U and G-SERIES SECONDARY CONCRETE CRUSHERS€¦ · U and G Series Crushers Operation Manual 7550 Independence Drive Walton Hills, OH 44146-5541 ... repair or troubleshoot the CONCRETE

U and G-SERIES SECONDARY CONCRETE CRUSHERS

MODELS U21J, U21JR, U31J, U31JR U45J, U45JR, G7, G18J, G26J, G30JR

OPERATION AND MAINTENANCE MANUAL

© Copyright 2012 NPK Construction Equipment, Inc. www.npkce.com U000-9600A 11-12 U and G Series Crushers Operation Manual

7550 Independence Drive Walton Hills, OH 44146-5541

Phone (440) 232-7900 Toll-free (800) 225-4379

Fax (440) 232-6294

"Use Genuine NPK Parts”

1

CONTENTS

SAFETY ........................................................................................................................................................ 2 OPERATION ............................................................................................................................................ 3 MAINTENANCE ....................................................................................................................................... 4

INTRODUCTION ........................................................................................................................................... 6 CARRIER COMPATIBILITY .......................................................................................................................... 7 MODEL SPECIFICATIONS .......................................................................................................................... 8 CRUSHER STRUCTURE ........................................................................................................................... 18 CRUSHER BOOSTER & CYLINDER ......................................................................................................... 19

I INTRODUCTION ............................................................................................................................... 19 II STRUCTURE OF THE BOOSTED CYLINDER ................................................................................. 20 III OPERATING PRINCIPLE ................................................................................................................. 21

HYDRAULIC INSTALLATION ..................................................................................................................... 27 HYDRAULIC QUICK DISCONNECTS ................................................................................................... 28

MOUNTING INSTALLATION ...................................................................................................................... 29 MOUNTING TO THE CARRIER ............................................................................................................ 29 REMOVAL FROM THE CARRIER ......................................................................................................... 30

OPERATION INSTRUCTIONS ................................................................................................................... 31 INSPECTION AND MAINTENANCE .......................................................................................................... 34

DAILY INSPECTION AND MAINTENANCE .......................................................................................... 34 INSPECTION AND MAINTENANCE .......................................................................................................... 38

WEEKLY MAINTENANCE ..................................................................................................................... 38 MINIMUM DISTANCE BETWEEN FIXED AND MOVEABLE JAW ........................................................ 38 TEETH MAINTENANCE & REPLACEMENT ......................................................................................... 39 TOOTH PLATE REPLACEMENT (BOLT-ON TYPE) ............................................................................. 39 TOOTH REPLACEMENT (WELD-ON TYPE) ........................................................................................ 39 TOOTH BUILD-UP ................................................................................................................................. 40 GENERAL HARDFACING ..................................................................................................................... 40 FRAME MAINTENANCE ....................................................................................................................... 40 FRAME CRACK REPAIR ....................................................................................................................... 41 REBAR CUTTER BLADE MAINTENANCE ........................................................................................... 41

CYLINDER DISASSEMBLY AND REPAIR ................................................................................................ 43 CYLINDER RE-ASSEMBLY ....................................................................................................................... 45 REPAIR ....................................................................................................................................................... 47

REPAIR OF JAWS AND MAIN FRAME ................................................................................................. 47 REPAIR OF ROTARY JOINT ASSEMBLY ............................................................................................ 50 ROTATION BEARING OUTER DIRT SEAL REPLACEMENT ............................................................... 55

CRUSHER RELIEF LOCATIONS ............................................................................................................... 56 U31 CONVERSION TO ROTATION ........................................................................................................... 57 TROUBLESHOOTING ................................................................................................................................ 58

DETERMINE THE TYPE OF PROBLEM ............................................................................................... 58 DETERMINE THE CAUSE OF THE PROBLEM .................................................................................... 58 LOSS OF POWER ................................................................................................................................. 59 SLOW CYCLE SPEED ........................................................................................................................... 66 JAW DRIFT ............................................................................................................................................ 67 ROTATION ............................................................................................................................................ 68

FASTENER TORQUE (U SERIES) ............................................................................................................ 69 FASTENER TORQUE (G SERIES) ............................................................................................................ 72 SERIAL NUMBER LOCATION ................................................................................................................... 76 WARRANTY STATEMENTS ...................................................................................................................... 79 STORAGE OF CRUSHER .......................................................................................................................... 81

2

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

3

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 CONCRETE CRUSHER while in operation.

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

4. Operate the CONCRETE CRUSHER from the operator’s seat only.

5. Use two people whenever operator visibility is limited, one to operate the CONCRETE CRUSHER, 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 CONCRETE CRUSHER

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

CRUSHER.

10. Match the CONCRETE CRUSHER size to excavator according to NPK

recommendations. The excavator must be stable during CONCRETE CRUSHER operation and during transport. See CARRIER COMPATIBILITY section of the NPK instruction manual.

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 within a few hours or gangrene may result.

14. The pressure generated by the power intensifier on the CONCRETE CRUSHER 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.

4

SAFETY MAINTENANCE

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

2. Use extreme caution in handling. A fully assembled CONCRETE CRUSHER can

weigh up to 5 tons (4-1/2 tonnes). 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. Wear safety glasses and protective clothing when working on the CONCRETE

CRUSHER. Wear thermal-protective gloves when handling heated parts. 4. Prevent exposure to hazardous fumes. Remove all paint, grease, and oil before

heating, cutting or welding on the CONCRETE CRUSHER. 5. Be especially cautious around hydraulic lines. Hydraulic oil can be extremely HOT!

Avoid skin contact with hydraulic oil. It can cause severe burns! 6. 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.

7. The pressure generated by the power intensifier on the CONCRETE CRUSHER

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.

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

5

SAFETY MAINTENANCE STANDARD PRACTICES

Maintenance of and repairs to the CONCRETE CRUSHER should be performed by an experienced service technician, thoroughly familiar with all standard practices and procedures, and most importantly, all safety precautions. The following is a review of common standard practices to be followed when working with hydraulic equipment, and is not meant to be all-inclusive. 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 foreign contaminants. Thoroughly clean the work area.

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 CONCRETE CRUSHER.

ATTENTION

6

INTRODUCTION

Thank you for your purchase of an NPK attachment. NPK prides itself in the design and manufacture of high quality attachments. The quality workmanship and materials, which go into all of our attachments, will provide maximum service life. With proper care, and use, your NPK attachment should provide you with many years of productive service. This manual contains information vital to the care and safe operation of your equipment. Operator safety, safety of others, and equipment life is largely dependent on how you operate and maintain your equipment. All personnel involved in the operation and service of this equipment should read and understand this manual prior to any operation and/or service. For additional information or help with any problem encountered, please contact your NPK authorized dealer. Use replacement parts sold by NPK only. NPK is not responsible for failures resulting from alterations not approved by NPK or substitution of parts not sold by NPK.

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CARRIER COMPATIBILITY

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

Mounting a CONCRETE CRUSHER that is too heavy for the carrier machine is inefficient and can be dangerous and damage the carrier. Verify carrier stability with the CRUSHER before transport or operation. Mounting a CRUSHER that is too small for the carrier machine can damage the unit and void the Warranty. If there is uncertainty whether the CRUSHER model is compatible, consult NPK.

CRUSHER MODEL

RECOMMENDED CARRIER WEIGHT RANGE 3rd Member Mounting

U.S. ton M tonne

U21J 21 – 31 19 – 28

U21JR 21 – 31 19 – 28

U31J 31 – 53 28 – 48

U31JR 31 – 53 28 – 48

U45J 45 – 50 41 – 45

U45JR 45 – 50 41 – 45

G7 6.6 – 11 6 – 10

G18J 20 – 25 18 – 23

G26J 25 – 35 23 – 32

G30JR 35 – 50 32 – 45

Specifications subject to change without notice.

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MODEL SPECIFICATIONS

U21J SECONDARY

CONCRETE CRUSHER

MODEL

Weight

lb (kg)

Excavator Class

ton (M tonne)

Crushing Force

ton (M tonne)

Max. Jaw Opening in (mm)

Cycle Time sec

*Max. Op. Pressure psi (bar)

Oil flow gpm (l/m)

U21J 4650 (2110)

21 – 31 (19 – 28)

d86 73 (66) d87 100 (90)

31.6 (802.4)

1.2 Open 1.6 Close

3771 (260)

26 – 53 (98 – 200)

Specifications subject to change without notice. Cycle time is full stroke at maximum flow. Carrier flow is set at minimal operating pressure of 1000 psi. *Maximum operating pressure is determined by reliefs in the crusher.

d46 = 91.5 in (2325 mm)

58 = Fixed

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U21JR SECONDARY

CONCRETE CRUSHER

MODEL

Weight

lb (kg)

Excavator Class

ton (M tonne)

Crushing Force

ton (M tonne)


Cycle Time sec


Oil flow gpm (l/m)

U21JR 5400 (2500)

21 – 31 (19 – 28)

d86 73 (66) d87 100 (90)

31.6 (802.4)

1.2 Open 1.6 Close

3771 (260)

26 – 53 (98 – 200)


d46 = 97.7 in (2482 mm)

59 = Rotating

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U31J SECONDARY

CONCRETE CRUSHER

MODEL

Weight

lb (kg)

Excavator Class

ton (M tonne)

Crushing Force

ton (M tonne)


Cycle Time sec


Oil flow gpm (l/m)

U31J 7000 (3175)

31 – 53 (28 – 48)

d86 130 (118) d87 173 (157)

38.6 (980)

2.4 Open 2.9 Close

4061 (280)

26 – 66 (98 – 250)


d46 = 100.4 in (2551 mm)

58 = Fixed

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U31JR SECONDARY

CONCRETE CRUSHER

MODEL

Weight

lb (kg)

Excavator Class

ton (M tonne)

Crushing Force

ton (M tonne)


Cycle Time sec


Oil flow gpm (l/m)

U31JR 8000 (3630)

31 – 53 (28 – 48)

d86 130 (118) d87 173 (157)

38.6 (980)

2.4 Open 2.9 Close

4061 (280)

26 – 66 (98 – 250)


d46 = 109.7 in (2786 mm)

59 = Rotating

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U45J SECONDARY

CONCRETE CRUSHER

MODEL

Weight

lb (kg)

Excavator Class

ton (M tonne)

Crushing Force

ton (M tonne)


Cycle Time sec


Oil flow gpm (l/m)

U45J 9000 (4080)

45 – 50 (41 – 45)

d86 142 (129) d87 195 (177)

44.5 (1130)

2.4 Open 3.0 Close

4350 (300)

46 – 73 (175 – 275)


d46 = 119.5 in (3035 mm)

58 = Fixed

13


U45JR SECONDARY

CONCRETE CRUSHER

MODEL Weight

lb (kg)

Excavator Class

ton (M tonne)

Crushing Force

ton (M tonne)


Cycle Time sec


Oil flow gpm (l/m)

U45JR 9920 (4500)

45 – 50 (41 – 45)

d86 142 (129) d87 195 (177)

44.5 (1130)

2.4 Open 3.0 Close

4350 (300)

46 – 73 (175 – 275)


d46 = 125.4 in (3185 mm)

59 = Rotating

14


G7 SECONDARY

CONCRETE CRUSHER

MODEL Weight

lb (kg)

Excavator Class

ton (M tonne)

Crushing Force

ton (M tonne)


Cycle Time sec


Oil flow gpm (l/m)

G7 1650 (750)

6.6 – 11 (6 – 10)

d86 39 (35) d87 52 (47)

21 (533.4)

0.9 Open 1.8 Close

3000 (206)

13 – 21 (49 – 80)


d46 = 58 in (1473.2 mm) d47 = 9.6 in (243.8 mm)

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G18J SECONDARY

CONCRETE CRUSHER

MODEL Weight

lb (kg)

Excavator Class

ton (M tonne)

Crushing Force

ton (M tonne)


Cycle Time sec


Oil flow gpm (l/m)

G18J 4400 (2000)

25 – 35 (18 – 23)

d86 72 (65) d87 93 (84)

33 (838.2)

1.8 Open 2.1 Close

3700 (255)

26 – 52 (98 – 197)


d46 = 83 in (2108.2 mm) d47 = 14.6 in (370.8 mm)

16


G26J SECONDARY

CONCRETE CRUSHER

MODEL Weight

lb (kg)

Excavator Class

ton (M tonne)

Crushing Force

ton (M tonne)


Cycle Time sec


Oil flow gpm (l/m)

G26J 6050 (2745)

25 – 35 (18 – 23)

d86 109 (99) d87 150 (136)

36 (965.2)

1.8 Open 3.2 Close

4000 (275)

26 – 66 (98 – 250)


d46 = 106 in (2692.4 mm) d47 = 17.3 in (439.4 mm)

17


G30JR SECONDARY

CONCRETE CRUSHER

MODEL Weight

lb (kg)

Excavator Class

ton (M tonne)

Crushing Force

ton (M tonne)


Cycle Time sec


Oil flow gpm (l/m)

G30JR 7000 (3175)

35 – 50 (32 – 45)

d86 109 (99) d87 150 (136)

36 (965.2)

1.8 Open 3.2 Close

4000 (275)

26 – 66 (98 – 250)


d46 = 105 in (2667 mm) d47 = 17.3 in (439.4 mm)

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CRUSHER STRUCTURE

II BOOSTER BP VALVE PLATEc11 CYLINDER ASSEMBLY m18 JOINT FITTINGBD MOVEABLE JAW m7 TOP BRACKETBE TOOTH PLATE BQ HYDRAULIC MOTORBF BUSHING BR GEAR BG BLADE BS LOCK PIN BH SHIM BT SLEWING RINGJJ COVER PP SEAL BI MAIN FRAME RR O-RING BJ PIN DD SWIVEL ELBOWBK PIN NUT c12 CYLINDER GUARDc13 CYLINDER PIN LOCKING PLATE BL FLANGE BM NYLON SIDE PLATE BU SPACER SPRINGBN SWIVEL ASSEMBLY K DOWEL PINBO ROTATION VALVE

19

CRUSHER BOOSTER & CYLINDER

I INTRODUCTION

The hydraulic cylinder used on NPK Crushers is equipped with a hydraulic booster. To close the jaw(s) of the crusher, oil from the excavator is directed to the base end of the cylinder, which extends the cylinder rod. Under no load, no boost is applied and this results in a rapid cycle time as compared to large, unboosted cylinders. When a load (material to be crushed) is encountered, pressure builds and shifts the sequence valve on the booster. This directs oil into the booster section, which intensifies the pressure well beyond the system operating pressure of the excavator. The compact NPK Boosted Cylinder System provides a working force equal to a far larger unboosted cylinder, which is working at excavator system pressure. Because the NPK boosted cylinder is smaller it requires less oil for full stroke as compared to a large diameter cylinder. This reduces cycle time for the NPK Crusher. To open the jaw(s) of the NPK Crusher, oil is directed to the rod end of the cylinder. This retracts the rod and pulls the jaw open. No boost is provided in the jaw opening mode.

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)

20


II STRUCTURE OF THE BOOSTED CYLINDER

FIG. 1 STRUCTURE OF THE BOOSTED CYLINDER As shown in (Figure 1), the booster consists of:

*Cylinder Piston and Rod Assembly *Booster Piston *Booster Valve and Plunger *Pilot Check Valve (c20) and Check Valve 1 (c21) thru Check Valve 5 (c25) *Sequence Valve (c16)

For a complete breakdown of the parts in the boosted cylinder assembly, see the parts manual for each unit.

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)

21


III OPERATING PRINCIPLE

FIG. 2 CYLINDER EXTEND (NO LOAD)

1. Cylinder Extend (Jaw Close) Under No Load (Figure 2)

When the cylinder is extended (jaw close), and no load is encountered, oil is directed through the booster unit to the base end of the cylinder. Hydraulic pressure is low at no load and no boost is provided. 2. Booster Actuation (Figures 3 thru 6)

When a load (material to be broken) is encountered on jaw close, the hydraulic pressure through the booster unit starts to rise. When the hydraulic pressure reaches a pre-set value, the sequence valve (c16) shifts and directs oil through the control valve 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 booster piston travel.


22

CRUSHER BOOSTER & CYLINDER 2-1 Forward Piston Stroke (Figure 3)

FIG. 3 FORWARD PISTON STROKE 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 chamber v1 is greater than the area at v4, the pressure at v4 is intensified. This higher pressure oil is pushed through v4 and to the base end of the cylinder and closes c23.


23

CRUSHER BOOSTER & CYLINDER 2-2 Booster Valve Shift (Figure 4)

FIG. 4 BOOSTER VALVE SHIFT

When the booster piston reaches full stroke, oil entering port (c26) of the piston transfers to port (c27) and to the plunger end of the booster control valve. This shifts the valve as seen in Figure 4.

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)

24

CRUSHER BOOSTER & CYLINDER 2-3 Reverse Piston Stroke (Figure 5)

FIG. 5 REVERSE PISTON STROKE

When the booster valve has been shifted, oil from the sequence valve (c16) 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 c23 to the base end of the cylinder. c24 and c20 are also closed.

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)

25

CRUSHER BOOSTER & CYLINDER 2-4 Valve Shift To Forward Stroke (Figure 6)

FIG. 6 VALVE SHIFT TO FORWARD STROKE

When the booster piston reaches full reverse stroke, oil drains out of the plunger end of the booster control valve through ports (c27) and (c28) 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 pedal in the cab is depressed and there is sufficient resistance (load) to crushing to keep the booster active.

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) v3 OIL CHAMBER (3) v4 OIL CHAMBER (4)

26

CRUSHER BOOSTER & CYLINDER 3. Cylinder Retract (Jaw Open) (Figure 7)

FIG. 7 CYLINDER RETRACT

When the crusher jaw(s) is opened, oil from the hydraulic circuit of the excavator is directed through the booster to the rod end of the cylinder. 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 cylinder as the rod retracts. As the cylinder rod retracts, the crusher jaw is opened. There is no boost on jaw opening.


27

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 (k1) of the carrier. Make sure the shut-off valves (k4) are turned to the “ON” (k5) position before operating the CRUSHER. 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 CRUSHER CLOSE m4 CRUSHER OPEN

28

HYDRAULIC INSTALLATION

HYDRAULIC QUICK DISCONNECTS NPK discourages the use of quick disconnects on hydraulic circuits operating NPK products, including Concrete Crushers, for the following reasons:

1. The hydraulic pulsations caused by the Crusher operating can cause internal pieces of the quick disconnect to disintegrate. These pieces would migrate into the Crusher, causing damage. Direct connection of the crusher hose to the stick tube (39) is approved.

2. Quick disconnects (32) create a restriction in the circuit. NPK Crushers are not back pressure sensitive, but restrictions cause unnecessary heating of the oil. Also, the pressure required to operate the Crusher, 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 Crusher operation.

39 = APPROVED CONNECTION 32 = NON-RECOMMENDED QUICK DISCONNECT

3. If quick disconnects are used, when the

Crusher 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 Crusher when re-connected. This, again, can cause damage.

NPK APPROVED CONNECTION QUICK DISCONNECTS (DX)

CONTACT YOUR NPK DEALER FOR ADDITIONAL INFORMATION ABOUT NPK QUICK DISCONNECTS

29

MOUNTING INSTALLATION

NPK MOUNTING INSTALLATION KITS include the parts required to adapt the NPK U-SERIES and G-SERIES SECONDARY CONCRETE CRUSHER 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 GRABBERS.

MOUNTING TO THE CARRIER

1. Position the CRUSHER (BV) horizontal on wood blocks (t20) as shown. Use wood blocks (t20) to prevent the cylinder rod cover (c12) from contacting the ground.

2. Align the stick pin holes. Install the stick pin (m1) and then the cylinder link pin (m2). 3. Connect the hydraulic hoses (AO). 4. Open the shut-off valves (k4).

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

ATTENTION

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

30

MOUNTING INSTALLATION U-SERIES AND G30JR SECONDARY CONCRETE CRUSHER TOP BRACKET

The U-Series and G30JR Secondary Concrete Crusher 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.

REMOVAL FROM THE CARRIER Reference Illustration: page 29 1. Close the shut-off valves (k4) and disconnect the hydraulic hoses (AO). 2. Disconnect the hydraulic hoses (AO) before laying the CRUSHER (BV) down.

Install plugs in the hydraulic hoses (AO) and caps on the stick tubes to keep out contamination.

3. Position the CRUSHER (BV) horizontal on wood blocks (t20), as shown on page 29. Do not allow the cylinder rod cover (c12) to contact the ground.

4. Remove the link pin (m2) and then the stick pin (m1).

31

OPERATION INSTRUCTIONS

Before operating the NPK CRUSHER, be sure to read safety information and perform the specified DAILY MAINTENANCE.

DO NOT OPERATE CRUSHER WITHOUT A DEMOLITION GUARD OR SHIELD IN PLACE! OPERATING THE CRUSHER The NPK U-SERIES AND G-SERIES NON-ROTATING

SECONDARY CONCRETE CRUSHER is intended for the crushing of loose, detached concrete only.

For most efficient operation, open the jaw only wide enough to grasp the material.

Grasp the material to be crushed as deep in the throat of the CRUSHER as possible. Do not force the material into the jaw.

Allow the hydraulic crushing forces of the CRUSHER jaw to do the work. Do not pry, twist or pull with the excavator boom.

If the concrete does not crush completely at first, open the jaws and close again in a chewing action.

Do not use the rebar cutters to cut rod over 1-1/4” diameter.

OPERATING PRECAUTIONS

Do not use the U-Series or G-Series non-rotating CRUSHER to crush fixed structures.

Do not use the CRUSHER with the excavator cylinders stroked fully open or closed. Do not strike the concrete with the CRUSHER body or outer surface of the jaw. Do not push, pull or scrape crushed

concrete, etc., with the CRUSHER jaw, use the body only.

Do not lift or load beyond the capacity of the CRUSHER or excavator.

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

32

OPERATION INSTRUCTIONS OPERATING INSTRUCTIONS ROTATING UNITS

Do not strike the material with the Rotating Crusher body (FP) or outer surface of the jaw (DO). Do not push, pull or scrape material with the Rotating Crusher Assembly (BV).

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

33

OPERATION INSTRUCTIONS

OPERATING INSTRUCTIONS ROTATING UNITS DO NOT:

Do not cut railroad rails or other hardened material. Do not lift or load beyond the capacity of the crusher or the excavator.

34

INSPECTION AND MAINTENANCE

DAILY INSPECTION AND MAINTENANCE The functions that the Crusher performs are demanding jobs in tough environments. Therefore, it is extremely important that the following maintenance and inspection procedures be performed daily. VERY IMPORTANT! Grease all lubrication points daily! Use moly EP2 or

equivalent grease. Lubrication points are at the following location points shown on pages 35, 36 and 37.

Check for oil leaks at the cylinder piston rods and all of the Crusher’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

REBAR CUTTER BLADE MAINTENANCE section for instructions). Check to ensure that blade-to-blade clearance is .010 to .040 inch (0.25 to 1.0 mm).

Shim if necessary (see REBAR CUTTER BLADE MAINTENANCE section for instructions).

35


LUBRICATION POINTS (U21J, U21JR, U31J, U31JR, U45J, U45JR) GR1 Cylinder rod pin: one lubrication point per cylinder located at jaw attachment

end. 10 strokes from grease gun once per shift. GR2 Cylinder pivot end pins: one lubrication point per side located at cylinder

trunnion flanges. 10 strokes from grease gun once per shift. GR3 Jaw pivot pin: two lubrication points on one side, one lubrication point on

other side. 15 strokes from grease gun per fitting per shift. GR4 Rotation Bearing: two lubrication points 180° apart. 5 strokes from grease

gun per fitting once per shift, if equipped. GR5 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 GR2 CYLINDER PIVOT (BOTH SIDES) GR3 JAW PIVOT PIN (BOTH SIDES) GR4 ROTATION BEARING, IF

EQUIPPED (5 SHOTS ONCE PER SHIFT) GR5 MOTOR PINION (NOT SHOWN)

36


LUBRICATION POINTS (G7, G18J, G26J)

GR1 Cylinder rod pin: one lubrication point per cylinder located at jaw attachment end. 10 strokes from grease gun once per shift.

GR2 Cylinder pivot end pins: one lubrication point per side located at cylinder trunnion flanges. 10 strokes from grease gun once per shift.

GR3 Jaw pivot pin: two lubrication points on one side, one lubrication point on other side. 15 strokes from grease gun per fitting per shift.

G7 LUBRICATION POINTS GR1. Cylinder Rod Pin GR2. Cylinder Pivot (Both Sides) GR3. Jaw Pivot Pin (Both Sides)

G18J LUBRICATION POINTS GR1. Cylinder Rod Pin GR2. Cylinder Pivot (Both Sides) GR3. Jaw Pivot Pin (Both Sides)

G26J LUBRICATION POINTS GR1. Cylinder Rod Pin GR2. Cylinder Pivot (Both Sides) GR3. Jaw Pivot Pin (Both Sides)

37


LUBRICATION POINTS (G30JR) GR1 Cylinder rod pin: one lubrication point per cylinder located at jaw attachment

end. 10 strokes from grease gun once per shift. GR2 Cylinder pivot end pins: one lubrication point per side located at cylinder

trunnion flanges. 10 strokes from grease gun once per shift. GR3 Jaw pivot pin: two lubrication points on one side, one lubrication point on

other side. 15 strokes from grease gun per fitting per shift. GR4 Rotation Bearing: two lubrication points 180° apart. 5 strokes from grease

gun per fitting once per shift, if equipped. GR5 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 GR2 CYLINDER PIVOT (BOTH SIDES) GR3 JAW PIVOT PIN (BOTH SIDES) GR4 ROTATION BEARING, IF

EQUIPPED (5 SHOTS ONCE PER SHIFT) GR5 MOTOR PINION (NOT SHOWN)

38


WEEKLY MAINTENANCE

Inspect the jaw teeth for wear. Hardface worn areas as needed. The jaw teeth can be cut off and replaced when worn beyond rebuild limits. Refer to page 39 for procedure. Working with excessively worn jaws will reduce working efficiency.

MINIMUM DISTANCE BETWEEN FIXED AND MOVEABLE JAW

The distance between the fixed (BI) and moveable jaw (BD) must be maintained on U-Series Crushers so that the crusher cylinder will not reach full stroke and become bottomed during operation. If the cylinder becomes bottomed, damage to the head cap or the piston retaining nut may occur. (Cylinder at full extension.)

When the jaw teeth become worn, allowing the gap (d3) to become less than the minimum shown in table , the teeth must be replaced or built up by welding to dimension (d3) shown in table .

U SERIES CRUSHER

G SERIES CRUSHER

(BD) MOVEABLE JAW (BI) FIXED JAW

TABLE 1 d3-DIMENSION

Minimum Gap mm inch

U21J 124 4-15/16” U21JR 124 4-15/16” U31J 100 3-15/16” U31JR 100 3-15/16” U45J 100 3-15/16” U45JR 135 5-5/16” G7 65 2-9/16” G18J 70 2-3/4” G26J 100 3-15/16” G30JR 100 3-15/16”

*If gap is greater than the specification, build teeth up by welding or install new teeth. See Welding Procedure.

TABLE 2 d3-DIMENSION

Approx. Std. Gap mm inch

U21J 140 5-1/2” U21JR 140 5-1/2” U31J 127 5” U31JR 127 5” U45J 115 4” U45JR 145 5-3/4” G7 77 3” G18J 100 3-15/16” G26J 127 5” G30JR 127 5”

ATTENTION

39


TEETH MAINTENANCE & REPLACEMENT The U-Series CRUSHER has two types of jaw teeth. Type “A” (BW) as found on the moveable jaw and Type “B” (BX) as found on the main frame. Both types can be cut off and replaced when worn beyond rebuildability. For build-up and hardfacing, use NPK templates to check teeth so that they are to the original profile. Contact NPK for the correct templates for each model.

TOOTH PLATE REPLACEMENT (BOLT-ON TYPE)

1. Unbolt and remove tooth plate from moveable jaw. Consult parts manual for part number of the tooth plate.

2. Bolt in new tooth plate. 3. Teeth on tooth plate can be built up and hardfaced. See below.

TOOTH REPLACEMENT (WELD-ON TYPE)

The following procedure should be followed in the replacement of NPK Crusher Teeth.

1. Remove worn teeth by carbon arc or acetylene cutting torch. 2. Prepare surface for new teeth. 3. Place new teeth into proper location. 4. Dry welding rod to 300F (150C) +. 5. Pre-heat weld area to 300F - 350F (150 - 175C). 6. 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, Stoody 2110, Postalloy 205, Hi-Pact #194 (Canada).

7. Hardfacing 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 1A, Cronatron 7355, Eutectic N6006, Postalloy 214, Stoody 31, Wear-X #176 (Canada), Stoody 19, 21, or 77, McKay Hardalloy 40 Tic, Hobart Smooth Arc 16.

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

40


TOOTH BUILD-UP Underlayment weld is necessary to build-up the base material 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, Stoody 2110,

Postalloy 205, Hi-Pact #194 (Canada). Dry welding rod at 300°F+ (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.

GENERAL HARDFACING Hardface can only be applied over base material or underlayment weld. Never hardface existing hardface. Welding rod: Airco Tubecraft 1A, Cronatron 7355, Eutectic N6006, Postalloy 214,

Stoody 31, Wear-X #176 (Canada), Stoody 19, 21 or 77, McKay Hardalloy 40 Tic, Hobart Smooth Arc 16.

Dry welding rod at 300°F (150C) +. Pre-heat the jaw weld area to 350°F (175C) 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.

FRAME MAINTENANCE Use a crosshatch (BY) pattern on wear areas of the CRUSHER as shown. Refer to Teeth Replacement Section for hardface rods and procedure.

Inspect frame for cracks periodically. Crushing is an abusive operation and eventually frame cracking may occur.

41


FRAME CRACK REPAIR 1. Drill 3/16” (5 mm) hole through the plate at the end of the crack to prevent further

crack propagation. 2. Grind out the crack and weld as shown. Use AWS E7018 or equivalent welding rod. 3a. For plate sizes up to 3/4” (20 mm) thick, use this weld joint:

3b. For plate sizes over 3/4” (20 mm) thick, use this weld joint:

4. Grind weld flush as shown:

22 DIRECTION OF GRINDING 23 DIRECTION OF PRINCIPLE

STRESS

REBAR CUTTER BLADE MAINTENANCE

REBAR CUTTER Maintain a blade to blade clearance (BG) side to side, of 0.010 to 0.040 inch (0.25 to 1.0 mm). Install necessary shims.

The proper cutter clearance must be maintained to prevent structural damage. Clearance can be maintained by shimming blades with shims included in the shim kits listed below.

MODEL PART NO. U21J 1614060 U21JR 1614060 U31J S1850-7000 U31JR S1850-7000 U45J 1615250 U45JR 1615250 G7 1609371 G18J S1850-7000 G26J S1850-7000 G30JR S1850-7000

42


REBAR CUTTER BLADE MAINTENANCE

When the cutter blades become damaged or rounded due to abrasion, regrind and shim as necessary.

Replace the cutter blade (BG) if it is chipped or worn beyond repair. The blade can be flipped 180° to increase service life. Torque the cutter blade bolts to the specification found on page 69.

ROD NUT INSTALLATION TORQUES

The torques listed below, are for the rod nuts (c1) used in the cylinder assemblies for the NPK Crushers. When assembling old style during rebuild, it is also recommended that thread adhesive is used to ensure complete clamping. New style rod nuts have an ND patch that does not require the use of thread adhesive.

CRUSHER

THREAD SIZE

Ft-Lb.

TORQUENm

SOCKET SIZE

OLD STYLE

NEW STYLE

U21J M65 x 3.0 3,250 4,400 90 mm 16084717 XU21JR M65 x 3.0 3,250 4,400 90 mm 16084717 XU31J M70 x 3.0 4,100 5,500 120 mm 16039992 G180-1000U31JR M70 x 3.0 4,100 5,500 120 mm 16039992 G180-1000U45J M70 x 3.0 4,100 5,500 140 mm 16064537 XU45JR M70 x 3.0 4,100 5,500 140 mm 16064537 XG7 M45 x 1.5 1,500 2,000 70 mm 16053050 XG18J M65 x 3.0 3,200 4,300 100 mm 16043903 S2250-4500G26J M70 x 3.0 4,100 5,500 120 mm 16039992 G180-1000G30JR M70 x 3.0 4,100 5,500 120 mm 16039992 G180-1000

43


CYLINDER DISASSEMBLY AND REPAIR

1. Remove bolts (OO).

2. Remove rod (c3) from cylinder barrel

(c4).

3. Check piston rings (c8). Rings should

be free in their grooves. If the rings are found to be stuck in the grooves, use the NPK grinder with the gray polishing stone and polish the rings until they spring out of the groove. If a ring is broken, replace the ring.

4. Using a ring expander (t16), remove all

of the piston rings.

5. Using the gray polishing stone (t8),

taper the leading edge of the groove (25) so that piston rings move freely.

44


CYLINDER DISASSEMBLY AND REPAIR 6. Remove rod nut set screw (c6) (if

equipped). Lightly heat the set screw (c6) using a torch to loosen the thread adhesive.

7. Remove the cylinder rod nut (c1),

piston (c2) and the cylinder cap (c5) from the cylinder rod (c3).

8. Inspect the bronze rod guide (c10).

(Lightly polish this area.) Replace all seals in the cylinder cap. Polish the cylinder rod as needed.

Note: The cylinder rod is a forged, high strength part. It is not possible to repair the rod. If this rod is bent, it must be replaced.

9. Using a straight edge (t15), check the

cylinder rod (c3) for straightness.

45


CYLINDER RE-ASSEMBLY 1. Inspect the main cylinder barrel (c4).

Lightly hone using a ball hone (t17) (if available).

2. Install new packing into the cylinder head cap and install the cylinder head cap onto

the cylinder rod. 3. Install the piston (c2) with the dimple

(24) found on the piston away from the rod eye.

4. After the nut has been tightened to the listed torque value, it is necessary to drill a

dimple in the piston through the set screw hole in the nut. This will allow the set screw to lock the nut to the piston. The maximum depth of the drilled hole should not exceed 0.5 mm or 1/64”. Apply a small amount of thread adhesive to the set screw before installing. Torque to 10 ft. lbs.

ROD NUT INSTALLATION TORQUES

5. The torques listed below are for rod nuts used in the cylinder assemblies for the NPK Crushers. When assembling old style during rebuild, it is also recommended that thread adhesive is used to ensure complete clamping. New style rod nuts have an ND patch that does not require the use of thread adhesive.

There are two styles of factory piston lock nuts. Figure (A) shows the early style. Figure (B) shows the current style. Figure (C) shows the replacement style. If the factory lock nuts are re-used, a “dimple” must be drilled into the piston rod (Fig. A) or piston (Fig. B) using the existing threaded hole as a guide. The maximum depth of the drilled hole should not exceed 0.5 mm (1/64 in). Apply a small amount of medium thread adhesive to the set screw before installing. If the lock nut is replaced, the replacement will have a nylon patch and not require a set screw (Fig. C).

Locknut with set screw Fig. (A)

Locknut with ND patch, set screw not required, Fig. (C)

Locknut with set screw Fig. (B)

46


CYLINDER RE-ASSEMBLY ROD NUT INSTALLATION TORQUES

6. Install the piston rings, using a ring

expander (t16).

7. Stand the main cylinder barrel on end.

Using a hoist, slowly lower the cylinder rod assembly into the barrel, taking care not to damage the piston rings (c8).

8. Install the head bolts (OO). Torque as

shown.

CYLINDER CAP BOLT TORQUES

The torques shown, are for bolts (OO) that clamp the cylinder cap to the main cylinder barrel. Lube the threads with grease or anti-seize compound.

CRUSHER

BOLT SIZE

TORQUE ADHESIVE OR

LUBED Ft/lb Nm

U21J M18 260 350 LUBED U21JR M18 260 350 LUBED U31J M20 365 500 LUBED U31JR M20 365 500 LUBED U45J M20 365 500 LUBED U45JR M20 365 500 LUBED G7 M16 190 255 LUBED G18J M18 260 350 LUBED G26J M20 365 500 LUBED G30JR M20 365 500 LUBED

47

REPAIR REPAIR OF JAWS AND MAIN FRAME

1. Gouge crack 100% using an air or electric hand held grinder (t1), carbon arc (t12), or torch (t13).

2. Grind gouged area to a 30° angle on each side to the full depth of the gouged area. If the crack is completely through the plate or jaw, grind the bevel in halfway from both sides. Remove all slag and grinding residue.

3. Consult “JAW AND FRAME REBUILD PROCEDURE” found on the following pages for pre-heat and welding instructions.

4. Peen or stress relieve after each pass. Maintain pre-heat.

5. After welding, grind area flush. Allow area to cool slowly, 8 hours minimum. Cover with a heat blanket or other suitable insulation. FAILURE TO DO SO MAY CAUSE CRYSTALLIZATION OF THE WELD AND SUBSEQUENT BREAKAGE.

NOTE: NPK Construction Equipment, Incorporated has developed this repair procedure based on known information about the structure and material. This, however, does not imply that repairs made using this procedure are guaranteed to be successful. NPK, therefore, cannot warranty this procedure. There is NO warranty regarding this repair either expressed or implied.

48

REPAIR REPAIR OF JAWS AND MAIN FRAME Due to the abrasive nature of the material being crushed, jaw wear will occur. 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, 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, Stoody 2110,

Postalloy 205, Hi-Pact #194 (Canada). 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.

49

REPAIR REPAIR OF JAWS AND MAIN FRAME 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, Wear-X #176 (Canada), Stoody 19, 21 or 77, McKay Hardalloy 40 Tic, Hobart Smooth Arc 16. 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

50

REPAIR REPAIR OF ROTARY JOINT ASSEMBLY ROTATING STYLE

LEAKAGE OF THE SEALS External leakage or internal (bypassing) of hydraulic oil will require the replacement of the seals in the rotary joint 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 Rotary Joint Seals for Internal Leakage” section.

TESTING THE ROTARY JOINT SEALS FOR INTERNAL LEAKAGE

If internal seal leakage is suspected, before disassembling the rotary joint assembly (CG), the relief valve pressure setting should be checked. Internal leakage will most likely prevent the unit from reaching the pressure setting in both open and close functions. The relief valve cartridges (c17 and c18) are located on the rotary joint assembly (CG) in blocks (bs24) that are attached to the spindle (CA). Access to this area is through the upper side plates of the crusher main frame. The relief valve adjustment screws (ma14) are located beneath the plastic caps (FN). Before attempting to adjust the relief setting, please check that the relief valve cartridge has not loosened in the block. Procedure Install 5,000 psi (350 bar) 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 rotary manifold to check for failed seals.

51

REPAIR REPAIR OF ROTARY JOINT ASSEMBLY ROTATING STYLE

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.

REPLACEMENT OF THE SEALS IN THE ROTARY JOINT

Tools needed: 19mm & 22mm open end wrenches 41mm & 46mm open end wrenches External snap ring pliers

The jaw of the crusher should be closed and the frame supported or pinned to prevent rotation during repair. Here, the shipping pins are inserted to lock the rotation.

Figure 1

52

REPAIR REPLACEMENT OF THE SEALS IN THE ROTARY JOINT Step 1 Remove the rotation hoses at the holding valve (top center of figure 1), see page 51. 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 to the top bracket (AO) from the “Spindle Case” (BZ), they will be used to help lift it off the “Spindle” (CA). Do not disturb the elbow fittings (CF) in the “Spindle Case” (BZ). Step 2 (Figure 2) Remove the snap ring (AJ) and washer (U) from the top of the swivel assembly. Pull the “Spindle Case” (BZ) off the “Spindle” (CA) (the hoses can be used for this).

Figure 2

AO Hoses to the top bracket BZ Spindle case CA Spindle CF Elbow fittings AJ Snap ring U Washer

53

REPAIR REPLACEMENT OF THE SEALS IN THE ROTARY JOINT Step 3 (Figure 3) Inspection: Visually inspect the sealing surfaces (120) of the spindle (CA) for damage, which may hamper the ability of the o-rings to seal. Polishing the surface may clean up light scratching. If heavy galling is found, replace the spindle. Heavy scratching or galling may indicate rotator-bearing play. Step 4 (Figure 4) 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 (118) in the “Spindle Case” (BZ) for burrs or scoring damage. Light polishing or honing may be required.

Figure 3

Figure 4

54

REPAIR REPLACEMENT OF THE SEALS IN THE ROTARY JOINT Step 5 (Figure 5) Install the back-up rings (SS) first, taking care not to crimp or fold the back-up rings (SS). Install the o-rings (RR). Lubricate the o-rings (RR) and back-up rings (SS) with grease. Lubricate the spindle (CA). Please refer to Figure 5 for o-ring (RR) and back-up ring (SS) placement. Slide the “Spindle Case” (BZ) over the “Spindle” (CA). Install the washer (U) and snap ring (AJ). Install the hoses and fittings removed.

Figure 5

55

REPAIR ROTATION BEARING OUTER DIRT SEAL REPLACEMENT

DIRT SEAL PART NO. SLEWING RING PART NO.

25309273 25309270, 25309550, 25309660, 25309670

25309283 25309280

25309353 25309350, 25309680

25309843 25309840 Additional items needed: High Strength Adhesive Brake Clean/Solvent

1. Remove old seal (QQ) from the bottom side (72) of the slewing ring (BT).

2. Thoroughly clean oil, grease, and dirt from the seal groove (25) and surrounding areas.

3. Clean groove (25) with brake clean and allow time to dry completely.

4. Apply small amount of super glue into the groove and install one end of seal (QQ). Take care not to get super glue on the lower lip of the seal.

5. Insert seal (QQ) into groove and work around the bearing applying a small amount of super glue every 12 in / 300 mm. Take care not to stretch seal as it is being installed around the bearing.

6. Cut excess seal material as you get back around to the other end so seal will butt against itself tightly. Apply super glue to groove and end of seal to make it one continuous ring.

56

CRUSHER RELIEF LOCATIONS

Relief valves for the “U” Series and the G30JR Crushers are located below the rotary joint (on rotator models) and below the joint assembly on fixed units. The reliefs are accessed through the same inspection plates on all models.

RELIEF VALVE LOCATION (c17, c18) J UNITS

RELIEF VALVE LOCATION (c17, c18) JR UNITS

The relief valves (c17) for the G7, G18J and the G26J Crushers are mounted on the cylinder boosters (c11).

Before attempting to adjust the relief pressures of a NPK crusher, the carrier circuit relief setting must be checked. The circuit relief setting must be at least 200 psi above the crusher relief (operating) pressure. The test ports on the NPK stop valves are used for checking the carrier relief settings and to test and set the crusher reliefs. Refer to the Hydraulic Installation section of the U-Series Secondary Concrete Crusher Operation and Maintenance Manual.

Models

Minimum Carrier Circuit Relief

Crusher Relief Setting

Oil Flow

psi (bar) psi (bar) gpm (l/m) U21J & U21JR 3,971 (274) 3,771 (260) 26 – 53 (98 – 200) U31J & U31JR 4,261 (294) 4,061 (280) 26 – 66 (98 – 250) U45J & U45JR 4,550 (314) 4,350 (300) 46 – 73 (175 – 275)

G7 3,200 (220) 3,000 (206) 13 – 21 (49 – 80) G18J 3,900 (269) 3,700 (255) 26 – 52 (98 – 197)

G26J – G30JR 4,200 (290) 4,000 (275) 26 – 66 (98 – 250)

57

U31 CONVERSION TO ROTATION

U Washer AF Hex head cap screw CI Hex nut CJ Subplate CK Joint assembly OO Socket head cap screw 60 Disconnect Existing Hoses

U Washer AR Cap BT Slewing ring CF Elbow CG Rotary joint assembly CH Top plate DD Swivel elbow m19 Top bracket component pkg. OO Socket head cap screw RR O-ring S Lock plate 61 Torque to 530 ft. lbs. (Lubricated) 62 Torque to 225 ft. lbs. (Use medium strength Loctite) 63 Torque to 93 ft. lbs. (Use medium strength Loctite) 64 Torque to 80 ft. lbs. (Lubricated) 65 Reconnect existing hoses

58

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). 1. LOSS OF POWER

NPK Crusher and Material Processor jaw crushing/cutting forces are determined by operating pressure settings and NPK pressure intensifier performance.

2. LOSS OF CYCLE SPEED NPK Crusher and Material Processor cycle speed is determined by oil flow to the unit. The installation circuit must be set to provide the correct flow.

DETERMINE THE CAUSE OF THE PROBLEM Technical problems are caused by either (1) the NPK Crusher or (2) the hydraulic system (carrier hydraulics or installation kit). Checking the hydraulic pressure and flow will determine if the problem is in the Crusher or the carrier. If the pressures and flow available to the Crusher are correct, the problem is in the Crusher.

59

TROUBLESHOOTING

LOSS OF POWER Loss of power can be caused by low carrier relief valve setting or low Crusher relief valve setting. Verify correct relief valve settings of the carrier and the Crusher, see troubleshooting chart Fig. 1 and pressure measuring procedure on page 60. If the relief valve pressures are to specification, proceed to troubleshooting chart Fig. 5 and the Intensifier operation section on page 63.

Fig. 1 TROUBLESHOOTING CHART

RELIEF VALVE CHECKING AND SETTING

60

TROUBLESHOOTING

LOSS OF POWER MEASURING OPERATING PRESSURES Tools and Equipment required: Pressure gauge – 5,000 psi (350 bar) Test port adapter – to fit #4 SAE female port in NPK shut-off valve Test hose – rated for 5,000 psi (350 bar)

RELIEF VALVE CHECKING AND SETTING PROCEDURE NPK Installation kits provide shut-off valves (k4) with test ports in both the jaw open and jaw close hydraulic lines. Install pressure test hoses in both test ports as shown in Fig 2.

A) CIRCUIT RELIEF VALVE Verify that the crusher (BV) is being supplied with the required pressure:

1. Install 0 – 5,000 psi (350 bar) pressure gauge in #4 SAE test port located in both shut-off valves at the end of the stick.

2. Turn shut-off valve (k4) to the “OFF” position.

3. Start machine. Set throttle position to full. Actuate hydraulic circuit to close jaw.

4. Pressure reading P3 at gauge should be at least 200 psi (14 bar) more than P2 on Fig. 4 chart, see page 61.

*NOTE: If pressure is less than relief shown on Fig. 4 chart, page 61, reset accordingly.

B) CRUSHER RELIEF VALVE After the Crusher circuit has been verified, check the Crusher relief valves settings: 1. With 0 – 5,000 psi (350 bar) gauge installed on both left (close) and right (open)

sides of the stick, open shut-off valves. 2. Start machine. Set throttle at full RPM and close jaw completely and hold for 10

seconds. Check psi (bar) on gauge and compare to P2 on Fig. 4 chart, page 61. Set relief on Crusher accordingly.

3. The booster will start to click. Depending on oil temperature, the booster will continue to click slowly compensating internal leaking in the main cylinder. This is normal.

4. If intensifier is clicking rapidly, pressure may not reach relief setting due to severe intensifier or cylinder leakage.

5. Open Crusher jaw to fully open position, hold for 10 seconds. Check psi (bar) on gauge and compare to Fig. 4 chart, page 61. Set relief on Crusher accordingly.

Fig. 2

61

TROUBLESHOOTING

LOSS OF POWER PRESSURE INTENSIFIER SEQUENCE VALVE AND RELIEF VALVE ACTUATION Close the jaws, without material in them. When the jaw cylinder is fully stroked, the load pressure (pr) rises until it reaches the sequence valve setting (P1), the oil is then diverted to the pressure intensifier. The load pressure momentarily (mo) levels off at the sequence valve pressure then rises to the Crusher relief valve setting (P2). The excavator relief valve acts only as a safety relief, and must be set a minimum of 200 psi (P3) above the NPK relief valve setting (P2) shown below.

Fig. 3 RELIEF VALVE AND SEQUENCE ACTUATION

Note: Do not adjust sequence valve setting. Factory preset.

MODEL

SERIAL NO.

P1 Crusher Sequence

Valve Setting

P2 Crusher Relief Valve Setting

P3 Excavator Relief

Valve Setting (min.)

psi bar psi bar psi bar U21J ALL 2990 210 3700 260 4000 275 U21JR ALL 2990 210 3700 260 4000 275 U31J ALL 2990 210 3980 280 4250 295 U31JR ALL 2990 210 3980 280 4250 295 U45J ALL 2990 210 4260 300 4480 315 U45JR ALL 2990 210 4260 300 4480 315 G7 ALL 1420 100 2990 210 3200 225 G18J ALL 2990 210 3700 260 3900 275 G26J 37451 – 39569 2600 180 3625 250 3850 265 40780 and up 3000 210 4000 280 4200 295 G30JR ALL 2990 210 3980 280 4200 295

Fig. 4 RELIEF VALVE AND SEQUENCE VALVE SETTINGS

pr = PRESSURE (PSI) ti = TIME (1-2 SEC) mo = MOMENTARILY

62

TROUBLESHOOTING

LOSS OF POWER

RELIEF VALVE LOCATION The Crusher relief cartridge (c17) close, (c18) open is located in the relief block that is bolted to the swivel base on JR (rotating units) and in the blocks bolted to the joint adapter block on J units.

RELIEF VALVE (c17, c18) LOCATION (J UNITS)

RELIEF VALVE (c17, c18) LOCATION (JR UNITS)

RELIEF VALVE (c17) LOCATION, CYLINDER (c11) MOUNTED (G7, G18J, G26J)

63

TROUBLESHOOTING

LOSS OF POWER

Fig. 5 TROUBLESHOOTING CHART PRESSURE INTENSIFIER / SEQUENCE VALVE

64

TROUBLESHOOTING

LOSS OF POWER PRESSURE INTENSIFIER OPERATION NPK’s exclusive pressure intensifier system is used in NPK Crushers and Material Processors to boost cylinder pressure to increase the jaw closing forces. When the intensifier is working properly, a rapid clicking sound will be heard, indicating the pressure intensifier is actuated, as the jaws begin to close against resistance. As the 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. PRESSURE INTENSIFIER (c14), MAIN VALVE (c15) AND SEQUENCE VALVE (c16) The main valve assembly and the sequence valve are located on the pressure intensifier assembly.

65

TROUBLESHOOTING

LOSS OF POWER

RAPID CONTINUOUS CLICKING IS HEARD AND THE MATERIAL IS NOT BEING BROKEN AS EXPECTED This indicates that a problem is not a relief valve or sequence valve setting, but in the intensifier or the cylinder of the Crusher. This requires further investigation by a mechanic/technician, see chart Fig. 5, page 63.

CHECKING BOOSTED PRESSURE

EXTREMELY HIGH PRESSURE OIL!

NPK gauge assembly, 0 – 15,000 psi (0 – 1,000 bar) P/N L017-8000 is available to directly check the boosted pressure on all Crushers and Material Processors. These units have three test ports on the intensifier assembly as shown below.

L017-8000 GAUGE ASSEMBLY fm4 L017-4020 Gauge

0 – 15,000 psi (0 – 1,000 bar) CD K023-6690 Male Adapter CB L007-6630 Female Swivel Adapter

1. Remove a plug from one of the test ports and install adapter (CD). Choose the port that will give you gauge clearance and best viewing.

2. Install adapter (CB) onto gauge (fm4). Use thread sealant.

3. Install gauge onto adapter (CD).

4. Close jaw all the way. Pressure will rise to the point where intensification starts (P1 on Fig 3, see page 61) and then go up to full boosted pressure of approximately 12,000+ psi. When the clicking of the booster slows, the booster is 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 intensifier or Crusher cylinder.

5. Open jaw all the way. You will now read the relief setting of the jaw open circuit. Note that the booster only works on jaw close. Jaw open sees Crusher relief or carrier circuit relief pressure, whichever is lower.

NOTE: IF ADDITIONAL ASSISTANCE IS REQUIRED, CALL NPK SERVICE DEPARTMENT AT 1-800-225-4379.

66

TROUBLESHOOTING

SLOW CYCLE SPEED

The specified cycle times of the Crusher are controlled by the flow provided by the circuit of the carrier. The published cycle times of the Crusher are a direct result of the maximum published oil flow, see CRUSHER SPECIFICATIONS section of instruction manual. Note: If jaws will not open or close, be sure right and left shut-off blocks are open.

Tools and Equipment required: Pressure gauge – 5,000 psi (345 bar) Test port adapter – to fit #4 SAE female port in shut-off valve Test hose – rated for 5,000 psi (345 bar) Flow meter – Pressure loading type, 60 gpm min. capacity

Procedure Install pressure gauge in test port located in shut-off valve and follow the procedure on page 67 and the flow chart Fig. 6 below:

Fig. 6 TROUBLESHOOTING CHART

SLOW CYCLE SPEED

67

TROUBLESHOOTING

SLOW CYCLE SPEED

CHECKING THE HYDRAULIC FLOW AT RATED PRESSURE 1. Installation of a Flow Meter Equipped with Pressure Loading Valve. Install the flow meter between the crusher close line and crusher open line as shown

below.

Typically, the jaw close line (CE) is on the left and the jaw open is on the right.

2. Determine Return Line Pressure (Pressure Drop). Open both stop valves and press the Crusher foot switch. 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 the flow and pressure with the flow meter (t36). 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 crusher close foot switch. Turn in the loading valve knob and record the pressure and flow at regular intervals on graph paper. Record pressure on one axis of the graph and flow on the other. Increase pressure until relief setting is reached. This is the circuit flow chart. Refer to CRUSHER SPECIFICATIONS section of instruction manual for correct flow at 1,000 psi (70 bar) pressure.

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

and close the shut-off valves on carrier. 2. Cap the bulkheads (#20 JIC caps). 3. If the jaw drifts, the problem is in the cylinder, intensifier pilot checks or internal

leakage in rotary joint. If no drift occurs, then the problem is in the carrier’s main control valve. Drift due to main control valve internal leakage may be inherent to the carrier and may not be solvable.

68

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 *RELIEF SETTING

gpm lpm psi (bar)

U21JR 6.5 – 10 rpm 2.5 – 4 gpm 10 – 15 lpm 3,000 (205)

U31JR 6.5 – 10 rpm 2.5 – 4 gpm 10 – 15 lpm 3,000 (205)

U45JR 6 – 9 rpm 5 – 8 gpm 20 – 30 lpm 3,000 (205)

G30JR 6 – 9 rpm 2.5 – 4 gpm 10 – 15 lpm 3,000 (205)

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

Flows are checked at a nominal operating pressure of 1000 psi (70 bar). 2000 psi (138 bar) cross port reliefs are included in the attachment rotation circuit. The *relief listed above is only necessary to protect the rotation supply componentry.

Excessive rotation speed will result in damage to the motor, gearbox, and bearing. UNIT WILL NOT ROTATE 1. Check the rotation circuit hydraulic flow, see above chart. 2. If flow is within specification, 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 (138

bar). 5. If 2,000 psi (138 bar) is not achieved, adjust relief valve cartridges (c17, c18) on the

rotation holding valve (BO), see below. 6. If pinion is broken from motor shaft.

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.

69

FASTENER TORQUE (U SERIES) This torque chart is to be used with the specific Crusher Parts Manual for the unit being repaired. Torques for the booster fasteners are found in the Hydraulic Booster Service Manual. All fasteners will be either lubed or use medium strength thread adhesive as indicated.

PIVOT PIN BOLT – CYLINDER TO MOVEABLE JAW TORQUE ADHESIVE or

MODEL BOLT ft/lb Nm LUBED U21J/JR M16 260 350 LUBED U31J/JR M16 260 350 LUBED U45J/JR M18 330 450 LUBED

PIVOT PIN BOLT – MOVEABLE JAW PIVOT TORQUE ADHESIVE or

MODEL BOLT ft/lb Nm LUBED U21J/JR M16 LUBED U31J/JR M16 260 350 LUBED U45J/JR M16 260 350 LUBED

CYLINDER PIVOT FLANGE BOLT TORQUE ADHESIVE or


CUTTING BLADE BOLT TORQUE ADHESIVE or


TOOTH PLATE TO MOVEABLE JAW TORQUE ADHESIVE or

MODEL BOLT ft/lb Nm LUBED U21J/JR M20 480 650 ADHESIVE U31J/JR M24 775 1050 ADHESIVE U45J/JR M24 775 1050 ADHESIVE

70

FASTENER TORQUE (U SERIES) CYLINDER CAP BOLTS

TORQUE ADHESIVE orMODEL BOLT ft/lb Nm LUBED U21J/JR M18 260 350 LUBED U31J/JR M20 365 500 LUBED U45J/JR M20 365 500 LUBED

CYLINDER ROD NUT TORQUE ADHESIVE or


CYLINDER ROD COVER PLATE BOLT(S)

TORQUE ADHESIVE orMODEL BOLT ft/lb Nm LUBED U21J/JR M24 640 870 ADHESIVE U31J/JR M30 400 550 ADHESIVE U45J/JR M30 400 550 ADHESIVE

NYLON GUIDE PLATE BOLTS TORQUE ADHESIVE or


GUIDE PLATE COVER TO CYLINDER BOLTS TORQUE ADHESIVE or


BOOSTER ASSEMBLY TO CYLINDER BOLTS

TORQUE ADHESIVE orMODEL BOLT ft/lb Nm LUBED U21J/JR M16 225 300 ADHESIVE U31J/JR M16 225 300 ADHESIVE U45J/JR M18 260 350 ADHESIVE

71

FASTENER TORQUE (U SERIES)

THE FOLLOWING TORQUES APPLY TO ROTATING CRUSHERS (JR) ONLY.

CRUSHER FRAME AND TOP BRACKET TO ROTATING BEARING BOLTS TORQUE ADHESIVE or

MODEL BOLT ft/lb Nm LUBED U21JR M24 700 950 LUBED U31JR M24 775 1050 LUBED U45JR M24 775 1050 LUBED

“ M27 1035 1400 LUBED

ROTATOR MOTOR TO TOP BRACKET BOLTS TORQUE ADHESIVE or

MODEL BOLT ft/lb Nm LUBED U21JR M16 260 350 ADHESIVE U31JR M16 260 350 ADHESIVE U45JR M16 260 350 ADHESIVE

MOTOR GEAR TO MOTOR BOLT TORQUE ADHESIVE or


COUNTER BALANCE VALVE PLATE TO TOP BRACKET BOLTS TORQUE ADHESIVE or

MODEL BOLT ft/lb Nm LUBED U21JR M12 95 130 LUBED U31JR M12 95 130 LUBED U45JR M12 95 130 LUBED

ROTARY JOINT ASSEMBLY TO CRUSHER FRAME BOLTS TORQUE ADHESIVE or


RELIEF VALVE BLOCK TO ROTARY JOINT BOLTS TORQUE ADHESIVE or

MODEL BOLT ft/lb Nm LUBED U21JR 10MM 45 60 LUBED U31JR 10MM 45 60 LUBED U45JR 10MM 45 60 LUBED

FLANGE ADAPTOR TO ROTARY JOINT BOLTS TORQUE ADHESIVE or

MODEL BOLT ft/lb Nm LUBED U21JR 12MM 80 105 LUBED U31JR 12MM 80 105 LUBED U45JR 12MM 80 105 LUBED

72

FASTENER TORQUE (G SERIES) This torque chart is to be used with the specific Crusher Parts Manual for the unit being repaired. Torques for the booster fasteners are found in the Hydraulic Booster Service Manual. All fasteners will be either lubed or use high strength thread adhesive as indicated.

PIVOT PIN BOLT – CYLINDER TO MOVEABLE JAW TORQUE ADHESIVE or

MODEL BOLT ft/lb Nm LUBED G7 M16 190 255 LUBED G18J M16 260 350 LUBED G26J M16 190 255 LUBED G30JR M16 260 350 LUBED

PIVOT PIN BOLT – MOVEABLE JAW PIVOT

TORQUE ADHESIVE or MODEL BOLT ft/lb Nm LUBED G7 M12 80 105 LUBED G18J M16 260 350 LUBED G26J M16 190 255 LUBED G30JR M16 260 350 LUBED

CYLINDER PIVOT FLANGE BOLT

TORQUE ADHESIVE or MODEL BOLT ft/lb Nm LUBED G7 M14 120 165 LUBED G18J M18 260 350 LUBED G26J M20 365 500 LUBED G30JR M20 480 650 LUBED

JOINT ADAPTOR BOLT

TORQUE ADHESIVE or MODEL BOLT ft/lb Nm LUBED G7 M12 93 125 ADHESIVE G18J M16 205 280 ADHESIVE G26J M12 93 125 ADHESIVE G30JR M12 80 110 ADHESIVE

CUTTING BLADE BOLT TORQUE ADHESIVE or

MODEL BOLT ft/lb Nm LUBED G7 M14 120 165 LUBED G18J M16 260 350 LUBED G26J M16 190 255 LUBED G30JR M16 260 350 LUBED

73

FASTENER TORQUE (G SERIES) TOOTH PLATE TO MOVEABLE JAW

TORQUE ADHESIVE orMODEL BOLT ft/lb Nm LUBED G7 -- -- -- -- G18J M20 480 650 ADHESIVE G26J M24 640 870 ADHESIVE G30JR M24 700 950 ADHESIVE

NOTE: “G” CRUSHERS THAT HAVE A “J” IN THE MODEL DESIGNATION HAVE TOOTH PLATES THAT BOLT TO THE MOVEABLE JAW.

CYLINDER CAP BOLTS TORQUE ADHESIVE or

MODEL BOLT ft/lb Nm LUBED G7 M16 190 255 LUBED G18J M18 260 350 LUBED G18J M20 365 500 LUBED G26J M18 260 350 LUBED G26J M20 365 500 LUBED G26J M22 400 550 LUBED G30JR M20 365 500 LUBED

NOTE: MEASURE BOLT SIZE ON G18J and G26J, AS SEVERAL DIFFERENT BOLT SIZES HAVE BEEN USED.

CYLINDER ROD NUT

TORQUE ADHESIVE orMODEL BOLT ft/lb Nm LUBED G7 M45 1400 1900 ADHESIVE G18J M65 3200 4400 ADHESIVE G26J M70 4100 5500 ADHESIVE G30JR M70 4100 5500 ADHESIVE

CYLINDER ROD COVER PLATE BOLT(S)


74

FASTENER TORQUE (G SERIES) NYLON GUIDE PLATE BOLTS


GUIDE PLATE COVER TO CYLINDER BOLTS TORQUE ADHESIVE or

MODEL BOLT ft/lb Nm LUBED G7 M12 93 125 ADHESIVE G18J M16 205 280 ADHESIVE G26J M16 190 255 ADHESIVE G30JR M16 260 350 ADHESIVE

BOOSTER ASSEMBLY TO CYLINDER BOLTS TORQUE ADHESIVE or

MODEL BOLT ft/lb Nm LUBED G7 M14 145 200 ADHESIVE G18J M16 225 300 ADHESIVE G26J M16 225 300 ADHESIVE G30JR M16 225 300 ADHESIVE

MANIFOLD BLOCK TO CYLINDER BOLTS TORQUE ADHESIVE or

MODEL BOLT ft/lb Nm LUBED G7 -- -- -- -- G18J M12 93 125 ADHESIVE G26J M12 93 125 ADHESIVE G30JR M12 93 125 ADHESIVE

75

FASTENER TORQUE (G SERIES) THE FOLLOWING TORQUES APPLY TO ROTATING CRUSHERS ONLY.

CRUSHER FRAME AND TOP BRACKET TO ROTATING BEARING BOLTS

TORQUE ADHESIVE orMODEL BOLT ft/lb Nm LUBED G30JR M24 700 950 ADHESIVE

ROTATOR MOTOR TO TOP BRACKET BOLTS TORQUE ADHESIVE or

MODEL BOLT ft/lb Nm LUBED G30JR M16 260 350 ADHESIVE

MOTOR GEAR TO MOTOR BOLT TORQUE ADHESIVE or

MODEL BOLT ft/lb Nm LUBED G30JR M12 93 125 ADHESIVE

COUNTER BALANCE VALVE PLATE TO TOP BRACKET BOLTS TORQUE ADHESIVE or

MODEL BOLT ft/lb Nm LUBED G30JR M12 95 130 LUBED

ROTARY JOINT ASSEMBLY TO CRUSHER FRAME BOLTS

TORQUE ADHESIVE orMODEL BOLT ft/lb Nm LUBED G30JR M16 260 350 ADHESIVE

RELIEF VALVE BLOCK TO ROTARY JOINT BOLTS TORQUE ADHESIVE or


FLANGE ADAPTOR TO ROTARY JOINT BOLTS TORQUE ADHESIVE or


76

SERIAL NUMBER LOCATION

Serial Number location (sn1)

77



78



79

WARRANTY STATEMENTS

80

WARRANTY STATEMENTS

81

STORAGE OF CRUSHER When the CRUSHER is removed from the excavator: Keep the piston rod drawn in (jaw open). Make sure the hydraulic hoses are plugged and stick tubes capped. Grease all lubrication points, see INSPECTION AND MAINTENANCE section of the

instruction manual. If stored outdoors, cover with waterproof tarp.

AR Stick tube must be capped. AS The whip hoses must be plugged. BD The jaw is open. c3 The cylinder rod must be retracted.

© Copyright 2012 NPK Construction Equipment, Inc. www.npkce.com U000-9600A 11-12 U and G Series Crushers Operation Manual

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U and G-SERIES SECONDARY CONCRETE CRUSHERS€¦ · U and G Series Crushers Operation Manual 7550 Independence Drive Walton Hills, OH 44146-5541 ... repair or troubleshoot the CONCRETE