NPK DG40 User manual

DEMOLITION GRAB

INSTRUCTION MANUAL

MODELS:

DG16

DG20

DG30

DG40

“Use Genuine NPK Parts”

7550 Independence Drive

Walton Hills, OH 44146-5541

Phone (440) 232-7900

Toll-free (800) 225-4379

Fax (440) 232-6294

DG16,DG20,DG30,DG40 Demolition Grab Instruction Manual 6-18

1

CONTENTS

CONTENTS .............................................................................................................................................. 1

SAFETY .................................................................................................................................................... 3

OPERATION ...................................................................................................................................... 4

MAINTENANCE ................................................................................................................................. 5

INTRODUCTION ....................................................................................................................................... 7

EXCAVATOR COMPATIBILITY ................................................................................................................. 7

SERIAL NUMBER LOCATION .................................................................................................................. 8

SPECIFICATIONS ..................................................................................................................................... 9

DG16 ................................................................................................................................................. 9

DG20 ................................................................................................................................................. 10

DG30 ................................................................................................................................................. 11

DG40 ................................................................................................................................................. 12

HYDRAULIC INSTALLATION .................................................................................................................... 13

HYDRAULIC LINES ........................................................................................................................... 13

SHUT-OFF VALVES .......................................................................................................................... 13

PORT CONNECTION DIAGRAM ....................................................................................................... 14

DEMOLITION GRAB HYDRAULIC CIRCUITS ........................................................................................... 15

MOUNTING INSTALLATION ..................................................................................................................... 18

MOUNTING TO THE EXCAVATOR ................................................................................................... 19

REMOVAL FROM THE CARRIER ..................................................................................................... 19

STORAGE OF DEMOLITION GRAB ......................................................................................................... 19

OPERATING INSTRUCTIONS .................................................................................................................. 20

OPERATING TECHNIQUES AND PRECAUTIONS............................................................................ 22

GENERAL MAINTENANCE ....................................................................................................................... 25

DAILY INSPECTION AND MAINTENANCE ....................................................................................... 25

ARM MAINTENANCE ........................................................................................................................ 26

FRAME MAINTENANCE .................................................................................................................... 26

FRAME CRACK REPAIR ................................................................................................................... 26

LUBRICATION POINTS ..................................................................................................................... 27

SLEWING RING INSPECTION AND MAINTENANCE ............................................................................... 28

MEASURING MAXIMUM AXIAL MOVEMENT ................................................................................... 28

NPK ASSEMBLY LUBRICANT .................................................................................................................. 29

ROTARY JOINT MAINTENANCE .............................................................................................................. 30

HYDRAULIC ROTARY JOINT ASSEMBLY ........................................................................................ 30

LEAKAGE OF THE SEALS ................................................................................................................ 30

TESTING THE ROTARY JOINT SEALS FOR INTERNAL LEAKAGE ................................................. 30

REPLACEMENT OF THE SEALS IN THE ROTARY JOINT ............................................................... 31

TROUBLESHOOTING ............................................................................................................................... 35

DETERMINE THE TYPE OF PROBLEM ............................................................................................ 35

MEASURING OPERATING PRESSURES ......................................................................................... 35

RELIEF VALVE CHECKING AND SETTING PROCEDURE ............................................................... 35

COUNTERBALANCE VALVE LOCATION .......................................................................................... 37

TROUBLESHOOTING CHART FOR LOW POWER ........................................................................... 38

CHECKING HYDRAULIC FLOW AT RATED PRESSURE ................................................................. 39

PROCEDURE FOR CHECKING HYDRAULIC FLOW AT RATED PRESSURE .................................. 39

TROUBLESHOOTING CHART FOR SLOW CYLINDER SPEED ....................................................... 41

JAW DRIFT........................................................................................................................................ 41

TO DETERMINE IF THE JAW DRIFT IS OCCURING FROM A BAD CYLINDER OR THE CARRIER. 41

ROTATION ........................................................................................................................................ 42

MEASURING ROTATION PRESSURES ............................................................................................ 42

ROTATION PRESSURE CHECKING PROCEDURE .......................................................................... 43

TROUBLESHOOTING CHART FOR ROTATION ............................................................................... 43

FASTENER TORQUE CHART .................................................................................................................. 45

CYLINDER TORQUE SPECIFICATIONS .................................................................................................. 47

ROD NUT AND PISTON TORQUES .................................................................................................. 47

CONVERT FROM DUAL MOTOR TO SINGLE MOTOR (DG20, DG30, DG40).......................................... 48

2

CONTENTS

WARRANTY STATEMENTS ..................................................................................................................... 49

KEYWORDS FOR COMMON DEMO GRAB COMPONENTS .................................................................... 51

NOTES...................................................................................................................................................... 52

SERVICE RECORD .................................................................................................................................. 52

3

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 Demolition Grab Attachment. 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 Demolition Grab Attachment. Keep

them clean and visible. NPK will provide decals free of

charge as needed.

4

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 DEMOLITION GRAB while in

operation.

3. Do not operate DEMOLITION GRAB without an

impact resistant shield between the DEMOLITION

GRAB and operator. Operate with extreme caution

near walls or columns that may collapse and near

concrete debris that may fall.

4. Operate the DEMOLITION GRAB from the

operator’s seat only.

5. Use two people whenever operator visibility is

limited, one to operate the DEMOLITION GRAB,

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 DEMOLITION GRAB within

reach of power lines.

9. Do not climb, sit, or ride on the DEMOLITION

GRAB.

10. Match the DEMOLITION GRAB size to excavator according to NPK

recommendations, see page 7. The excavator must be stable during DEMOLITION

GRAB 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. Make daily visual inspections of all fasteners, boom pins, hoses, etc.

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

5

SAFETY

MAINTENANCE

1. Use only NPK supplied replacement parts. NPK specifically disclaims any

responsibility for bodily injury or DEMOLITION GRAB damage that results from the

use of parts not sold or approved by NPK.

2. Use extreme caution in handling. A fully assembled DEMOLITION GRAB can

weigh over 2 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. The supplied safety bar (t79) MUST always be installed during transport, repairs,

dismounting and mounting to the carrier, changing the cutters and all other routines

at the attachment (GZ).

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

GRAB. 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 DEMOLITION GRAB.

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

6

SAFETY

MAINTENANCE

STANDARD PRACTICES

Maintenance of and repairs to the DEMOLITION GRAB 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

DEMOLITION GRAB.

ATTENTION

7

INTRODUCTION

NPK prides itself on the design and manufacture of high quality products. This tradition

of quality workmanship and materials continues in our DEMOLITION GRABS. Many

years of productive service can be realized with proper operation and care of the

DEMOLITION GRAB.

The purpose of this manual is to provide you with the information and instructions

required to properly operate and maintain the DEMOLITION GRAB. This will result in

maximum DEMOLITION GRAB reliability and productivity.

Read this manual thoroughly before attempting to operate, remove, disassemble,

repair or troubleshoot the DEMOLITION GRAB or any of its components.

Follow all the safety precautions contained in this manual. Failure to do so, can

result in death, personal injury, injury to others, and property damage.

EXCAVATOR COMPATIBILITY

These excavator weight ranges are intended as a guideline only. Other factors, such as

stick length, counterweights, undercarriage, etc., must be taken into consideration.

Mounting a DEMOLITION GRAB that is too heavy for the excavator can be dangerous

and damage the machine. Verify excavator stability with the DEMOLITION GRAB

before transport or operation.

Mounting a DEMOLITION GRAB that is too small for the excavator can damage the

DEMOLITION GRAB and void Warranties. Please consult NPK Engineering for specific

detailed information.

MODEL

RECOMMENDED EXCAVATOR

CLASS

3rd member mounting

US ton

(Metric ton)

DG-16

11 – 17.5

(10 - 16)

DG-20

15 - 22

(14 - 20)

DG-30

20 - 33

(18 - 30)

DG-40

27 - 44

(25 - 40)

8

SERIAL NUMBER LOCATION

DG16, DG20, DG30, DG40

sn2 – serial number tag

9

SPECIFICATIONS

DG16

MODEL

WEIGHT

CLOSING

CAPACITY

MAXIMUM

FORCE

(volume)

HOIST LOAD

lbs.

(kg)

ton

(kN)

cu. yd.

(liter)

lbs.

(kg)

DG16

1,895

(860)

4.8

(48)

.55

(425)

7,716

(3,500)

ROTATION:

Rotation is 360°

MODEL

OIL FLOW

PRESSURE

MAIN JAWS

gpm

(lpm)

psi

(bar)

DG16

16 - 26

(60 - 100)

3,625 - 5,100

(250 - 350)

MODEL

OIL FLOW

PRESSURE

ROTATION

gpm

(lpm)

psi

(bar)

DG16

5 - 8

(20 - 30)

1,450 - 2,030

(100 - 140)

NOTE: Specifications subject to change without notice.

10

SPECIFICATIONS

DG20

MODEL

WEIGHT

CLOSING

CAPACITY

MAXIMUM

FORCE

(volume)

HOIST LOAD

lbs.

(kg)

ton

(kN)

cu. yd.

(liter)

lbs.

(kg)

DG20

2,535

(1,150)

5.2

(52)

.65

(500)

9,920

(4,500)

ROTATION:

Rotation is 360°

MODEL

OIL FLOW

PRESSURE

MAIN JAWS

gpm

(lpm)

psi

(bar)

DG-20

16 - 26

(60 - 100)

3,625 - 5,100

(250 - 350)

MODEL

OIL FLOW

PRESSURE

ROTATION

gpm

(lpm)

psi

(bar)

DG-20

9 - 16

(35 - 60)

1,450 - 2,030

(100 - 140)

OPTIONAL SINGLE MOTOR

MODEL

OIL FLOW

PRESSURE

ROTATION

gpm

(lpm)

psi

(bar)

DG-20

5 - 8

(20 - 30)

1,450 - 2,030

(100 - 140)

NOTE: Specifications subject to change without notice.

11

SPECIFICATIONS

DG30

MODEL

WEIGHT

CLOSING

CAPACITY

MAXIMUM

FORCE

(volume)

HOIST LOAD

lbs.

(kg)

ton

(kN)

cu. yd.

(liter)

lbs.

(kg)

DG30

3,858

(1,750)

7.2

(72)

1.05

(800)

12,125

(5,500)

ROTATION:

Rotation is 360°

MODEL

OIL FLOW

PRESSURE

MAIN JAWS

gpm

(lpm)

psi

(bar)

DG-30

21 - 32

(80 - 120)

3,625 - 5,100

(250 - 350)

MODEL

OIL FLOW

PRESSURE

ROTATION

gpm

(lpm)

psi

(bar)

DG-30

9 - 16

(35 - 60)

1,450 - 2,030

(100 - 140)

OPTIONAL SINGLE MOTOR

MODEL

OIL FLOW

PRESSURE

ROTATION

gpm

(lpm)

psi

(bar)

DG-30

5 - 8

(20 - 30)

1,450 - 2,030

(100 - 140)

NOTE: Specifications subject to change without notice.

12

SPECIFICATIONS

DG40

MODEL

WEIGHT

CLOSING

CAPACITY

MAXIMUM

FORCE

(volume)

HOIST LOAD

lbs.

(kg)

ton

(kN)

cu. yd.

(liter)

lbs.

(kg)

DG40

4,519

(2,050)

7.2

(72)

1.18

(900)

12,125

(5,500)

ROTATION:

Rotation is 360°

MODEL

OIL FLOW

PRESSURE

MAIN JAWS

gpm

(lpm)

psi

(bar)

DG-40

21 - 32

(80 - 120)

3,625 - 5,100

(250 - 350)

MODEL

OIL FLOW

PRESSURE

ROTATION

gpm

(lpm)

psi

(bar)

DG-40

9 - 16

(35 - 60)

1,450 - 2,030

(100 - 140)

OPTIONAL SINGLE MOTOR

MODEL

OIL FLOW

PRESSURE

ROTATION

gpm

(lpm)

psi

(bar)

DG-40

5 - 8

(20 - 30)

1,450 - 2,030

(100 - 140)

NOTE: Specifications subject to change without notice.

13

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.

See your NPK dealer for details or call NPK at 1-800-225-4379.

HYDRAULIC LINES

Typically, the pressure line to close is arranged on the left side of the boom and the

open line is on the right side.

SHUT-OFF VALVES

Most NPK Hydraulic Installation Kits use two shut-off valves (k4) on the dipper stick (k1)

of the carrier. These valves control the hydraulic oil going to the close side (m3) and

the open side (m4) from the Demo Grab attachment.

Pressure test ports (k8) are located in the shut-off valves. Each shut-off valve has an

“ON” (k5) and an “OFF” (k6) position.

14

HYDRAULIC INSTALLATION

PORT CONNECTION DIAGRAM

m3

HOSE: arm close

m4

HOSE: arm open

m39a

ROTATION HOSE: for clockwise movement

m39b

ROTATION HOSE: for counter-clockwise movement

MODEL

OPEN/CLOSE

ROTATION

DG16

12 JIC

8 JIC

DG20

12 JIC

8 JIC

DG30

12 JIC

8 JIC

DG40

12 JIC

8 JIC

15

DEMOLITION GRAB HYDRAULIC CIRCUITS

CYLINDER HYDRAULIC CIRCUIT

BN

ROTARY JOINT ASSEMBLY

c11

CYLINDER

cb1

COUNTERBALANCE VALVE

m3

ARM CLOSE PORT

m4

ARM OPEN PORT

16

DEMOLITION GRAB HYDRAULIC CIRCUITS

SINGLE MOTOR HYDRAULIC CIRCUIT

BQ4

HYDRAULIC MOTOR

fr

FLOW REGULATOR

ma4

CROSS PORT RELIEF

m39a

CLOCKWISE ROTATION PORT

m39b

COUNTER-CLOCKWISE ROTATION PORT

17

DEMOLITION GRAB HYDRAULIC CIRCUITS

DUAL MOTOR HYDRAULIC CIRCUIT

BQ4

HYDRAULIC MOTOR

ma4

CROSS PORT RELIEF

m39a

CLOCKWISE ROTATION PORT

m39b

COUNTER-CLOCKWISE ROTATION PORT

18

MOUNTING INSTALLATION

NPK Mounting Installation Kits include the parts required to adapt the NPK Demolition

Grab to the stick or arm of the excavator. The kits include all necessary stick and link

pins, bolts, etc.

m1

STICK PIN (optional)

m2

LINK PIN (optional)

m3

WHIP HOSE - CLOSE

(optional)

m4

WHIP HOSE - OPEN

(optional)

m7

TOP BRACKET

m11

BRACKET BOLT

m12

HEX NUT

m13

WASHER

m27

SWIVEL TOP

m39

ROTATION HOSE

(optional)

m42

HEX NUT

m43

PIN BOLT

19

MOUNTING INSTALLATION

MOUNTING TO THE EXCAVATOR

1. Position the Demolition Grab on wood blocks (t20) as shown.

2. Align the stick pin bore (m24). Install the stick pin (m1).

3. Align the link pin bore (m25). Install the link pin (m2).

4. Clean away any dirt found on the hose connections, connect the whip hoses (m3

and m4) and the rotation hoses (m39).

5. Open the shut off valves (k4).

6. Remove safety bar.

REMOVAL FROM THE CARRIER

1. Retract the cylinder to open jaws fully.

2. Position the Demolition Grab horizontal on wood blocks (t20), as shown above.

3. Install safety bar.

4. Close the shut-off valves.

5. Shut off engine and relieve all hydraulic pressure.

6. Disconnect the hydraulic hoses before setting the Demolition Grab down. Install

plugs in the hydraulic hoses and caps on the stick tubes to keep out contamination.

STORAGE OF DEMOLITION GRAB

1. Make sure the hydraulic hoses are plugged and stick tubes capped.

2. Grease all lubrication points, see page 27.

3. If stored outdoors, cover with waterproof tarp.

The hydraulic lines must be handled carefully to

prevent contamination from entering the

Demolition Grab or the carrier hydraulic system.

ATTENTION

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