NPK M35G User manual

MATERIAL PROCESSOR
INSTRUCTION MANUAL
MODELS:
M35G
M35K
M35S
“Use Genuine NPK Parts”
7550 Independence Drive
Walton Hills, OH 44146-5541
Phone [phone]
Toll-free [phone]
Fax [phone]
© Copyright 2018 NPK Construction Equipment, Inc. www.npkce.com M000-9601B M35 Material
Processor Instruction Manual 10-18

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CONTENTS
SAFETY .................................................................................................................................................... 4
OPERATION ............................................................................................................................................. 5
MAINTENANCE ........................................................................................................................................ 6
INTRODUCTION ....................................................................................................................................... 8
EXCAVATOR COMPATIBILITY ................................................................................................................. 8
M-SERIES SPECIFICATIONS ................................................................................................................... 9
M35G MATERIAL PROCESSOR ............................................................................................................... 9
M35K MATERIAL PROCESSOR ............................................................................................................... 10
M35S MATERIAL PROCESSOR ............................................................................................................... 11
K JAW CUTTING CAPACITY .................................................................................................................... 12
SERIAL NUMBER LOCATION .................................................................................................................. 13
JAW SET IDENTIFICATION ...................................................................................................................... 14
PROCESSOR BOOSTER & CYLINDER .................................................................................................... 17
INTRODUCTION ....................................................................................................................................... 17
STRUCTURE OF THE BOOSTED CYLINDER .......................................................................................... 18
OPERATING PRINCIPLE .......................................................................................................................... 19
HYDRAULIC INSTALLATION .................................................................................................................... 26
HYDRAULIC KITS ..................................................................................................................................... 26
FLOW DIRECTION ................................................................................................................................... 26
SHUT-OFF VALVES.................................................................................................................................. 26
TEST PORT LOCATIONS ......................................................................................................................... 27
PREVENTION OF CONTAMINATION ....................................................................................................... 28
HYDRAULIC QUICK DISCONNECTS ....................................................................................................... 29
MOUNTING INSTALLATION ..................................................................................................................... 31
M35 SERIES TOP BRACKET .................................................................................................................... 31
MOUNTING TO THE CARRIER ................................................................................................................ 32
REMOVAL FROM THE CARRIER ............................................................................................................. 32
STORAGE OF THE M35 MATERIAL PROCESSOR .................................................................................. 33
HOSE INSTALLATION .............................................................................................................................. 34
WHIP HOSE INSTALLATION TIPS ........................................................................................................... 34
OPERATING INSTRUCTIONS .................................................................................................................. 36
OPERATING TECHNIQUES AND PRECAUTIONS ................................................................................... 40
GENERAL MAINTENANCE ....................................................................................................................... 42
DAILY INSPECTION AND MAINTENANCE ............................................................................................... 42
LUBRICATION POINTS ............................................................................................................................ 43
HOSE INSTALLATION TIPS ..................................................................................................................... 44
CUTTER BLADE MAINTENANCE ............................................................................................................. 46
G and S JAWS ........................................................................................................................... 46
M35K JAW MAINTENANCE ...................................................................................................................... 48
DAILY MAINTENANCE .............................................................................................................. 48
CUTTER BLADE MAINTENANCE ............................................................................................................. 49
K JAWS ...................................................................................................................................... 49
K JAW BLADE SET UP PROCEDURE ...................................................................................................... 50
M35K ......................................................................................................................................... 50
COMPONENT DESCRIPTION .................................................................................................................. 51
M35K ......................................................................................................................................... 51
K JAW BLADE MAINTENANCE AND ADJUSTMENT ................................................................................ 52
PIERCING TIP MAINTENANCE AND REPLACEMENT ............................................................................. 59
MAINTENANCE ......................................................................................................................... 59
JAW INSPECTION AND MAINTENANCE.................................................................................................. 60
JAW INSPECTION: G and S JAWS .......................................................................................................... 60
WEEKLY INSPECTION .............................................................................................................. 60
JAW PROFILES: G and S JAWS .............................................................................................................. 60
JAW BUILD-UP AND HARDFACING (M35S) ............................................................................................ 60
TEETH BUILD-UP AND HARDFACING (M35G) ........................................................................................ 61
REPLACEABLE TOOTH PLATES – G JAWS ............................................................................................ 62
JAW AND TOOTH REBUILD PROCEDURE: S and G JAWS ................................................................... 62

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CONTENTS
JAW CONTACT AREAS ............................................................................................................................ 65
S and G JAW CONTACT AREAS ............................................................................................... 65
FRAME MAINTENANCE ........................................................................................................................... 66
REPAIR OF MAIN FRAME ........................................................................................................................ 66
ROUTINE WELD REPAIR .......................................................................................................... 66
INSPECTION AND MAINTENANCE .......................................................................................................... 68
BOOSTER CYLINDER .............................................................................................................................. 68
DISASSEMBLY .......................................................................................................................... 68
INSPECTING AND CLEANING CYLINDER COMPONENTS ..................................................................... 71
SUGGESTED REPAIR TOOLS AND EQUIPMENT ................................................................................... 73
JAW SET INTERCHANGE ........................................................................................................................ 78
TOOLS AND SUPPLIES............................................................................................................................ 78
JAW SET INTERCHANGE ........................................................................................................................ 79
PROCEDURE FOR JAW SET INTERCHANGE ......................................................................................... 79
UNIT POSITIONING .................................................................................................................................. 79
DETACHMENT OF THE EYE AND FORKED JAWS FROM THE CYLINDER SUB-ASSEMBLIES ............. 79
REMOVAL OF THE JAW SET ASSEMBLY FROM THE MAIN FRAME ..................................................... 80
JAW SET STORAGE................................................................................................................................. 81
JAW SET INSTALLATION INTO THE MAIN FRAME ................................................................................. 82
SLEWING RING INSPECTION AND MAINTENANCE ............................................................................... 83
MEASURING MAXIMUM AXIAL MOVEMENT ........................................................................................... 83
SWIVEL MANIFOLD MAINTENANCE ....................................................................................................... 84
SWIVEL MANIFOLD ASSEMBLY .............................................................................................................. 84
LEAKAGE OF THE SEALS ....................................................................................................................... 84
TESTING THE SWIVEL SEALS FOR INTERNAL LEAKAGE ..................................................................... 85
TEST PROCEDURE.................................................................................................................................. 85
REPLACEMENT OF THE SEALS IN THE SWIVEL ................................................................................... 86
FASTENER TORQUE SPECIFICATIONS ................................................................................................. 90
HOSE TORQUE SPECIFICATIONS .......................................................................................................... 92
TROUBLESHOOTING ............................................................................................................................... 93
DETERMINE THE TYPE OF PROBLEM ................................................................................................... 93
DETERMINE THE CAUSE OF THE PROBLEM ......................................................................................... 93
LOSS OF POWER .................................................................................................................................... 93
TROUBLESHOOTING GUIDE FOR LOW POWER ................................................................................... 94
RELIEF VALVE CHECKS ........................................................................................................... 94
MEASURING OPERATING PRESSURES ................................................................................................. 96
RELIEF VALVE CHECKING AND SETTING PROCEDURE ...................................................................... 96
PRESSURE INTENSIFIER SEQUENCE VALVE AND RELIEF VALVE ACTUATION ................................. 98
M35 MATERIAL PROCESSOR RELIEF VALVE AND CARRIER RELIEF VALVE SETTINGS.................... 99
RELIEF VALVE LOCATION....................................................................................................................... 99
PRESSURE INTENSIFIER OPERATION .................................................................................................. 102
PRESSURE INTENSIFIER (BOOSTER) .................................................................................................... 102
RAPID CONTINUOUS CLICKING IS HEARD AND THE MATERIAL IS NOT BEING
CRUSHED/SHEARED AS EXPECTED ............................................................................................... 102
CHECKING BOOSTED PRESSURE ......................................................................................................... 103
SLOW CYCLE SPEED .............................................................................................................................. 104
TEST PROCEDURE.................................................................................................................................. 104
CHECKING THE HYDRAULIC FLOW AT RATED PRESSURE ................................................................. 106
JAW DRIFT ............................................................................................................................................... 108
TO DETERMINE IF THE JAW DRIFT IS WITH THE M35 MATERIAL PROCESSOR OR THE CARRIER .. 108
ROTATION ................................................................................................................................................ 109
KEYWORDS FOR COMMON M35 PROCESSOR COMPONENTS ........................................................... 112
KEYWORDS FOR COMMON M35 PROCESSOR “K” JAW COMPONENTS ............................................. 113
KEYWORDS FOR COMMON M35 PROCESSOR CYLINDER COMPONENTS ......................................... 114
WARRANTY STATEMENTS ..................................................................................................................... 115
NOTES...................................................................................................................................................... 117
SERVICE RECORD .................................................................................................................................. 117

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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
(part number H100-7210) must be installed in the cab, visible
to the operator.
WARNING – STAY CLEAR decal (part number H100-7200)
is 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. Install metal or plastic plugs/caps where applicable to prevent entry
of debris into the hydraulic system.
 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.
Never apply uncured thread adhesive to a fastener that has cured adhesive on it.
Clean the fastener and the threaded bore. A tap and die may be helpful for this task.
Be sure to remove loose debris from the threaded bore.
 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

- 8 -
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.
The purpose of this manual is to provide you with information and instructions required
to properly operate and maintain the M35 MATERIAL PROCESSOR. This will result in
maximum ATTACHMENT reliability and productivity.
Read this manual thoroughly before attempting to operate, remove, disassemble,
repair, or troubleshoot the MATERIAL PROCESSOR or any of its components. For
additional information or help with any problem encountered, please contact your
authorized NPK dealer.
Follow all the safety precautions contained in this manual. Failure to follow safety
precautions can result in death, personal injury, injury to others and property
damage.
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.
EXCAVATOR 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 MATERIAL PROCESSOR that is too heavy for the carrier can be dangerous
and damage the carrier. Verify carrier stability with the MATERIAL PROCESSOR
before transport or operation.
Mounting a MATERIAL PROCESSOR that is too small for the carrier can damage the
MATERIAL PROCESSOR and void Warranties. Please consult NPK Service or
Engineering for specific detailed information.
PROCESSOR
RECOMMENDED CARRIER WEIGHT RANGE
MODEL
3rd member mounting
US ton
(Metric ton)
M35
30 - 40
(27 - 36)
Specifications subject to change without notice.

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M-SERIES SPECIFICATIONS
M35G MATERIAL PROCESSOR
MODEL
Weight
Maximum Jaw
Oil Flow
Cycle Time
Opening
seconds
lb.
(kg)
in.
(mm)
gpm
(lpm)
open
close
M35G
7,590
(3,450)
38.6
(981)
50-80
(190-300)
1.6
3.1
MODEL
Maximum
Crushing Force
Operating Pressure
at Tip
US
(Metric
psi
(bar)
Ton
Ton)
M35G
3,700
(255)
127
(115)
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 (69 bar).
*Maximum operating pressure is determined by reliefs in the crusher.

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M-SERIES SPECIFICATIONS
M35K MATERIAL PROCESSOR
MODEL
Weight
Maximum Jaw
Oil Flow
Cycle Time
Opening
seconds
lb.
(kg)
in.
(mm)
gpm
(lpm)
open
close
M35K
7,370
(3,350)
22
(559)
50-80
(190-300)
1.6
3.1
MODEL
Maximum
Crushing Force
Operating Pressure
at Tip
US
(Metric
psi
(bar)
Ton
Ton)
M35K
3,700
(255)
125
(113)
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 (69 bar).
*Maximum operating pressure is determined by reliefs in the crusher.

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M-SERIES SPECIFICATIONS
M35S MATERIAL PROCESSOR
MODEL
Weight
Maximum Jaw
Oil Flow
Cycle Time
Opening
seconds
lb.
(kg)
in.
(mm)
gpm
(lpm)
open
close
M35S
7,535
(3,425)
43
(1,092)
50-80
(190-300)
1.6
3.1
MODEL
Maximum
Crushing Force
Operating Pressure
at Tip
US
(Metric
psi
(bar)
Ton
Ton)
M35S
3,700
(255)
110
(100)
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 (69 bar).
*Maximum operating pressure is determined by reliefs in the crusher.

- 12 -
K JAW CUTTING CAPACITY
NOTE: Cutting capacities listed below are based on a single pass cut. Larger material
can be cut using multiple pass cuts.
APPETITE GUIDE: MILD STEEL
MODEL
A
B
C
D
in
(mm)
in
(mm)
in
(mm)
in
(mm)
M35K
16
(406)
16
(406)
5/8
(15.9)
5/8
(15.9)
MODEL
E
F
in
(mm)
in
(mm)
M35K
2-1/2
(63.5)
3/4
(19.1)

- 13 -
SERIAL NUMBER LOCATION
M35

- 14 -
JAW SET IDENTIFICATION
 G Jaw Set (Pulverizer/Secondary Concrete Crusher) for the downsizing of concrete
and the separation of concrete and rebar.

- 15 -
JAW SET IDENTIFICATION
 K Jaw Set (Shear) for the demolition of steel structures, such as buildings and
bridges, as well as for processing of scrap, including steel, wood, rubber and
plastics.

- 16 -
JAW SET IDENTIFICATION
 S Jaw Set (Primary Breaker) for the demolition of concrete pillars, buildings,
retaining walls, bridges, and highway barriers.
Jaw sets can easily be removed from and installed onto the Material Processor at the
job site, see the “JAW SET INTERCHANGE” section, page 78, of this manual.

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PROCESSOR BOOSTER & CYLINDER
INTRODUCTION
The hydraulic cylinders used on the NPK Material Processor are equipped with
hydraulic boosters. To close the jaws of the processor, hydraulic oil from the carrier is
directed to the base end of the cylinders, which extends the cylinder rods. Under no
load, no boost is applied and this results in a rapid cycle time as compared to large,
non-boosted cylinders.
When a load (material to be crushed or sheared) is encountered, the oil is directed into
the booster sections of the cylinders, 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 non-boosted 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 Material Processor. To open the jaws of the NPK Material
Processor, oil is directed to the rod end of the cylinder. This retracts the rod and pulls
the jaw open. No boost is provided in the jaw opening mode.
c11
Jaw Cylinder
c14
Booster Piston
c15
Main Valve Assembly
c17
Relief Valve (close)
c18
Relief Valve (open)
c44
Swivel Manifold
k2
Carrier Hydraulic Pump
k7
Carrier Control Valve

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PROCESSOR BOOSTER & CYLINDER
STRUCTURE OF THE BOOSTED CYLINDER
Fig. 1
For a complete breakdown of parts in the booster
cylinder assembly, see the parts manual for each
unit by serial number.
As shown in Fig. 1, the booster
cylinder consists of:
bs34
Inlet Check Valve
c11
Jaw Cylinder
c14
Booster Piston
c15
Main Valve Assembly
c17
Relief Valve (close)
c18
Relief Valve (open)
c19
Plunger
c20
Pilot Check Valve
Assembly
c21
Check Valve 1 - booster
piston inner "B"
c22
Check Valve 2 - booster
piston inner "A"
c23
Check Valve 3 - booster
sleeve "B"
c24
Check Valve 4 - booster
sleeve "A"
c25
Check Valve 5 - Return
c26
Port C1 Piston
c27
Port C2 Piston
c28
Port C3 Piston
c44
Swivel Manifold
c47
Small Plunger
k2
Carrier Hydraulic Pump
k7
Carrier Control Valve
v1
Oil Chamber - 1
v2
Oil Chamber - 2
v3
Oil Chamber - 3
v4
Oil Chamber - 4

- 19 -
PROCESSOR BOOSTER & CYLINDER
OPERATING PRINCIPLE
Fig. 2 CYLINDER EXTEND (NO LOAD)
When the cylinders (c11) are extended (jaw close)
and no load (material to be crushed or sheared) is
encountered, oil is directed from the carrier control
valve (k7) to the base end of the cylinders by way
of the pilot check valves (c20) in the booster
assemblies. When there is no load condition,
hydraulic pressure is low and no boosted pressure
is required.
c11
Jaw Cylinder
c20
Pilot Check Valve Assembly
k7
Carrier Control Valve

- 20 -
PROCESSOR BOOSTER & CYLINDER
OPERATING PRINCIPLE
Fig. 3 BOOSTER ACTUATION
When a load (material to be crushed or sheared) is
encountered on jaw close, the hydraulic pressure in
the booster unit starts to rise, which redirects the
hydraulic oil through the control valve (c15) of the
booster, then to the booster piston (c14). This
starts the boosting process. The booster piston is
double ended and provides boost in each direction
of booster piston travel.
c14
Booster Piston
c15
Main valve Assembly