NPK PH1 Operator's Manual
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NPK PH1 Operator's Manual

Ph series hammers
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HYDRAULIC HAMMER
OPERATORS MANUAL
PH SERIES HAMMERS
© Copyright 2016 NPK Construction Equipment, Inc.
PH4 Operators Manual 3-16
PH1
PH3
"Use Genuine NPK Parts"
PH2
PH4
Walton Hills, OH 44146-5541
www.npkce.com
H050-9660C PH1, PH2, PH3,
7550 Independence Drive
Phone (440) 232-7900
Toll-free (800) 225-4379
Fax (440) 232-6294

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  • Page 1 OPERATORS MANUAL PH SERIES HAMMERS “Use Genuine NPK Parts” 7550 Independence Drive Walton Hills, OH 44146-5541 Phone (440) 232-7900 Toll-free (800) 225-4379 Fax (440) 232-6294 © Copyright 2016 NPK Construction Equipment, Inc. www.npkce.com H050-9660C PH1, PH2, PH3, PH4 Operators Manual 3-16...

  • Page 2: Table Of Contents

    GREASING PROCEDURE ..................17 CORRECT GREASE AND GREASE INTERVALS ........... 18 CORRECT GREASE FOR HYDRAULIC HAMMERS ..........19 NPK HAMMER GREASE ..................19 AUTO LUBE SYSTEMS ..................19 AUTO LUBE GREASE LINE PRE-FILLING .............. 20 HAMMER MOUNTED AUTO LUBE GREASE LINE PRE-FILLING ......23 LUBRICATION ......................
  • Page 3 CHANGING THE TOOL .................... 50 MAXIMUM TOOL TO TOOL BUSHING CLEARANCE ..........52 TOOL INSPECTION ....................54 CHISEL TOOL RESHARPENING ................55 STANDARD LENGTH FOR NPK TOOLS ..............56 TOOL RETAINING PIN INSPECTION ..............57 GAS CHARGE ......................59 NITROGEN GAS PRESSURE .................. 59 GAS CHARGING KIT ....................

  • Page 4: Safety

    WARNING and BASIC OPERATING INSTRUCTIONS decals are included with each NPK hammer and installation kit. Decals must be installed in the cab, visible to the operator while operating the hammer. STAY CLEAR, PRESSURE VESSEL, GAS PRESSURE and TOOL SHARPENING decals are installed on all NPK hammer models.
  • Page 5 See CARRIER MACHINE COMPATIBILITY section of the NPK instruction manual. 10. Do not make any alterations to the TOOL without authorization from NPK Engineering. 11. Use proper lifting equipment and tools when handling or servicing the HAMMER.

  • Page 6: Introduction

    NPK authorized dealer. Whenever repair or replacement of component parts is required, only NPK parts should be used. NPK is not responsible for failures resulting from substitution of parts not sold or approved by NPK. This manual will also assist NPK Dealers and Customers to obtain the longest possible life from the NPK Demolition Tools.

  • Page 7: Carrier Machine Compatibility

    Mounting a HAMMER that is too small for the carrier machine can damage the HAMMER, cause tool breakage and void Warranties. Please consult NPK Engineering for specific detailed information. CARRIER WEIGHT lbs. (kg)

  • Page 8: Hammer Specifications

    HAMMER SPECIFICATIONS HAMMER IMPACT FREQUENCY MOUNTING WORKING TOOL MODEL ENERGY STYLE WEIGHT DIA. WORKING CLASS LENGTH ft. lb. lbs. (kg) (mm) (mm) 550 - 1,100 Excavator (192) 2.24 (57) 14.0 (356) Skid Steer (306) 500 - 1,200 Excavator (221) 2.60 (66) 15.1 (384)

  • Page 9: Structure

    STRUCTURE STRUCTURAL DRAWING MODELS PH1 – PH4 GREASE FITTING MAIN BODY PLUNGER RETAINING PIN RETAINING RING TOOL BUSHING TOOL GAS HEAD CHARGE VALVE PISTON MAIN BODY SLEEVE (A) MAIN BODY SLEEVE (B) VALVE SPOOL - 8 -...

  • Page 10: Hammer Serial Number Location

    HAMMER SERIAL NUMBER LOCATION SERIAL NUMBER LOCATION (sn1) - 9 -...

  • Page 11: Hydraulic Installation

    “OUT” port (5) on the right side. Flow to the hammer is controlled from an auxiliary valve on the carrier or from an NPK supplied valve. Hydraulic oil, generally, is routed back to the tank thru the carrier’s oil cooler and filter.
  • Page 12 Inlet pressure connects to port “P” on the NPK flow control valve (ma3). Regulated flow from valve port “H” (m5) connects to the “IN” port on the NPK hammer. The “OUT” port on the hammer connects to port “T2” (m6) on the flow control valve. “T1” connects to the return line (m4) on the skid steer.

  • Page 13: Prevention Of Contamination

    HYDRAULIC INSTALLATION PREVENTION OF CONTAMINATION 1. A hydraulic hammer is harder on oil than using a bucket, so the oil is apt to deteriorate and breakdown sooner. Neglect of the oil system can not only damage the hydraulic hammer but also cause problems in the carrier which could result in damaged components.

  • Page 14: Hydraulic Quick Disconnects

    This, again, can cause damage. 3. Most quick disconnects create a restriction in the circuit. NPK Hammers are not backpressure sensitive, but restrictions cause unnecessary heating of the oil. Also,...
  • Page 15 HYDRAULIC INSTALLATION HYDRAULIC QUICK DISCONNECTS If hydraulic quick disconnects are used with the NPK Hammer, it is recommended that the following precautions be followed. 1. Periodic inspection of both male (DXm) and female (DXf) ends is recommended ensure couplers are in good working condition.

  • Page 16: Mounting Installation

    MOUNTING INSTALLATION NPK Mounting Installation Kits include the parts required to adapt the NPK HYDRAULIC HAMMER to the carrier. NPK mounting kits include the hammer mounting bracket, mounting pins (optional), flow control valve (optional), and hoses to connect to the carrier hydraulic system (optional).

  • Page 17: Removal From The Skid Steer

    MOUNTING INSTALLATION REMOVAL FROM THE SKID STEER 1. Position the hammer (DR) horizontally onto the ground or wood blocks (t20) as shown. 2. Disconnect both inlet and outlet hoses. 3. Unlatch the mechanism holding the hammer bracket carrier’s coupler plate. (Consult the machine manufacturer’s operator/instruction manual for this procedure.

  • Page 18: Lubrication

    LUBRICATION GREASING PROCEDURE 1. Place the hammer in a vertical position, applying enough down force to push the tool up into the hammer. 2. Turn the machine off. 3. Grease the hammer until grease begins to come out around the tool and lower bushing.

  • Page 19: Correct Grease And Grease Intervals

    CORRECT GREASE The type of grease used is very important. NPK recommends a lithium soap base EP (Extreme Pressure) NLGI #2 Grease, with Moly (Molybdenum Disulfide) or other surface protecting additives. A high drop point 500°F (260°C) grease is desirable.

  • Page 20: Correct Grease For Hydraulic Hammers

    LUBRICATION bushing wear. NPK GH Series hammer models have a connection port (26) for an automatic greasing system. Refer to the NPK AUTO LUBE Instruction Manual for details. If the AUTO LUBE is not used, you can grease unit through fitting (30) as shown.

  • Page 21: Auto Lube Grease Line Pre-Filling

    2. Turn the machine off. 3. Fill the NPK Auto Lube pump reservoir with a power greaser through the fill fitting on the side of the pump, or from the top by removing the fill cover. Use a premium quality grade EP-2, high temperature grease with wear inhibiting additive.
  • Page 22 LUBRICATION AUTO LUBE GREASE LINE PRE-FILLING 8. Pump grease through the grease line (29) until a steady stream of grease (28) realized opposite (hammer) end. 9. Re-attach the grease line (29) to the hammer (KK). 10. Pump twenty more shots of grease into the grease line (29).
  • Page 23 LUBRICATION AUTO LUBE GREASE LINE PRE-FILLING G100-8050 Hose Fill Assembly B160-4010 Grease Fitting - ¼” NPT male K301-6620 Male x Female Adapter - #6 JIC male x ¼” NPT Female - 22 -...

  • Page 24: Hammer Mounted Auto Lube Grease Line Pre-Filling

    LUBRICATION HAMMER MOUNTED AUTO LUBE GREASE LINE PRE-FILLING It is mandatory that the supply line from the Auto Lube main pump to the connection on the hammer is primed with grease before it is used. Failure to do this will result in no grease being administered to the hammer tool for a period of time.
  • Page 25 LUBRICATION HAMMER MOUNTED AUTO LUBE GREASE LINE PRE-FILLING PRIMING THE GREASE LINE 6. Pump grease through the pump to the grease line (29) until a steady stream of grease (28) is realized at the opposite (hammer) end. 6a. It is also possible to purge the grease line to the hammer by disconnecting it at the hammer then pumping grease through the grease fitting provided on...

  • Page 26: Lubrication

    LUBRICATION LUBRICANT TERMS AND DEFINITIONS TERM DEFINITION ADHESIVE The ability of grease, gear lubricant or oil to cling to metal. Used to help combat metal-to-metal contact, thus ANTI WEAR AGENTS reducing wear. The ability of grease, gear lube or oil to cling to itself, COHESIVE thus resisting tearing apart.
  • Page 27 LUBRICATION LUBRICANT TERMS AND DEFINITIONS TERM DEFINITION RESERVOIR A container for keeping a supply of working fluid in a hydraulic system. A quivering or trembling motion. VIBRATION Viscosity is the actual SAE weight of the product. VISCOSITY Example motor oils come in 10, 20, 30, 40, 50 and 15/40 SAE weight.
  • Page 28 AUTO LUBE / UNDERWATER PORT IDENTIFICATION NPK PH Series Hammers are equipped with two ports on the main body (A) used in adapting for AUTO LUBE and underwater use. The air port (17) will allow the connection of an air line that will allow the hammer to be used underwater. The grease port (26), located in line with the air port, will allow for AUTO LUBE connection.

  • Page 29: Start-Up Operation

    1. Check the nitrogen gas pressure. The nitrogen gas pre-charge is factory checked before shipment. However, it is recommended the pressure be checked before using the NPK HYDRAULIC HAMMER for the first time. For the inspection procedure, see CHECKING THE GAS PRESSURE.

  • Page 30: Before Starting The Hammer

    Before operating the NPK HYDRAULIC HAMMER, be sure to perform the specified inspection, see “ROUTINE INSPECTION AND MAINTENANCE”. Warm up the NPK HYDRAULIC HAMMER, see below, and the base machine in accordance with the machine manufacturer’s instruction manual. This is especially important during cold weather operation.

  • Page 31: Operation

    OPERATION SAFE OPERATING INSTRUCTIONS DO NOT OPERATE THE HAMMER WITHOUT AN IMPACT RESISTANT CAB WINDOW OR SHIELD IN PLACE! BEWARE OF FLYING DEBRIS FROM THE HAMMER TOOL POINT! An impact resistant cab window or shield must be in place to protect the operator. Do not use the hammer in a way as to cause rock, etc.

  • Page 32: Operating Techniques & Precautions

    NPK HYDRAULIC HAMMER. Applying excessive force to the hammer will raise the carrier too high and jolt the operator when the material breaks. Let the NPK HYDRAULIC HAMMER do the work. AVOID BLANK HAMMERING As soon as the material is broken, release the control lever or pedal to prevent unnecessary blank hammering.
  • Page 33 OPERATION OPERATING TECHNIQUES & PRECAUTIONS DO NOT SLANT HAMMER For the most efficient demolition, align the direction of force (51) from the boom with the penetration direction (52) of the tool (HH). Failure to do this decreases the transfer of energy from the piston to the rock and increases the bending forces at the fulcrum of the tool.
  • Page 34 OPERATION OPERATING TECHNIQUES & PRECAUTIONS DO NOT USE THE HAMMER TOOL AS A PRY BAR Excessive prying can cause premature bushing wear and tool or tie rod breakage. When hammering materials that allow the tool to penetrate before breaking, move the hammer slightly fore and aft to create a cone-shaped hole.
  • Page 35 OPERATION OPERATING TECHNIQUES & PRECAUTIONS DO NOT DROP THE HAMMER RAPIDLY ON AN OBJECT Remember, the hammer assembly (DR) is heavier than an empty bucket and will move faster than expected. DO NOT USE THE HAMMER ASSEMBLY (DR) TO MOVE LARGE OBJECTS Do not use the hammer assembly (DR) for purposes other than for what...
  • Page 36 – contact your NPK dealer for more information. DO NOT SUBMERGE A HOT TOOL IN WATER The tip of the tool (HH) may be hot from operation.

  • Page 37: Impact Energy Transmission Through Tools

    IMPACT ENERGY TRANSMISSION THROUGH TOOLS A hydraulic hammer converts hydraulic power to kinetic energy. The kinetic energy is delivered by the hammer piston to the tool as an impact force. Unlike a slowly transmitted force, such as the force with which a hydraulic cylinder extends, the impact force produced by the piston when it hits the tool is transmitted through the interior of the tool as a compression stress wave until it reaches the rock, concrete, or other material that the tool is about to break.

  • Page 38: Impact Stress Waves At The End Of The Tool

    IMPACT ENERGY TRANSMISSION THROUGH TOOLS IMPACT STRESS WAVES AT THE END OF THE TOOL When the tool is in contact with the material to be broken, most of the compression stress waves are transferred to the material, and the energy of the compression waves then...

  • Page 39: Tool Breakage

    1. Properly position the hammer so as not to develop a bending moment in the tool. 2. Apply sufficient grease to prevent the tool from developing cracks due to galling. This will also assure longer tool bushing life. WARRANTY NPK Warranty does not apply to this type of failure. - 38 -...

  • Page 40: Tool Breakage Due To Excessive Wear Of The Tool Holder Bushings

    TOOL BREAKAGE TOOL BREAKAGE DUE TO EXCESSIVE WEAR OF THE TOOL HOLDER BUSHINGS If the hydraulic hammer is used with tool holder bushings worn beyond specifications, the tool will be at an excessive angle to the piston at the moment of impact. The entire force of the piston is concentrated in a small area of the impact head of the tool (Fig.
  • Page 41 “MAXIMUM TOOL TO TOOL BUSHING CLEARANCE” section of this manual. HAMMER MAXIMUM CLEARANCE MODEL (mm) BF. Tool Bushing HH. Tool d15. Clearance d16. Tool Diameter WARRANTY NPK Warranty does not cover tool failure caused by worn tool holder bushings. - 40 -...

  • Page 42: Chipping In Retaining Pin Slot

    TOOL BREAKAGE A. CHIPPING IN RETAINING PIN SLOT The tool may become chipped at the upper end of the retaining pin slot where it contacts the retaining pin. Free standing oversize rock may sometimes be broken with only a few hammer blows. If the operator does not stop hammering immediately, the tool will hit the retaining pin (blank hammering), and can chip the upper end of the retaining pin slot.

  • Page 43: Deformation Of The Tool Tip

    TOOL BREAKAGE C. DEFORMATION OF THE TOOL TIP Hammering continuously in one position for over 30 seconds will overheat the tool tip. If this is done repeatedly, the tip will lose temper and mushroom. Overheating wears the tip faster and can allow the tip to chip. PREVENTATIVE MEASURES Move tool position if material is not broken after 30 seconds of hammering.

  • Page 44: Chipping Of A Moil Point Tool Tip

    Overheating tool by hammering for more than 30 seconds in one spot can cause chipping. PREVENTATIVE MEASURES Use correct size hammer for job conditions. Do not hammer for more than 30 seconds without moving hammer. WARRANTY NPK Warranty does not cover types A, B, C, D and E problems. - 43 -...

  • Page 45: Temperature Related Tool Problems

    Warm the tool before starting to operate the hammer when temperature is below 32°F, (0°C). WARRANTY NPK Warranty does not cover this type of failure. EXCESSIVE SLANT HAMMERING When constant slant hammering is performed while using boom downforce, the tool may become deformed as shown in the picture below.

  • Page 46: Tool Breakage Due To Corrosion

    Dry the tool and coat it with grease to protect it from corrosion. WARRANTY NPK Warranty does not cover this type of failure. TOOL BREAKAGE DUE TO DEFECTIVE MATERIAL If metal fatigue originates from the interior, not the exterior, the material has some defect and fatigue will break the tool.

  • Page 47: Routine Inspection And Maintenance

    Inspect for damage. HYDRAULIC OIL: MAINTAIN A CLEAN HYDRAULIC SYSTEM If non-petroleum oil is used, contact the NPK Service Department for compatibility. Keep hoses clean and capped when dismounting or storing hammer. Change oil and filters as recommended by carrier manufacturer. Periodic oil sampling is recommended.

  • Page 48: Weekly Inspection

    WEEKLY INSPECTION 1. WELDS Check for cracks, repair as necessary. Consult your authorized NPK Dealer or NPK Service Department for additional information. 2. TOOL RETAINING PIN Remove the retaining pin and inspect for peening caused by excessive blank hammering. If necessary, grind edges smooth as shown in TOOL RETAINING PIN INSPECTION, see page 57.

  • Page 49: Tools

    PH1 – PH4  Soil compaction TAMPER PLATE  Driving sheeting (use with adapter tool) 12” x 12” for PH1 – PH2 16” x 16” for PH3 – PH4  Driving guard rails  Driving fence posts POST and PIPE DRIVER (use with adapter tool) for PH1 –...

  • Page 50: Tool Identification

    TOOLS TOOL IDENTIFICATION NPK demolition tools can be identified by the numbers found stamped in the retaining pin slot area. These numbers must be included in all warranty correspondences regarding a broken tool. Photos must also be included. - 49 -...

  • Page 51: Changing The Tool

    TOOLS CHANGING THE TOOL TOOL REMOVAL 1. Remove the two socket head cap screws (OO) that attach the retaining pin stopper plate (GK) to the hammer bracket. Remove the retaining pin stopper plate. Figure 1 2. Remove the retaining pin ring (E) by using a screwdriver (t22), see Figures 2 and 3. It will easily come out if pried at an angle as shown in Figure 3.
  • Page 52 TOOLS CHANGING THE TOOL TOOL REMOVAL 6. Remove the tool (HH). Figure 6 TOOL INSTALLATION 1. Clean the retaining pin bore. 2. Coat the surface of the tool (HH) with grease, then install. Figure 7 3. Coat the retaining pin (D) with grease, then install. 4.

  • Page 53: Maximum Tool To Tool Bushing Clearance

    TOOLS MAXIMUM TOOL TO TOOL BUSHING CLEARANCE Replace the tool bushing (BF), and/or tool (HH), when the tool to bushing gap reaches the maximum clearance. To determine whether the bushing or tool requires replacement, follow the instructions and charts shown below: Step 1 Measure the tool to bushing gap (d15) with the hammer horizontal, as illustrated below.
  • Page 54 TOOLS MAXIMUM TOOL TO TOOL BUSHING CLEARANCE Step 3 Measure the inside diameter of the tool bushing. The maximum tool bushing inside diameter is compared to a new tool only. If the tool bushing dimensions are at or above the charted value, the bushing must be replaced. HAMMER NEW BUSHING MAXIMUM BUSHING...

  • Page 55: Tool Inspection

    TOOLS TOOL INSPECTION 1. Deformation may occur on the tool in the retaining pin contact area (15) or thrust surface (31). If these areas are mushroomed, the tool may become difficult to remove from the tool holder. Dress with a grinder. 2.

  • Page 56: Chisel Tool Resharpening

    TOOLS CHISEL TOOL RESHARPENING Worn chisel tools can be re-sharpened by machining according to the dimensions below. DO NOT hardface or sharpen the tool point with a cutting torch! Re-sharpen only with a lathe or milling machine using sufficient coolant. HAMMER d16 (ref) MODEL...

  • Page 57: Standard Length For Npk Tools

    TOOLS STANDARD LENGTH FOR NPK TOOLS d23 = Length of tool from top to bottom. d22 = Length of tool exposed from bottom of tool bushing to end of tool. d16 = Diameter of bearing surface of tool. NEW TOOL...

  • Page 58: Tool Retaining Pin Inspection

    TOOLS TOOL RETAINING PIN INSPECTION Deformation may occur on the retaining pin in the tool contact area (AN). If this area is mushroomed, the retaining pin may become difficult to remove. Dress areas shown (AN) with a grinder. - 57 -...
  • Page 59 TORQUE VALUES FOR HAMMER FASTENERS If hammer bracket fasteners are found to be loose, use the following chart. If repairs are to be made, see the NPK Hydraulic Hammer Service Manual. *HAMMER BRACKET **ADAPTER BRACKET HAMMER BRACKET BOLT TORQUE BOLT TORQUE...

  • Page 60: Gas Charge

    See the chart “Ambient Temperature” below. DO NOT OVERCHARGE THE HAMMER! Exceeding the gas pre-charge specifications can result in damaging hammer components. The NPK WARRANTY does not cover failures resulting from exceeding the specified nitrogen gas pressure. NITROGEN GAS PRE-CHARGE...

  • Page 61: Gas Charging Kit

    GAS CHARGING KIT (Part Number 7300588) ALL NPK HYDRAULIC HAMMERS are furnished with the following gas charging kit. In addition, a nitrogen tank and pressure regulator valve (not furnished with the hammer) is required. These can be obtained from your local welding supply house. An optional regulator valve, part no.

  • Page 62: Checking The Gas Pressure

    3. Turn the NPK charge adapter T-handle (g2) to a full counterclockwise position. 4. Install the NPK charging adapter (g1) on the hammer charge valve located on hammer gas head (L). 5. Tighten the charge adapter cap (g6).
  • Page 63 GAS CHARGE CHECKING THE GAS PRESSURE 6. Turn the T-handle (g2) clockwise. As the T-handle is screwed in, a resistance is encountered. By turning the T-handle further, the nitrogen gas pressure will be indicated on the pressure gauge (g8). Stop turning the T-handle when the gauge reads pressure.

  • Page 64: Charging The Hammer

    GAS CHARGE CHARGING THE HAMMER USE NITROGEN GAS ONLY . STAY CLEAR OF THE TOOL WHILE CHARGING THE HAMMER WITH GAS. The tool may be impacted by the piston and forced out abruptly. PROCEDURE 1. Carry out steps 1 thru 4 of CHECKING THE GAS PRESSURE. 2.

  • Page 65: Discharging The Gas Pressure

    GAS CHARGE DISCHARGING THE GAS PRESSURE THE NITROGEN GAS MUST BE DISCHARGED FROM THE HAMMER BEFORE DISASSEMBLY! PROCEDURE 1. Remove the charge valve 2. Turn the NPK charge 3. Install charge cap (M1) from the charge adapter T-handle (g2) adapter...

  • Page 66: Storage Of Hydraulic Hammer

    (HH) is liberally greased and the hydraulic hoses (m3 and m4) are capped. Cover with a waterproof tarp (t21), not shown. If the NPK HYDRAULIC HAMMER is not to be used for a long period of time (months), it is recommended the gas pressure be discharged at the charge valve (M). The tool (HH) should be removed, and the piston (N) pushed all the way in.

  • Page 67: Warranty Registration For New Units

    WARRANTY REGISTRATION FOR NEW UNITS Complete and send to NPK after installation or complete on line at www.npkce.com Online warranty registration can be done by the dealer or the end user. The registration can be done in any of the following ways: 1.

  • Page 68: Tool Warranty

     Custom or special application tools which are excluded from warranty. NPK RESPONSIBILITY NPK will, at its option, replace with a new or reconditioned tool, any warranted tool that fails by reason of defective material or workmanship, free of charge, delivered at a place of business of an NPK Dealer.
  • Page 69  Replacement due to tip or shank wear.  Installations not approved by NPK.  Use of parts not sold by NPK. THE USE OF “WILL FIT” PARTS WILL VOID THE WARRANTIES OF ANY AND ALL PARTS DAMAGED AS A RESULT OF THE FAILURE OF THE “WILL FIT”...

  • Page 70: Warranty Statements

    WARRANTY STATEMENTS - 69 -...
  • Page 71 WARRANTY STATEMENTS - 70 -...
  • Page 72 WARRANTY STATEMENTS - 71 -...
  • Page 73 WARRANTY STATEMENTS - 72 -...

  • Page 74: Notes And Records

    NOTES AND RECORDS NPK HYDRAULIC HAMMER MODEL NUMBER _______________ SERIAL NUMBER _______________ NPK INSTALLATION KIT NUMBER ___________________________ CARRIER MANUFACTURER MODEL NUMBER SERIES SERIAL NUMBER DATE OF INSTALLATION _________________ DATE OF 20 HOUR INSPECTION ___________ WARRANTY REGISTRATION SENT  - 73 -...
  • Page 75 © Copyright 2016 NPK Construction Equipment, Inc. www.npkce.com H050-9660C PH1, PH2, PH3, PH4 Operators Manual 3-16...

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