinder located at jaw attachment

end. 10 strokes from grease gun every 4 hours. C Jaw pivot pin: two lubrication points on one side, one lubrication point on

other side. 15 strokes from grease gun per fitting every 4 hours. D Rotation Bearing: two lubrication points 180 apart. 5 strokes from grease

gun per fitting once per shift. E Slewing ring/pinion teeth: one lubrication point on each side of the motor,

located on the top bracket. 5 strokes from grease gun per fitting once per shift.

(GR1) CYLINDER ROD PIN (GR3) MAIN PIVOT PIN (15 SHOTS TWICE PER SHIFT) (GR4) ROTATION BEARING (5 SHOTS ONCE PER SHIFT) (GR5) MOTOR PINION (GR6) BARREL END OF CYLINDERS (10 SHOTS PER SHIFT)

- 46 -

CYLINDER MAINTENANCE CYLINDER CAP BOLT TORQUES The torques listed below are for the bolts that clamp the cylinder cap to the cylinder body. Lube the threads with grease or anti-seize compound.

MATERIAL PROCESSOR

BOLT SIZE CAP (OO)

TORQUE ft lb Nm

M20 M18 260 350

M28 M18 260 350

M38 M18 260 350

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CYLINDER MAINTENANCE ROD NUT TORQUES The torques listed below, are for the rod nuts used in the cylinder assemblies for the NPK Crushers. When assembling during rebuild, it is also recommended that Locktite is used to ensure complete clamping.

MATERIAL PROCESSOR

SIZE TORQUE SOCKET SIZE

PART NO.

Ft lb Nm

M20 M45 x 1.5 1,500 2,000 70 mm 16053050

M28 M65 x 3.0 3,200 4,300 100 mm 16043903

M38 M70 x 3.0 4,100 5,500 120 mm 16039992

After the nut has been tightened to the above listed torque value, it is necessary to drill a dimple (24) in the rod through the set screw hole in the rod nut. This will allow the set screw (c6) to lock the cylinder rod nut (c1) to the piston. The maximum depth of the drilled hole should not exceed .5 mm or 1/64”. Apply a small amount of thread lock to the set screw before installing.

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SLEWING RING INSPECTION AND MAINTENANCE MEASURING MAXIMUM AXIAL MOVEMENT

1. While the unit is attached to the excavator, position the processor in the vertical position.

2. Using a dial indicator (t40), block the base of the dial indicator onto the lower frame

of the processor. Indicate the other end of the dial onto the top bracket face as shown. Using the excavator, slightly rock the processor back and forth using slight stick movement. Note the movement shown by the dial. Take this reading (d59) in four places. If your readings are greater than shown, please contact the NPK Service Department at 800-225-4379.

MODEL

M20 M28 M38

MODEL

M20 M28 M38

NEW

MAXIMUM inch (mm)

<.010 (0.25) <.010 (0.25) <.010 (0.25)

MAXIMUM ALLOWABLE

WEAR inch (mm)

0.138 (3.50) 0.138 (3.50) 0.138 (3.50)

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SWIVEL MANIFOLD MAINTENANCE SWIVEL OIL MANIFOLD ASSEMBLY

The swivel assembly is located between the top bracket, which is pinned to the carrier, and the crusher frame that rotates. Hydraulic oil for both open and close operations passes through it. The swivel assembly consists of two main parts, the “Spindle Case”, which contains the oil seals, and the “Spindle”, which rotates with the crusher frame.

LEAKAGE OF THE SEALS External leakage or internal (bypassing) of hydraulic oil will require the replacement of the seals in the swivel assembly. For external leakage, please review the seal replacement procedure in the next section. If internal leakage is suspected, please proceed to the “Testing the Swivel Seals for Internal Leakage” section.

TESTING THE SWIVEL SEALS FOR INTERNAL LEAKAGE If internal seal leakage is suspected, before disassembling the swivel assembly, the relief valve pressure setting should be checked. Internal leakage will most likely prevent the unit from reaching relief in both open and close functions. The relief valves are located below the swivel assembly in blocks that are attached near the four hose connections. Access to these is through the upper side plates of the crusher main frame. The relief valve setting adjustment screws are located beneath the plastic cap. Before attempting to adjust the relief setting, please check that the relief valve has not loosened in the block. See Figure 1. Procedure Install 5,000 psi gauges in the NPK stop valves (located on the stick of the machine). Close the jaw and keep the function activated and read the pressure. Compare the pressure reached with the specifications for your model crusher. Repeat check while opening the jaw and read pressure. Please note that if the relief pressure cannot be reached with the jaw closed and the intensifier booster is clicking rapidly, this indicates a booster problem not a relief problem. If the proper relief pressure cannot be reached and the booster slows or stops, then disassemble the swivel to check for failed seals.

ReliefValve

Figure 1

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SWIVEL MANIFOLD MAINTENANCE REPLACEMENT OF THE SEALS IN THE SWIVEL Tools needed: 19mm & 22mm open end wrenches 41mm & 46mm open end wrenches External snap ring pliers

The jaws of the material processor should be closed and the frame supported or pinned to prevent rotation during repair. Here, the shipping pins are inserted to lock the rotation. Step 1 Remove the rotation hoses at the holding valve (top center of Figure 2). Remove the rotation motor hoses and motor fittings. Disconnect the cylinder hoses at the side plates of the top bracket. Do not remove the hoses (AO) from the “Spindle Case” (B2), they will be used to help lift it off the “Spindle” (CA). Do not disturb the elbow fittings (CF) in the “Spindle Case” (B2). Step 2 (Figure 3) Remove the snap ring (AJ) and washer (U) from the top of the swivel assembly. Pull the “Spindle Case” (B2) off the “Spindle” (CA) (the hoses can be used for this).

Figure 2

Figure 3

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SWIVEL MANIFOLD MAINTENANCE REPLACEMENT OF THE SEALS IN THE SWIVEL Step 3 (Figure 4) Inspection: Visually inspect the sealing surfaces of the spindle for damage, which may hamper the ability of the o-rings to seal. Polishing the surface may clean up light scratching. Heavy scratching or galling may indicate rotator-bearing play. Step 4 (Figure 5) 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). Check the grooves in the “Spindle Case” for burrs or scoring damage. Light grinding or polishing may be required.

Figure 4

Figure 5

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SWIVEL MANIFOLD MAINTENANCE SWIVEL ASSEMBLY Step 5 (Figure 6) Lubricate the o-rings (RR) and back-up rings (SS) with grease. Install the back-up rings first, taking care not to crimp or fold the back-up rings. Install the o-rings. Please refer to Figure 6 for o-ring and back-up ring placement. Slide the “Spindle Case” (BZ) over the “Spindle” (CA), which includes the relief valves (c17/c18). Install the washer (U) and snap ring (AJ). Install the hoses and fittings removed.

Figure 6

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M-SERIES JAW IDENTIFICATION

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

1. Letter designating jaw type, i.e., S, G, C, K. 2. Number denoting male or female jaw. NOTE: Even numbers indicate male jaws, odd numbers indicate female jaws.

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

“S” STYLE

PRIMARY DEMOLITION “G” STYLE

SECONDARY/PRIMARY DEMOLITION

“C” STYLE

COMBO CUTTER “K” STYLE

DEMOLITION SCRAP PROCESSING

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

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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.

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JAW SET IDENTIFICATION G Jaw Set (Pulverizer/Secondary Concrete Crusher) for the downsizing of concrete

and the separation of concrete and rebar.

- 56 -

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.

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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.

Jaw sets can easily be removed from and installed into the Material Processor in an indoor facility or at a job site. Changing jaw sets at a job site can be easily accomplished, see the “Jaw Set Interchange” section, page 84, of this manual.

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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

M20 M28 M38 in (mm) in (mm) in (mm)

A 12 (305) 16 (406) 19 (483) B 12 (305) 16 (406) 19 (483) C 1/2 (12.7) 5/8 (15.9) 3/4 (19.1)D 1/2 (12.7) 5/8 (15.9) 3/4 (19.1)


E 2 (50.8) 2-1/2 (63.5) 3 (76.2)


F 1/2 (12.7) 3/4 (19.1) 1 (25.4)

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JAW INSPECTION AND MAINTENANCE JAW WEAR AND REPAIR

WEEKLY INSPECTION AND MAINTENANCE With new S or G jaw sets, the teeth will contact before the cylinders reach full stroke. As the teeth continue to wear, the cylinders will reach full stroke and a gap will be apparent between the opposing jaws. If wear continues to this point or beyond, the crushing efficiency may decrease and the full cylinder force will be transferred to the cylinder end cap (c5) and retaining bolts (OO). This situation should be avoided. The jaws (“S” units) or teeth (“G” units) should be inspected and maintained to avoid this gap.

S, C & G JAWS: Profiles can be checked against NPK original profile templates(t72). Call the NPK Service Department for assistance at 1-800-225-4379. S JAWS: These jaws are hardfaced. The best time to rebuild them is as soon as the hardface pattern is worn off. If the hardface pattern is gone, the profile should be rebuilt to that of the template. Do not allow tip wear to exceed .75” (20mm) compared to the template or the cylinder will bottom out. G JAWS: On the eye jaw, wear on the small side teeth (mp2) determines when the cylinders are approaching full extension. The large center teeth (mp1) are for crushing purposes only. New small teeth are 1.97” (50mm) high on the M28 and M38 units. On the M20 units, the teeth are 1.57” (40mm) high new. The small teeth, on each side of the removable jaw plate, should not be allowed to wear to less than .97” (25mm) on the M28 and M38 units. The M20 units should not be allowed to wear to less than .78” (20 mm). They should be rebuilt or replaced at this time. The small tooth part number is M3802-2000 for the M38G (qty. 4), M2802-2015 for the M28G (qty. 2) and M2002-2010 for the M20G (qty. 2). Tip wear of the two large teeth may affect crushing efficiency. This profile can be rebuilt to that of the template.

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JAW INSPECTION AND MAINTENANCE JAW WEAR AND REPAIR Another alternative is to replace the entire bolt on plate, part number M3802-2015 for the M38G, M2802-2020 for the M28G and M2002-2000 for the M20G.

CY- NEW PROFILE CZ – OLD PROFILE

See Sections on Jaw and Tooth Rebuild or Teeth Replacement for procedures. K JAWS: Several surfaces of the K jaws have been hardfaced. The best time to rebuild them is as soon as the hardface pattern is worn off. If the hardface pattern is completely worn, the surfaces should be rebuilt and hardfaced such that they are even with or slightly above the adjoining blades. See pages 75 and 76 for underlayment and hardface procedures.

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JAW INSPECTION AND MAINTENANCE CUTTING BLADE MAINTENANCE When the cutter blades become damaged or rounded due to abrasion, grind the rounded areas of the blades to a sharp 90° edge.

Use care in handling to avoid bodily harm.

Do not over grind blades to the point that the surface becomes blue or discolored. This will make the blades brittle. Re-install sharpened cutter blades with necessary shims, see page 62. Torque the cutter blade bolts to 525 ft. lbs. (715 Nm) lubed. Cutter blades can be flipped four times to increase service life. Torque the cutter blade bolts to 525 ft. lbs. (715 Nm) lubed. If all cutter blades are chipped or worn beyond repair, replace the blades. DO NOT WELD CUTTER BLADES!

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JAW INSPECTION AND MAINTENANCE CUTTING BLADE MAINTENANCE

BLADE-TO-BLADE CLEARANCE M20, M28, M38 S, G and C Jaws

A blade-to-blade (‘A’-‘A’) clearance of .010” to .040” (0.25 to 1.00mm) should be maintained for optimum performance. Install shims (BH) under blade (BG) as necessary, see Fig. 1.

Shim Kits M20 S & G Jaws NPK p/n M2000-7000 M28 S & G Jaws NPK p/n M2800-7000 M38 S & G Jaws NPK p/n M3800-7000

Fig. 1 M20, M28, M38 S, G and C Jaws

BLADE-TO-BLADE CLEARANCE M20K, M28K and M38K

A blade-to-blade clearance of .000” to .010” (.00 to 0.25mm) should be maintained for optimum performance. See Fig. 2 and 3 for cutting blade and shim arrangement. Refer to NPK Parts Manual for part numbers.

PIERCING TIP TO TUNNEL GAP M20K, M28K and M38K The piercing tip to tunnel blade gap can be increased by removing the tunnel spacer, which can be helpful in some piercing operations. Removal of the spacer on the M20K increases the gap by .20 inch (5mm). Removal of the spacer on the M28K increases the gap by .47 inch (12mm). Removal of the spacer on the M38K increases the gap by .75 inch (19mm).

FIG. 2 M20K, M28K and M38K With weld-on Piercing Tip

BD Arm BG Cutter Blade BH Shim Pack (Drive Arm Only) BI Drive Arm DA Weld-on Piercing Tip DB Tunnel Blade DC Spacer DE Spacer Plate DF Guide Blade (Not Shown)

FIG. 3 M20K Early model with bolt-on Piercing Tip

BG Cutter Blade BD Arm BH Shim Pack (Drive Arm Only) BI Drive Arm DB Tunnel Blade DC Spacer DE Spacer Plate DF Guide Blade (Not Shown) DG Bolt-on Piercing Tip

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JAW INSPECTION AND MAINTENANCE PIERCING TIP MAINTENANCE AND REPLACEMENT Before maintenance is performed on the piercing tip, it is recommended that the fixed jaw (tunnel) be repaired first.

MAINTENANCE To maintain maximum piercing efficiency, the piercing tip should be checked daily for wear. The rate of wear that will occur is going to be influenced greatly due to the types of material being processed and the amount of piercing being done. To check the jaw and tip for wear, close the shear until the piercing tip is beginning to enter the lower jaw (tunnel). The piercing tip should fit squarely in the fixed jaw tunnel. If a large gap is noted and the tip is rounded, this is an indication that the piercing tip requires attention. Also, if it is noted that material is being drug through the tunnel and not efficiently pierced by the tip, this is also an indication that the tip is in need of attention. The length of time between piercing tip maintenance will greatly influence if a tip can be repaired or if the tip must be replaced.

BUILD-UP OF THE PIERCING TIP Before beginning the build-up of the existing piercing tip, it is necessary to first grind off all remaining hardface material. After determining the amount of build-up required, preheat the tip and surrounding area to 300° - 400°F (150° - 200° C). Using a suitable underlay rod build-up the areas in question by using stringer welds. Peen after each pass. Continue to build the areas by overlaying weld stringers. Stop periodically and cycle the piercing tip through the fixed jaw tunnel to check the amount of build-up that is still required. Maintain preheat of jaw area. After build-up is complete, it may be required to hardface the piercing tip. Hardfacing will help prolong the life of the tip and increase the amount of time a tip can be used before maintenance is once again required. Refer to pages 75 and 76 and use the same procedure.

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JAW INSPECTION AND MAINTENANCE REPLACING PIERCING TIP To install a new tip, carbon arc off the old tip approximately the dimension of your model piercing tip, please note that a seat for the top is present in the upper jaw, see Fig. A. The surface must be prepared by chamfering the upper, see Fig. B. NOTE: Be sure area is free from all carbon residue, leaving it flat and smooth.

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

Move tip squarely against the edge, making sure it is level, then tack firmly in place, see Fig. C and D. Cycle the SHEAR to check the clearance of the new tip. The leading edge of the tip should pass within .045” of the upper lip of the fixed jaw. NOTE: Some grinding may be required to fit the tip properly to the tunnel. 1. Remove worn tip by carbon arcing or torch cutting. 2. Prepare surface for new tip by grinding away any remaining slag. 3. Place new tip into proper location. 4. Dry welding rod to 300°F + (150°C +). 5. Preheat weld area to 300°F - 400°F (150° - 200°C). Joining and build-up For joining, stringer beads are best. For build-up, weaving is acceptable. Use one of the following rods (or wire equivalent) or equal: Airco Austex 361, Cronatron 7770, Eutectic 3205, Hobart Smooth Arc MC, McKay Chrome-mang, Stoody 2110.

Fig. A Fig. B

Fig. C Fig. D

- 65 -

PIERCING TIP MAINTENANCE AND REPLACEMENT 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. Perform the following steps to determine whether the piercing tip can be built up or should be replaced. Step 1:

Using a steel straight edge, place the straight edge (t15) on the face of the primary blades (BG), the side of the piercing tip (DA) should be even/parallel with the primary blade face. Record the amount of clearance/gap (d65) between the straight edge and the side of the tip.

Step 2:

Close the jaws until the piercing tip (DA) just enters the female jaw (BI) (tunnel), note the wear on the corners of the piercing tip (DA) and also the gap (d66) between the lead edge of the piercing tip (DA) and the tunnel blade (DB).

Step 3:

If the gap between the straight edge and the piercing tip is minor, and the wear on the lead edge and the corners of the tip is not excessive, weld build-up of the tip is recommended. Follow the Build-up Procedures listed in the service manual. If tip wear is excessive, REPLACE the piercing tip. Follow the Replacing Piercing Tip procedures listed in the “Jaw Inspection and Maintenance” section of this manual.

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PIERCING TIP MAINTENANCE AND REPLACEMENT Step 4:

After completing the welding and grinding build of the tip, place the straight edge, once again, on the face of the primary blades to confirm that the side of the piercing tip and primary blades are parallel. Step 5:

Slowly close the jaws until the piercing tip (DA) enters the tunnel, verify the clearance (d66) between the lead edge of the piercing tip (DA) and tunnel blade (DB). This clearance should be approximately .020” to .040”. Additional welding or grinding maybe required to achieve the desired clearance. When installing a new piercing tip, the clearance between the piercing tip and tunnel blade can be set when placing the new tip in the male jaw.

Step 6:

Close the jaw until the side of the piercing tip (DA) is next to the guide blade (DF), measure the clearance and add shims to achieve a clearance (d63) of .005”. Apply thread adhesive and torque the guide blade bolts to NPK specifications.

Step 7:

After completing all welding maintenance, allow the jaws to cool slowly.

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K-JAW BLADE SET UP PROCEDURE ST1. Install primary blades first, (male jaw). Check to ensure primary blade faces are

parallel. ST2. Install secondary blades, (female jaw), and shim to primary blades. ST3. Install tunnel blade. ST4. Install guide blade and shim to side of piercing tip. These set up procedures are to be used when the piercing tip is new.

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M-SERIES “K” (SHEAR) JAW MAINTENANCE The following information is to be used as a general guide for maintaining the jaws 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. These failures are not covered under the standard NPK warranty.

Use care when handling blades.

Do not over grind the cutter blades. Do not weld on the cutter blades.

During normal use of a processor, the jaws and cutter blades will become worn. Regular maintenance must be performed to ensure that the maximum efficiency is realized.

DAILY MAINTENANCE

Grease the two arm pins and the center pivot area 2 times per shift using an EP #2 grease (15 pumps of grease).

Check the jaw weldments for cracks. Contact NPK for repair procedure, if a crack is found.

Inspect for loose, broken, and missing fasteners. Replace and re-torque, as required.

Check the condition of the cutting blades. If the edge is rounded and dull, grind the edges back to 90°. Rotate the blades if extreme wear or chipping on the cutting edge is noted. If the blades are replaced or rotated, they must be shimmed. Blades should be shimmed from .005” to a maximum of .010”. Replace the blades if they are cracked.

Use the following procedure when performing piercing tip and blade maintenance.

COMPONENT DESCRIPTION Male jaw (BD) contains the primary cutting blades (BG), spacer plates (DE), and piercing tip (DA).

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M-SERIES “K” (SHEAR) JAW MAINTENANCE COMPONENT DESCRIPTION

Female jaw (BI) contains the secondary cutting blades (BG), tunnel blade (DB), blade spacer (DC), guide blade (DF), and spacer plate (DE).

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 tip but can be built up via a weld procedure. The piercing tip is also replaceable.

When replacing or turning cutting blades, the following steps must be followed to achieve accurate blade shimming and final blade clearance. Step 1:

Start with the male jaw (BD) (primary blades); these blades should be installed first. Prior to installing, the male jaw blade pocket (DM) needs to be free from debris and raised edges. Clean pocket and remove any raised edges (74) from the blade pocket using a grinder (t1).

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

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M-SERIES “K” (SHEAR) JAW MAINTENANCE BLADE MAINTENANCE AND ADJUSTMENT Each primary blade will have a spacer plate placed between the blade and the blade pocket. Install and tighten blade bolts. Step 2:

Using a steel straight edge (t15), place the straight across the face of the primary blades (BG). There should not be any gap (d3) between either blade and the straight edge. If the blades are being turned, and a gap (d3) is found between either of the blades and the straight edge, measure the gap (d3) using feeler gauges then remove the measured amount from the high blade by grinding, (blade may require surface grinding at a machine shop). If the difference between the blades is excessive, install new blades. DO NOT ADD SHIMS BEHIND THE PRIMARY BLADES.

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 blade bolts (OO) and torque to the NPK specifications.

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M-SERIES “K” (SHEAR) JAW MAINTENANCE BLADE MAINTENANCE AND ADJUSTMENT Step 3:

Install either reconditioned (used) or new secondary blades (BG1) in female jaw (BI) blade pockets (DM), tighten blade bolts.

Begin closing the jaws until the first primary jaw blade (BG) begins passing the first secondary blade (BG1), stop closing the jaws and measure the clearance (d60) between the two blades. Record the clearance, (example .015”); continue closing the jaws stopping to record the clearance (d61) at the second female blade and the clearance (d62) at the third female blade.

- 72 -

M-SERIES “K” (SHEAR) JAW MAINTENANCE BLADE MAINTENANCE AND ADJUSTMENT

NPK shim packs have a variety of shims (i.e., .005, .010, .024, .060, .120), install the required amount of shims behind each secondary blade until a clearance of .005 is achieved between all primary and secondary blades. (One shim pack for each blade recommended).

After blade shimming is complete, remove each secondary blade bolt and apply thread adhesive and torque to NPK specifications. Step 4:

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

The guide blade (DF) must also be shimmed as close as possible to the side of the piercing tip (DA). Begin closing the jaws until the piercing tip (DA) just enters the tunnel, stop and measure the clearance (d63) between the guide blade (DF) and the side of the piercing tip (DA). Install the required amount of shims to reduce this gap to .005”. Apply thread adhesive and torque the guide blade bolts to NPK specifications.

Special Note: The guide blade clearance will have to be rechecked after any weld build-up of the piercing tip.

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M-SERIES “K” (SHEAR) JAW MAINTENANCE BLADE MAINTENANCE AND ADJUSTMENT Step 5:

Inspect the tunnel blade (DB), located in the bottom of the female jaw (BI). If the lead edge is worn or rounded off, remove and turn the blade. This blade can be turned four times. There is a spacer plate (DE) between the blade and the pocket, be sure to install this spacer. Tunnel blade does not require shimming. Apply thread adhesive and torque bolts to NPK specifications.

- 74 -

JAW INSPECTION AND MAINTENANCE HARDFACING If hardfacing is to be performed, the jaw must be preheated to 300°- 400°F (150° - 200° C) before the hardfacing is applied. Failure to preheat the tip area will result in the hardfacing to crack and chip off prematurely. Using a suitable hardface rod, apply the material in stringer beads vertically on the front and sides of the piercing tip and parallel to the moveable jaw on the lower face of the piercing tip. This pattern will allow for the most efficient piercing and the least amount of interference. Peen after each pass and maintain inner pass temperature. DO NOT APPLY MORE THAN TWO (2) LAYERS OF HARDFACE MATERIAL! After hardfacing is completed, grind the piercing tip to the desired profile. Do not pierce with the tip until the tip area temperature has normalized. This process takes approximately 12 hours. It is recommended that the tip area is covered with a heat blanket, covered with dry sand, floor dry or other suitable material. Refer to page 76 and use the same procedure.

- 75 -

JAW INSPECTION AND MAINTENANCE JAW AND TOOTH REBUILD PROCEDURE Due to the abrasive nature of the material being crushed, jaw wear will occur on the M20S/M28S/M38S and M20G/M28G/M38G. The jaws must be built up with hardface weld when the clearance between the tip of the jaws in the closed position is worn to the extent that the material can no longer be crushed efficiently. To ensure maximum crushing performance of the M20S/M28S/M38S or M20G/M28G/M38G, this rebuild procedure, comprised of three steps, should be followed:

1. Surface Preparation 2. Underlayment Weld 3. Hardface Weld

1. SURFACE PREPARATION Grind the entire worn area until it is smooth and clean. Remove all paint, grease, oil, dirt and old hardfacing material before welding. 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 hardface directly over old hardfacing. Welding rod: Airco Austex 361, Cronatron 7770, Eutectic 3205, Postalloy 205,

Stoody 2110 or equal. In Canada: NCH Canada Inc. Hi-Pact #194 or equal. Dry welding rod at 300F+ (150°C +). Pre-heat the jaw weld area to 300° to 400°F (150° to 200°C) and maintain this

temperature during the welding operation. It is very important to maintain this temperature in cold environments.

Adjust weld current to rod manufacturer’s specification. Peen each layer. Cool slowly. Cover weld in cold environments.

- 76 -

JAW INSPECTION AND MAINTENANCE JAW AND TOOTH REBUILD PROCEDURE 3. HARDFACE

Hardface (WW) can only be applied over base (DH) material or underlayment weld (XX). Never hardface existing hardface. 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 300F+. Pre-heat the jaw weld area to 350F and maintain this temperature during the

welding operation. It is very important to maintain this temperature in cold environments.

Adjust weld current to rod manufacturer’s specifications. Peen each layer. Do not exceed 2-3 layers of hardface. Cool slowly. Cover weld in cold environments.

DO NOT WELD OVER OLD HARDFACING

Remove all old hardfacing before applying new underlay rod.

1. BEFORE REBUILD

2. AFTER REBUILD

CORRECT BD/BI CRUSHER JAW DI WORN AREA WW HARDFACE XX UNDERLAYMENT

CORRECT

BD/BI CRUSHER JAW DJ OLD WELD DK END OF NEW WELD WW HARDFACE XX UNDERLAYMENT 73 FINISH GRIND TO

BLEND

INCORRECT BD/BI CRUSHER JAW DK END OF NEW WELD DL OVERFLOW

- 77 -

JAW INSPECTION AND MAINTENANCE TEETH BUILD-UP AND HARDFACING (M20G, M28G, M38G) For build-up and hardfacing of teeth, use the NPK template to check teeth so that they are to original profile. Contact NPK for correct template, drawing no. M3802-9500 (M38G), drawing no. M2802-9500 (M28G), drawing no. M2002-9500 (M20G). Then, refer to pages 75 and 76 for Surface Preparation, Underlayment and Hardfacing.

M20C (EYE JAW) (FR) M20C (FORK JAW) (FS)

(CY) NEW PROFILE (CZ) WORN PROFILE (CY) NEW PROFILE (CZ) WORN PROFILE

M28C/M38C (EYE JAW) (FR) M28C/M38C (FORK JAW) (FS)

(CY) NEW PROFILE (CZ) WORN PROFILE (CY) NEW PROFILE (CZ) WORN PROFILE

- 78 -

JAW INSPECTION AND MAINTENANCE “G” JAW CONTACT AREAS In contact areas of jaws, hardfacing (WW) may be added to increase the wear life of these surfaces. For hardfacing instructions, see Jaw and Tooth Rebuild Procedure in this manual.

- 79 -

JAW INSPECTION AND MAINTENANCE TEETH REPLACEMENT The M20G/M28G/M38G Material Processor has three types of jaw teeth (FQ). All three types can be cut off and replaced when worn beyond rebuildability.

Following is the procedure for teeth replacement: 1. Remove worn teeth. 2. Prepare surface for new teeth. 3. Place new teeth into proper location. 4. Heat dry welding rod to 300F+ (150°C+). 5. Pre-heat weld area to 300F - 400°F (150°- 300°C). 6. For joining, stringer beads are best. For build-up, weaving is acceptable. Use one of the following rods (or wire equivalent) or equal: Airco Austex 361, Cronatron

7770, Eutectic 3205, Hobart Smooth Arc MC, McKay Chrome-mang, Stoody 2110. 7. Hardface rod for tooth and structure wear surfaces. Pre-heat as in Step 5. Use two

passes maximum for hardfacing. Use one of the following rods (or wire equivalent) or equal: Airco Hardcraft CR-70, Cronatron 7350, Eutectic Eutectrode N70, Hobart Smooth Arc 16, McKay Hardalloy 40 Tic, Stoody 19, 21 or 77.

8. Adjust weld current to rod manufacturer’s specification. 9. Peen each layer. 10. Cool slowly. Cover weld in cold environments.

- 80 -

JAW INSPECTION AND MAINTENANCE TEETH REPLACEMENT The M20G/M28G/M38G Material Processors also have a removable tooth plate (BE), bolted to the eye jaw. M20 – M2002-2000 M28 – M2802-2020 M38 – M3802-2015

- 81 -

JAW INSPECTION AND MAINTENANCE “C” JAW CONTACT AREAS In contact areas of jaws, hardfacing (WW) may be added to increase the wear life of these surfaces. For hardfacing instructions, see Jaw and Tooth Rebuild Procedure in this manual.

- 82 -

JAW INSPECTION AND MAINTENANCE TEETH REPLACEMENT The M20C/M28C/M38C Material Processor has two types of jaw teeth (FQ). Both types can be cut off and replaced when worn beyond rebuildability.

Following is the procedure for teeth replacement: 1. Remove worn teeth. 2. Prepare surface for new teeth. 3. Place new teeth into proper location. 4. Heat dry welding rod to 300F+ (150C+). 5. Pre-heat weld area to 300F - 400F (150 - 300C). 6. For joining, stringer beads are best. For build-up, weaving is acceptable. Use one

of the following rods (or wire equivalent) or equal: Airco Austex 361, Cronatron 7770, Eutectic 3205, Hobart Smooth Arc MC, McKay Chrome-mang, Stoody 2110.

7. Hardface rod for tooth and structure wear surfaces. Pre-heat, as in Step 5. Use two passes maximum for hardfacing. Use one of the following rods (or wire equivalent) or equal: Airco Hardcraft CR-70, Cronatron 7350, Eutectic Eutectrode N70, Hobart Smooth Arc 16, McKay Hardalloy 40 Tic, Stoody 19, 21, or 77.

8. Adjust weld current to rod manufacturer’s specification. 9. Peen each layer. 10. Cool slowly. Cover weld in cold environments.

- 83 -

JAW INSPECTION AND MAINTENANCE TEETH REPLACEMENT The M28C/M38C Material Processors also have a removable tooth plate (BE), bolted to the eye jaw. M28 – M2804-2015 M38 – M3804-2015

- 84 -

JAW SET INTERCHANGE TOOLS AND SUPPLIES Following are the tools and supplies needed to properly change jaw sets. At least one lifting device, such as a crane or lift truck with adequate capacity for the particular model. Lifting strap or chain with adequate capacity for the particular model Securing device such as a chain or strap Three wood blocks, 4 x 4” (100 x 100mm) or larger Supporting device, such as a second crane or lift truck 14 mm hex key socket (Available as P/N M380-1000) ½” drive breaker bar 14 mm hex key Brass drift Dead blow hammer or non-metallic rod or hammer (such as nylon or wood) Ball peen hammer Sledge hammer Assembly tube, NPK P/N 35027310 for the M20 and P/N 35027200 for both the M28 and M38 Spanner wrench ¾ and ½” air gun (if available) 2 - #20 JIC steel caps If removed jaw set is to be stored: Grease Wood pallet Protective tarp for outside storage is recommended

- 85 -

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 model or jaw sets. UNIT POSITIONING For ease of pin removal/assembly, it is recommended that the unit be positioned with the pins parallel to the ground. Changing the jaw sets with the pins perpendicular to the ground is possible, but more difficult. Removal of a jaw set from the Material Processor may be accomplished more easily with the jaw set in the open position. Cap hydraulic ports at this time. 1. To place the unit in the best position,

wrap a lifting strap or chain around one of the cylinder sub-assemblies (c11) near the cylinder jaw pin (c9).

2. Using the crane or lifting device (t34),

slowly raise the unit until it is resting on a cylinder rod cover (c29).

- 86 -

JAW SET INTERCHANGE 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 end. Also place a wood block (t20) under the cylinder rod cover near the cylinder jaw pin. These wood block positions will help stabilize the unit and will provide sufficient ground clearance for jaw set removal.

4. Reposition the lifting strap or chain (t4)

by wrapping it through the bore of the upper jaw (BI). For safety, maintain crane or lifting device engagement.

The unit is now positioned for detachment of the jaws from the cylinders and detachment of the jaw set from the main frame by removal of the three pins circled in the illustration.

- 87 -

JAW SET INTERCHANGE

DETACHMENT OF JAWS FROM THE CYLINDER SUB-ASSEMBLIES 5. Support the top cylinder sub-assembly

(c11) with a wood block (t20) to prevent its fall and potential damage when the cylinder jaw pin (c9) is removed.

6a. Begin with either of the cylinder jaw

pins. Using a hex key socket (t42), remove the two socket head bolts (OO), early units.

6b. Begin with either of the cylinder jaw

pins using a hex key socket (t42), remove the socket head bolt (OO), late units.

- 88 -

JAW SET INTERCHANGE 7a. Manually remove the cylinder pin lock

plate (c30), early units.

7b. Using a socket, remove the cylinder

pin locking plate (c31). Note: Left hand thread (49), late

units. 8a. Remove the cylinder pin (c9), early

units. 8b. Remove the cylinder pin (c9), late

units.

Once the cylinder jaw pin is removed, the jaw may rock forward.

9. Repeat Steps 6 through 8 to detach the second jaw from the second cylinder sub-assembly.

- 89 -

JAW SET INTERCHANGE

DETACHMENT OF A JAW SET FROM THE MAIN FRAME 10. Locate the socket head bolt (OO) on

the pivot pin nut (c32).

11. Using a hex key socket (t42), remove

the socket head bolt (OO).

12. Loosen the pivot pin nut (c32) with a

spanner wrench or by angling a brass drift (t43) into one of the blind holes, and tapping with a hammer (t29).

Avoid damaging the threads in the frame.

ATTENTION

- 90 -

JAW SET INTERCHANGE

DETACHMENT OF A JAW SET FROM THE MAIN FRAME

13. Once loosened, remove the pivot pin

nut (c32).

14. Using a non-metallic (e.g. nylon,

wood) rod (t3) or hammer, drive the jaw pivot pin (BJ) so that it extends out only about 1” (25mm) on this side.

- 91 -

JAW SET INTERCHANGE

DETACHMENT OF A JAW SET FROM THE MAIN FRAME

It is at this stage that the assembly tube, NPK P/N 35027310 for M20 or P/N 35027200 for M28/M38, is used to keep the jaws united as the jaw pivot pin is removed.

15. Set assembly tube in the bore snugly against the jaw pivot pin.

16. Install the assembly tube (t44) by

carefully driving it through the bore. This action will simultaneously push the jaw pivot pin (BJ) out the other side, and lock the jaws together. Continue careful driving of the assembly tube until the jaw pivot pin extends 12 - 14” (300-350mm) from the main frame, then stop.

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.

Avoid damaging the threads when the pin is removed.

18. Continue driving the assembly tube until it is centered in the jaw set.

19. Complete the removal of the jaw pivot pin by pulling it out or tapping on the underside of the pin’s head plate.

ATTENTION

- 92 -

JAW SET INTERCHANGE JAW SET REMOVAL 20. For easier removal of the jaw set (DO)

from the main frame (DN), chain (t4) or strap the jaws together to restrict their movement. Remove the jaw set from the main frame with a crane or other lifting device by moving forward, not up or down.

JAW SET STORAGE If the removed jaw set is to be stored, pack bushings with grease, lay the jaw set on a pallet, and cover with a waterproof tarp if storage is outside.

INSTALLATION OF A JAW SET INTO THE MAIN FRAME

NOTE: New jaw sets are shipped pre-assembled with factory-installed assembly tubes. Jaw sets that have been used and removed from a Material Processor will be equipped with the assembly tube from the removal operation. If this is not the case, contact the NPK Service Department for assistance. 21. For easier installation of the jaw set

(DO) into the main frame (DN), chain or strap (t4) the jaws together to restrict their movement. Wrap a lifting strap or chain (t4) through the bore in the upper jaw and attach it to a crane or other lifting device.

- 93 -

JAW SET INTERCHANGE 22. Lift the jaw set (DO) and insert it into

the main frame (DN) from the front, not the top or the bottom. For better movement control, a second strap can be used to help level the jaw set. Adjust as necessary to align the jaw pivot pin bore on the jaw set with the jaw pivot pin bore on the main frame. Maintain this position. This is a tight, no-shim design. Alignment for insertion is critical.

ATTACHMENT OF JAWS TO THE MAIN FRAME 23. Manually insert the jaw pivot pin (BJ)

into the jaw pivot pin bore until it rests in the bore without support.

24. Drive the jaw pivot pin (BJ) in until the

assembly tube (t44) extends out about 10” (250mm) on the other side. Remove the assembly tube.

Continue driving the jaw pivot pin (BJ) until the head plate is flush with the main frame (DN).

- 94 -

JAW SET INTERCHANGE 25. Install the pivot pin nut (c32). Tighten

with a spanner wrench, or by driving with a brass drift (t43). The bore on the pivot pin nut (c32) must be aligned with the threaded bore (75) on the main frame.

26. Using a hex key socket (t42), install the

socket head bolt (OO) securing the pivot pin nut (c32). See bolt torques section for correct torque.

ATTACHMENT OF JAWS TO THE CYLINDER SUB-ASSEMBLIES

27. Begin with either of the cylinder jaw pins. Align the bore on the jaw with the bore on the cylinder.

28. Insert the cylinder jaw pin (c9) into the bore, early units.

Late Units

- 95 -

JAW SET INTERCHANGE 29. Install the cylinder pin lock plate

(c30), early units.

29a. Install the cylinder pin lock plate

(c31). NOTE: left hand thread (49), late units.

30. Using a hex key socket (t42), install

the two socket head bolts (OO) securing the cylinder pin lock plate. See bolt torques section for correct torque, early units.

30a. Using a hex key socket (t42),

install the socket head bolt (OO) securing the cylinder pin lock plate, late units.

- 96 -

JAW SET INTERCHANGE 31. Remove the chain that is holding

the jaws together. Lift the unit so as to align the bore of the second jaw (BD) with the cylinder jaw pin bore (c33) on the second cylinder (c11).

32. Repeat Steps 28 through 30 to attach the second jaw to the second cylinder sub-

assembly.

33. Jaw set change is complete.

- 97 -

FASTENER TORQUE CHART This torque chart is to be used with the specific “M” Series parts manual for the unit being repaired. Torques for the booster fasteners are found in the Hydraulic Booster Service Manual. 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; then cleaned with compressed air. Threaded holes must be cleaned with a tap; then cleaned with solvent; then cleaned with compressed air. Use a common chassis or wheel bearing grease on fasteners listed as lubed. Grease the threads of the bolt and the contact surface under the bolt head. Grease the contact surface of nuts. Use a few drops of medium strength thread adhesive on the threads of fasteners listed as torqued with adhesive. Do not use anti-seize compound on any fasteners, unless otherwise noted. PIVOT PIN KEEPER BOLT CYLINDER EYE TO JAW

MODEL

BOLT

TORQUE ft lb Nm

ADHESIVE OR LUBED

M20 M16 190 255 LUBED

M28 M16 190 255 LUBED

M38 M20 360 490 LUBED

MAIN JAW PIVOT PIN KEEPER BOLT

MODEL

BOLT TORQUE

ft lb Nm ADHESIVE OR

LUBED

M20 M16 190 255 LUBED

M28 M16 190 255 LUBED

M38 M16 190 255 LUBED

BARREL END CYLINDER PIN KEEPER BOLT

MODEL

BOLT TORQUE


LUBED

M20 M24 530 720 LUBED

M28 M24 530 720 LUBED

M38 M24 530 720 LUBED

- 98 -

FASTENER TORQUE CHART JOINT ADAPTER BOLT TO TOP FRAME

MODEL

BOLT

TORQUE ft lb Nm

ADHESIVE OR LUBED

M20 M12 65 90 LUBED

M28 M12 65 90 LUBED

M38 M12 65 90 LUBED

CUTTING BLADE BOLT – G & S JAWS

MODEL

BOLT TORQUE


LUBED

M20 M16 190 255 LUBED

M28 M20 360 490 LUBED

M38 M24 530 720 LUBED

CUTTING BLADE BOLT – C & K JAWS

MODEL

BOLT TORQUE


LUBED

M20 M16 190 255 LUBED

M28 M20 360 490 LUBED

M38 M24 530 720 LUBED

TUNNEL FRONT BLADE BOLT – K FORKED JAW

MODEL

BOLT TORQUE


LUBED

M20 M16 190 255 LUBED

M28 M20 365 495 LUBED

M38 M24 530 720 LUBED

TOOTH PLATE TO MOVEABLE JAW - G JAW

MODEL

BOLT TORQUE


LUBED

M20 M20 365 495 ADHESIVE



- 99 -

FASTENER TORQUE CHART CYLINDER END CAP BOLTS

MODEL

BOLT

TORQUE ft lb Nm

ADHESIVE OR LUBED

M20 M18 260 350 LUBED

M28 M18 260 350 LUBED

M38 M18 260 350 LUBED

CYLINDER ROD NUT

MODEL

BOLT TORQUE


LUBED

M20 M45 1500 2000 ADHESIVE

M28 M65 3200 4300 ADHESIVE

M38 M70 4100 5500 ADHESIVE

CYLINDER ROD COVER PLATE BOLTS

MODEL

BOLT TORQUE


LUBED

M20 M16 190 255 LUBED

M28 M18 260 350 LUBED

M38 M18 260 350 LUBED

NYLON WEAR PLATE TO CYLINDER BOLTS

MODEL

BOLT TORQUE


LUBED

M20 N/A N/A N/A N/A



BOOSTER OR VALVE BOX ASSEMBLY TO CYLINDER BOLTS

MODEL

BOLT TORQUE


LUBED




MANIFOLD BLOCK TO CYLINDER BOLTS (EARLY UNITS)

MODEL

BOLT TORQUE


LUBED



M38 M12 93 125 ADHESIVE (LATE UNITS)

MODEL

BOLT

TORQUE ft lb Nm

ADHESIVE OR LUBED




- 100 -

FASTENER TORQUE CHART CRUSHER FRAME AND TOP BRACKET TO ROTATING BEARING BOLTS

MODEL

BOLT

TORQUE ft lb Nm

ADHESIVE OR LUBED

M20 M24 530 720 LUBED

M28 M24 530 720 LUBED

M38 M24 530 720 LUBED

ROTATOR MOTOR TO SWIVEL TOP

MODEL

BOLT TORQUE


LUBED




MOTOR PINION GEAR TO MOTOR BOLT

MODEL

BOLT TORQUE


LUBED




COUNTER BALANCE VALVE PLATE TO TOP BRACKET BOLTS

MODEL

BOLT TORQUE


LUBED

M20 M12 80 105 LUBED

M28 M12 80 105 LUBED

M38 M12 80 105 LUBED

ROTARY JOINT ASSEMBLY TO CRUSHER FRAME BOLTS

MODEL

BOLT TORQUE


LUBED




RELIEF VALVE BLOCK TO ROTARY JOINT BOLTS

MODEL

BOLT TORQUE


LUBED

M20 M12 80 105 LUBED

M28 M12 80 105 LUBED

M38 M12 80 105 LUBED

- 101 -

TROUBLESHOOTING DETERMINE THE TYPE OF PROBLEM Performance problems are classified as “LOSS OF POWER” or “LOSS OF CYCLE SPEED” (assuming the problem is not due to misapplication).

TROUBLESHOOTING FOR LOSS OF POWER Tools and Equipment required: Pressure gauge – 5,000 psi Test port adapter – to fit #4 SAE female port in shut-off valve Test hose – rated for 5,000 psi

Procedure Install pressure test hoses in both shut-off valve test ports, see page 32 for location, and proceed according to the flow chart below.

- 102 -

TROUBLESHOOTING

TROUBLESHOOTING FOR LOSS OF POWER

- 103 -

TROUBLESHOOTING

PROPER OPERATION OF BOOSTER CRUSHER BOOSTER WORKING PROPERLY (CLOSE CYCLE) A rapid clicking sound will be heard as the jaws begin to close and meet resistance. As jaws grasp tighter onto the material, the clicking will begin to slow. This slowing will continue until the material is either broken or the crusher meets full resistance. At full resistance, the clicking will slow dramatically or sometimes stop completely. If this occurs, the crusher/booster is functioning correctly. DETERMINING IF THE PRESSURE INTENSIFIER IS ACTUATING

Close the jaws, without material in them. When the CRUSHER cylinder is fully stroked, the load pressure rises until it reaches the sequence valve setting (P1) and the oil is diverted to the pressure intensifier. The load pressure momentarily levels off at the sequence valve pressure, then rises to the CRUSHER (BV) relief valve setting (P2). The excavator relief valve acts only as a safety relief, and must be set a minimum of 200 psi above the CRUSHER relief valve setting P2 shown below.

If the pressure intensifier is functioning correctly, it will make a rapid clicking sound for several seconds and then slow down.

PROCESSOR MODEL

SERIAL NO.

Sequence Valve Pressure Setting P1

Processor Relief Valve Setting P2

psi bar psi bar M20 ALL 2,950 210 3,625 250 M28 ALL 2,950 210 3,625 250 M38 ALL 2,950 210 3,625 250

FIG. 1

- 104 -

TROUBLESHOOTING

CHECKING BOOSTED PRESSURE

NPK has a gauge assembly (0 – 15,000 psi), P/N L017-8000, available to directly check the boosted pressure on all Material Processors. These units have three hex head o-ring plugs on the booster assembly as shown below. The procedure for testing is shown below: 1. Remove one of the plugs shown and install adapter P/N K023-6690. Choose the

plug that will give you gauge clearance and best viewing. 2. Install adapter P/N L007-6630 onto gauge P/N L017-4020. Use thread sealant. 3. Install gauge onto adapter P/N K023-6690, which has been installed on booster. 4. Close jaw all the way with the engine speed just above idle. Pressure will rise to the

point where booster starts (3,000 psi), and then go up to full boosted pressure of approximately 12,000+ psi. When the clicking of the booster slows, then you are at full intensification; click. . . .click. . . .click . . . .etc., is normal. If the clicking continues rapidly and will not slow down, then there may be a problem with the booster or crusher cylinder.

5. Open jaw all the way. You will now read the relief setting of the jaw open circuit,

3,625 psi. Note that the booster only works on jaw close. Jaw open sees Processor relief or machine circuit relief, whichever is lower.

NOTE: CALL NPK SERVICE DEPARTMENT FOR ADDITIONAL ASSISTANCE IF

REQUIRED AT 1-800-225-4379.

L017-8000 GAUGE ASSEMBLY fm4 L017-4020 Gauge

0 – 15,000 PSI CB K023-6690 Male Adapter CD L007-6630 Female Swivel Adapter

HIGH PRESSURE OIL!

- 105 -

TROUBLESHOOTING IF THE UNIT APPEARS NOT TO BE FUNCTIONING CORRECTLY, THE FOLLOWING CHECKS MUST BE MADE: JAW CLOSES AND NO CLICKING IS HEARD AND MATERIAL IS NOT BEING BROKEN AS EXPECTED This indicates that the crusher is not going into the boosted mode. This may indicate a problem with the crusher or the carrier crusher circuit. This will require further investigation by a mechanic using Material Processor Service Manual, see pages 101 and 102 and/or contacting the NPK Service Department at 1-800-225-4379. RAPID CONTINUOUS CLICKING IS HEARD AND THE MATERIAL IS NOT BEING BROKEN AS EXPECTED This indicates that a problem is in the booster or the cylinder of the Material Processor. This requires further investigation by a mechanic/technician, Ref. to chart, Fig. 1 on page 103 to determine if booster is functioning to specifications. JAW DRIFT Some drift may be experienced depending on Processor position. Acceptable drift may occur over a number of minutes. Rapid drift: This may indicate a problem with the cylinders, booster, swivel manifold

and carrier circuit. TO DETERMINE IF THE JAW DRIFT IS OCCURRING FROM A BAD CYLINDER 1. Remove the hoses from the bulkhead fittings on the outside of the crusher frame. 2. Cap the bulkheads (#20 JIC caps). 3. If the jaw drifts, the problem is in the cylinder or pilot checks in booster. If no drift

occurs, then problem is in the carriers main control valve. If drift is due to main control valve internal leak, this problem may be inherent to your carrier and may not be solvable.

CYCLE TIMES Note: If jaws will not open or close, be sure right and left shut-off blocks are open. The specified cycle times of the Processor are controlled by the flow provided by the circuit of the carrier. The published cycle times of the Processor are a direct result of the maximum published oil flow, see pages 12 thru 23.

- 106 -

TROUBLESHOOTING ROTATION The rotation speed is a direct result of the amount of flow (GPM) supplied by the rotation circuit of the carrier. The chart below lists the recommended rotation speed and approximate flow required.

MODEL ROTATION SPEED APPROXIMATE FLOW

M20 6.5 – 10 RPM 2.5 – 4 GPM 10 – 15 LPM

M28 6.5 – 10 RPM 2.5 – 4 GPM 10 – 15 LPM

M38 6 – 9 RPM 2.5 – 4 GPM 10 – 15 LPM

Adjust the rotation flow so that the RPM is within the guidelines shown for your model.

Excessive overspeeding of the unit rotation will result in damage to the motor, gearbox, and bearing. UNIT WILL NOT ROTATE 1. Check hydraulic flow through the rotation circuit (ref. chart above for proper flow

rates for your unit). 2. If flow is good, install gauges in the rotation circuit lines. 3. Position unit so that it will not rotate. 4. Attempt to rotate the unit in both directions. Each gauge should read 2,000 psi. 5. If 2,000 psi is not achieved, adjust relief valve cartridges (c17,c18) on the rotation

holding valve (BO) (Fig. 1).

6. If adjustment is not possible, call NPK at 1-800-225-4379. UNIT WILL NOT HOLD POSITION 1. Follow steps 2 through 6 above.

- 107 -

TROUBLESHOOTING

TROUBLESHOOTING FOR SLOW CYCLE SPEED Tools and Equipment required: Pressure gauge – 5,000 psi Test port adapter – to fit #4 SAE female port in shut-off valve Test hose – rated for 5,000 psi Flow meter – Pressure loading type, 60 gpm min. capacity Procedure Install pressure gauge in test port located in shut-off valve, see page 32, and proceed according to the flow chart below:

- 108 -

TROUBLESHOOTING CHECKING THE HYDRAULIC FLOW AT RATED PRESSURE

1. Installation of a Flow Meter Equipped with Pressure Loading Valve. Install the flow meter (t36) between the crusher close line (CE) and return (not

shown) as shown below.

Generally, the pressure line is on the left and the return is on the right.

2. Determine Return Line Pressure (Pressure Drop). Open both stop valves and actuate the circuit. Measure the pressure with the load valve of the pressure / flow meter in full open condition.

3. Determine Relief Valve Pressure and Oil Flow. Measure flow and pressure with the

flow meter. Adjust the load valve to zero restriction. Warm up the hydraulic system of the excavator to normal operating temperature. Set engine throttle to maximum. Press hammer foot switch. Turn in the loading valve knob and record the pressure and flow at regular intervals (P1) on graph paper. Record pressure on one axis of the graph and flow on the other. Increase pressure until relief setting (P2) is reached. This is the circuit flow chart. Refer to Processor (A) specification chart for correct flow at 1,000 psi pressure.

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TROUBLESHOOTING CHECKING THE HYDRAULIC FLOW AT RATED PRESSURE, CONTINUED

5. OUT 6. IN fm1 LOAD VALVE fm2 FLOW/TEMPERATURE DISPLAY fm3 FLOW/TEMPERATURE SWITCH fm4 PRESSURE GAUGE

Typical flow meter with pressure loading valve.

FLOW VS. PRESSURE CHART

TYPICAL EXAMPLE

fl FLOW (GPM) pr PRESSURE (PSI)

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KEYWORDS FOR COMMON PROCESSOR COMPONENTS

M38G SHOWN

BD JAW ASSEMBLY BE PLATE or TOOTH BF BUSHING BG BLADE BH SHIM BI JAW ASSEMBLY BJ PIN BN SWIVEL BO ROTATION VALVE BP VALVE PLATE BQ HYDRAULIC MOTOR BR GEAR BT SLEWING RING c11 CYLINDER ASSEMBLY c13 LOCK PLATE c32 NUT c35 MANIFOLD DN MAIN FRAME DP LOCK PIN II BOOSTER JJ COVER m7 TOP BRACKET m18 JOINT FITTING PP SEAL RR O-RING

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WARRANTY STATEMENTS

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WARRANTY STATEMENTS

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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

© Copyright 2015 NPK Construction Equipment, Inc. www.npkce.com M000-9600H 7-15 Material Processor Instruction Manual

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