GREASING PROCEDURE ..................19 CORRECT FUNCTION OF GREASING AND GREASE INTERVALS ...... 20 CORRECT GREASE FOR HYDRAULIC HAMMERS ..........20 NPK HAMMER GREASE ..................21 AUTO LUBE SYSTEMS.................... 22 AUTO LUBE GREASE LINE PRE-FILLING .............. 23 HAMMER MOUNTED AUTO LUBE GREASE LINE PRE-FILLING ......26 PRIMING THE GREASE LINE ................
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MAXIMUM TOOL TO TOOL BUSHING CLEARANCE ..........56 TOOL INSPECTION ....................58 CHISEL TOOL SHARPENING .................. 59 STANDARD LENGTH FOR NPK TOOLS ..............60 TOOL RETAINING PIN INSPECTION ..............61 TORQUE VALUES FOR HAMMER FASTENERS ............62 GAS CHARGE ......................63 NITROGEN GAS PRESSURE ..................
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.
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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.
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.
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)
STRUCTURE STRUCTURAL DRAWING MODELS E200 – E203 OUT PORT IN PORT GREASE FITTING MAIN BODY PLUNGER BUSHING DRAIN PLUG PLUNGER TOOL HOLDER RETAINING PIN RETAINING RING UPPER TOOL BUSHING LOWER TOOL BUSHING TOOL IMPACT RING (SPACER SECTION) GAS HEAD CHARGE VALVE PISTON MAIN BODY SLEEVE (A) MAIN BODY SLEEVE (B)
STRUCTURE STRUCTURAL DRAWING MODELS E204 – E205 GREASE FITTING MAIN BODY PLUNGER BUSHING DRAIN PLUG PLUNGER TOOL HOLDER RETAINING PIN SWIVEL ELBOW RETAINING RING UPPER TOOL BUSHING LOWER TOOL BUSHING TOOL IMPACT RING (SPACER SECTION) GAS HEAD CHARGE VALVE PISTON MAIN BODY SLEEVE (A) MAIN BODY SLEEVE (B) TIE ROD...
STRUCTURE STRUCTURAL DRAWING MODELS E207 GREASE FITTING MAIN BODY PLUNGER BUSHING DRAIN PLUG PLUNGER TOOL HOLDER RETAINING PIN SWIVEL ELBOW RETAINING RING UPPER TOOL BUSHING LOWER TOOL BUSHING TOOL HELICOIL IMPACT RING (SPACER SECTION) GAS HEAD CHARGE VALVE PISTON MAIN BODY SLEEVE (A) MAIN BODY SLEEVE (B) TIE ROD TOP NUT...
“IN” port (6) and the return line is routed from the hammer “OUT” port (5) on the right side. Flow to the hammer is controlled from the carrier’s auxiliary valve or from an NPK supplied flow valve. Hydraulic oil is generally routed back to the tank thru the carrier’s oil cooler and filter.
Inlet pressure connects to port “P” on the NPK flow control valve. 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. Port “T1” connects to the return line (m4) on the skid steer.
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.
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, the pressure required to operate the hammer, plus the restriction in the disconnects may push an older, low pressure, carrier machine to the limit of its hydraulic system.
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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.
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).
MOUNTING INSTALLATION REMOVAL FROM THE SKID STEER 1. Position 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 to the carrier’s coupler plate.
LUBRICATION GREASING PROCEDURE Manual greasing for hammers without an Auto Lube System. 1. Place the hammer in a vertical position, applying enough downforce 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 (HH) and lower bushing (see arrow).
CORRECT GREASE FOR HYDRAULIC HAMMERS 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.
LUBRICATION CORRECT GREASE FOR HYDRAULIC HAMMERS NPK HAMMER GREASE NPK now offers hammer grease specially formulated to meet severe job requirements. The grease is available in two different temperature ranges - 350°F (177°C), 500°F (260°C). “Universal Plus” and “Super Duty” are lithium soap-based products that resist washout and contain NPK-10 additive for surface protection in friction affected areas.
The pump output is adjustable according to the replacements of the hammer model and to compensate for tool bushing wear. NPK E Series hammer models have a connection port (26) for an automatic greasing system. Refer to the NPK Auto Lube Instruction Manuals for details.
2. Turn the excavator/backhoe off. 3. Fill the NPK Auto Lube pump reservoir with a power greaser through the fill fitting (30) on the side of the pump or from the top by removing the fill cover (a1).
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LUBRICATION AUTO LUBE GREASE LINE PRE-FILLING 5. Install NPK part number G100-8050, hose fill adapter (a13), onto the #6 JIC female end of the grease line (29) previously removed. ITEM PART DESCRIPTION NUMBER Grease Fitting - 1/4” B160-4010 NPT male...
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LUBRICATION AUTO LUBE GREASE LINE PRE-FILLING 10. Pump twenty more shots of grease, using a grease gun or power greaser, into the grease line (29). This will prime the hammer tool cavity and pre- lube the tool (HH). Look for grease coming out around the tool at the tool bushing (see arrow).
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 two to three hours.
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LUBRICATION HAMMER MOUNTED AUTO LUBE GREASE LINE PRE-FILLING 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. 7. Re-attach the grease line (29) to the hammer assembly (KK).
LUBRICATION LUBRICANT TERMS AND DEFINITIONS TERM DEFINITION ADHESIVE The ability of grease, gear lubricant or oil to cling to metal. ANTI WEAR AGENTS Used to help combat metal-to-metal contact, thus reducing wear. COHESIVE The ability of grease, gear lube or oil to cling to itself, thus resisting tearing apart.
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LUBRICATION LUBRICANT TERMS AND DEFINITIONS TERM DEFINITION RESERVOIR A container for keeping a supply of working fluid in a hydraulic system. VIBRATION A quivering or trembling motion. VISCOSITY Is the actual SAE weight of the product. Example motor oils come in 10, 20, 30, 40, 50 and 15/40 SAE weight. The viscosity designation of a lubricant indicates its internal resistance to flow.
AUTO LUBE / UNDERWATER PORT IDENTIFICATION NPK E203 through E207 models are equipped with two ports on the main body (A) or impact ring/cylinder spacer (J) 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.
HIGH HEAT APPLICATION NPK offers a high heat conversion kit for the E204 through E207 hammers. HAMMER KIT PART MODEL NUMBER E204 E2040-9505 E205 E2050-9513 E207 E2070-8055 Kit includes: Hex Head Cap Screw Boom Pin Collar Hex Nut Retaining Pin NOTE: No special seals are required.
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 64.
Before operating the NPK HYDRAULIC HAMMER, be sure to perform the specified ROUTINE INSPECTION, see page 51. 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.
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.
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.
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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.
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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.
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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 BRACKET MOVE LARGE OBJECTS Do not use the hammer bracket for purposes other than for what it was intended.
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Underwater operation will damage the hammer and allow water to enter the hydraulic system. The hammer can be modified for underwater operation - contact the NPK Dealer for more information. DO NOT SUBMERGE A HOT TOOL IN WATER The tip of the tool (HH) may be hot from operation.
OPERATION OPERATING TECHNIQUES & PRECAUTIONS TAMPER PAD OPERATION Always use the full width of the pad when compacting. Using part of the pad to compact can cause adapter tool breakage. - 40 -...
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.
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 breaks the material.
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. - 43 -...
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.
The tool should be checked periodically for chipped areas. Grind smooth any chipped areas to prevent stress cracks in the tool. WARRANTY NPK Warranty does not apply to these types of failures. - 46 -...
PREVENTATIVE MEASURES Move tool position if material is not broken after 30 seconds of hammering. If the material still resists breaking, a larger hammer may be required. WARRANTY NPK Warranty does not apply to this type of failure. - 47 -...
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 apply to these types of failures. - 48 -...
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.
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.
E205 models, inspect tie rod assemblies for loose top nuts. On the E207 model, inspect tie rod assemblies for cracked or missing lock plates and lock rings. If these parts are missing, consult the NPK Service Department at 440-232-7900. See page 62 for torque values.
HAMMER FASTENERS”. 2. WELDS Check for cracks and repair as necessary, see “MOUNTING PLATE”. Consult your authorized NPK Dealer or NPK Service Department for additional information. 3. TOOL RETAINING PIN Remove the retaining pin and inspect for peening caused by excessive blank hammering.
16” x 16” for E204, E205 • Driving guard rails POST and PIPE DRIVER • Driving fence posts (use with adapter tool) for E201 thru E205 TOOLS FROM H SERIES HAMMERS WILL NOT ALWAYS FIT E SERIES! CHECK PART NUMBERS! - 53 -...
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. - 54 -...
TOOLS CHANGING THE TOOL REMOVAL 1. Remove the retaining pin ring (E) by using pliers or a screwdriver (t22), see Figures 1 and 2. It will easily come out if pulled at an angle as shown in Figure 2. Figure 1 Figure 2 2.
TOOLS MAXIMUM TOOL TO TOOL BUSHING CLEARANCE Replace the tool bushing (G), 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.
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(tool or bushing) that will bring the maximum clearance to below the value seen in the chart of Step 1. Replacing both the tool and bushing would bring the clearance back to new. NOTE: NPK offers a tool for measuring tool to tool bushing clearance. - 57 -...
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.
TOOLS CHISEL TOOL SHARPENING Worn chisel tools can be sharpened by machining according to the dimensions below. DO NOT hardface or sharpen the tool point with a cutting torch! Sharpen only with a lathe or milling machine using sufficient coolant. HAMMER d16a (ref.) MODEL...
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. HAMMER NEW TOOL...
TOOLS TOOL RETAINING PIN INSPECTION The tool retaining pin (D) serves to keep the tool in place when the hammer is raised off the ground for repositioning. The retaining pin will become worn during normal use. Figure “A” shows the retaining pin when it is new. Note: the two guide grooves (AN). The guide groove areas and the area (122) between the grooves is where the wear will take place.
TORQUE VALUES FOR HAMMER FASTENERS If hammer or 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 MOUNTING *HAMMER BRACKET **ADAPTER BRACKET BOLT...
Pressures listed are maximum allowed. Use tolerance of Plus 0, minus 25 psi (2 bar). GAS CHARGING KIT 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.
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).
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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.
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.
GAS CHARGE DISCHARGING THE GAS PRESSURE PROCEDURE 1. Remove charge 2. Turn the NPK charge 3. Install the NPK charge valve cap (M1) from the adapter T-handle (g2) to adapter (g1) onto the charge valve (M). a full counterclockwise hammer charge valve not remove the charge position.
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.
• You do NOT need to fill in username and password. • Select the “Warranty Registration” Link. • Enter your information in each field and continue to register your NPK unit(s). • At any time, you may select the “Help” tab for step by step tutorial.
• 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.
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• 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” PARTS.
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 ❑ - 76 -...
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