Table of Contents
Related Manuals for NPK E Series
Summary of Contents for NPK E Series
- Page 1 HYDRAULIC HAMMER OPERATORS MANUAL E SERIES HAMMERS E200 E204 E201 E205 E202 E207 E203 "Use Genuine NPK Parts” Copyright © 2012 NPK Construction Equipment, Inc. www.npkce.com H033-9600E E200 - E207 Hyd Ham Operators Manual 11/12...
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Page 2: Table Of Contents
LUBRICATION ......................12 GREASING PROCEDURE ..................12 CORRECT GREASE AND GREASE INTERVALS ........... 13 NPK HAMMER GREASE ..................15 AUTOLUBE SYSTEMS ..................... 15 AUTOLUBE GREASE LINE PRE-FILLING ............... 16 LUBRICANT TERMS AND DEFINITIONS ..............19 ... -
Page 3: 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 4 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.
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Page 5: Introduction
For additional information or help with any problem encountered, please contact your 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. - 4 -... -
Page 6: 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 7: Hammer Specifications
HAMMER SPECIFICATIONS HAMMER IMPACT WORKING MOUNTING TOOL MODEL ENERGY FREQUENCY WEIGHT STYLE WORKING CLASS LENGTH ft lb (Kg) in (mm) in (mm) E200 480 - 1200 (225) Skid Steer 1.7 (42) 12 (311) (107) Excavator E201 500 - 1200 (250) Skid Steer 1.9 (47) 13 (333) -
Page 8: Hydraulic Installation
Typically, the pressure line is arranged on the left side of the boom and the return line 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 is routed back to the tank thru the carrier’s oil cooler and filter. - Page 9 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.
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Page 10: Hydraulic Quick Disconnects
This, again, can cause damage. 3. Most quick disconnects create a restriction in the circuit. NPK Hammers are not back pressure sensitive, but restrictions cause unnecessary heating of the oil. Also, the pressure required to operate the hammer, plus the restriction of the disconnects may push an older, low pressure, carrier machine to the limit of its hydraulic system. - Page 11 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 female ends recommended ensure couplers are in good working condition.
- Page 12 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, flow control valve (if required), and hoses to connect to the carrier hydraulic system.
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Page 13: Lubrication
LUBRICATION GREASING PROCEDURE Manual greasing for hammers without AUTOLUBE system. 1. Place the hammer in a vertical position, applying enough downforce to push the tool up into the hammer. This prevents grease from entering piston impact area. 2. Turn the machine off. 3. -
Page 14: 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 15 LUBRICATION CORRECT GREASE FOR HYDRAULIC HAMMERS BRAND NAME MANUFACTURER LI-2M Amalie Oil Co. Rykotac EP Grease Amoco Amolith Grease 94601 Rykon Premium Grease EP (Grade 94108) Rykon Premium Moly Grease (Grade 94114) Amoco Molylith Grease 92006 Amsoil, Inc. BP Oil, Inc. Bearing Gard-2 Caterpillar Multipurpose Molydbenum Grease (MPGM)
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Page 16: Npk Hammer Grease
NPK hammer models E203, E204, E205 and E207 have a connection port (A) for an automatic greasing system (C). Do not use the plugged port in the tool holder assembly. -
Page 17: Autolube Grease Line Pre-Filling
2. Turn the machine off. 3. Fill the NPK Autolube 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 18 LUBRICATION AUTOLUBE GREASE LINE PRE-FILLING 8. Pump grease through the grease line (29) until a steady stream of grease (28) is realized at the 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 19 LUBRICATION AUTOLUBE GREASE LINE PRE-FILLING G100-8050 Hose Fill Assembly B160-4010 Grease Fitting – ¼” NPT male DQ K301-6620 Male x Female Adapter - #6 JIC male x ¼” NPT female - 18 -...
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Page 20: Lubricant Terms And Definitions
LUBRICATION LUBRICANT TERMS AND DEFINITIONS TERM DEFINITION The ability of grease, gear lubricant or oil to cling to ADHESIVE 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. - Page 21 LUBRICATION LUBRICANT TERMS AND DEFINITIONS TERM DEFINITION A container for keeping a supply of working fluid in a RESERVOIR 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.
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Page 22: 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 41. -
Page 23: Before Starting The Hammer
Before operating the NPK HYDRAULIC HAMMER, be sure to perform the specified ROUTINE INSPECTION, see page 29. 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 24: 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 25: Operating Techniques & Precautions
TOOL Raise the front of the machine slightly by applying downforce on the demolition tool. Press the control lever or the foot pedal to start the NPK HYDRAULIC HAMMER. Applying excessive force hammer will raise the carrier too high and jolt the operator when the material breaks. - Page 26 OPERATION OPERATING TECHNIQUES & PRECAUTIONS ATTENTION DO NOT SLANT HAMMER For the most efficient demolition, align the direction of force (F) from the boom with the penetration direction (P) of the tool. 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 27 OPERATION OPERATING TECHNIQUES & PRECAUTIONS ATTENTION 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 28 OPERATION OPERATING TECHNIQUES & PRECAUTIONS ATTENTION DO NOT DROP THE HAMMER RAPIDLY ON AN OBJECT Remember, the hydraulic hammer 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 is was intended.
- Page 29 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 may be hot from operation.
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Page 30: Routine Inspection And Maintenance
Do not hardface or sharpen the tool point with a cutting torch. Excessive heat from torching or welding causes embrittlement, breakage, and flying pieces. Resharpen only with a surface grinder or milling machine using sufficient cooling. Please consult your authorized NPK Dealer or NPK Service Department for additional information. - 29 -... -
Page 31: Twenty Hour Inspection
1. WARRANTY REGISTRATION Complete and send to NPK after initial 20 hour inspection. 2. WELDS Check for cracks, repair as necessary. 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. -
Page 32: Tools
POST and PIPE DRIVERS Driving fence posts for E201 thru E205 (use with adapter tool) Small E Series demolition tools are identified by dark green color. ATTENTION TOOLS FROM H SERIES HAMMERS WILL NOT FIT E SERIES! - 31 -... -
Page 33: Changing The Tool
TOOLS CHANGING THE TOOL REMOVAL 1. Remove the retaining pin ring (A) by using pliers or screwdrivers (C), 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. -
Page 34: Maximum Tool To Tool Bushing Clearance
TOOLS MAXIMUM TOOL TO TOOL BUSHING CLEARANCE Replace the tool bushing (A), and/or tool (B), 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 (C) with the hammer horizontal, as illustrated below. - Page 35 TOOLS MAXIMUM TOOL TO TOOL BUSHING CLEARANCE Step 3 Measure the inside diameter of the lower and upper tool bushings. 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. NEW BUSHING MAXIMUM BUSHING MODEL...
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Page 36: Tool Retaining Pin Inspection
TOOLS TOOL RETAINING PIN INSPECTION Deformation may occur on the retaining pin in the tool contact area (A). If this area is mushroomed, the retaining pin may become difficult to remove. Dress with a grinder. E200 through E204 E205 and E207 - 35 -... -
Page 37: Tool Inspection
TOOLS TOOL INSPECTION 1. Deformation may occur on the tool in the retaining pin contact area or on thrust surface (A). If these areas are mushroomed, the tool may become difficult to remove from the tool holder. Dress with a grinder. 2. -
Page 38: Tie Rods
200 (270) 1-3/16” E202 200 (270) 1-1/4” E203 200 (270) 1-7/16” E204 200 (270) 1-5/8” E205 200 (270) 1-13/16” E207 200 (270) 2-1/2” *Sweeney 503 Anti-seize recommended. If you have any questions call NPK Service Department at 800-225-4379. - 37 -... -
Page 39: Torque Values For Hammer Fasteners
If hammer or hammer bracket fasteners are found to be loose, use the following charts. If repairs are to be made, see the NPK Hydraulic Hammer Service Manual. Medium strength thread adhesive should be used on all the valve assembly bolts and the gas charge valve. -
Page 40: Gas Charge
See the chart “Ambient Temperature” below. ATTENTION 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 AT AMBIENT... -
Page 41: Gas Charging Kit
GAS CHARGE 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) are required. These can be obtained from your local welding supply house. A regulator valve is available from NPK. -
Page 42: Checking The Gas Pressure
THE HAMMER MUST NOT BE RESTING ON THE POINT. 2. Remove the charge 3. Turn the NPK 4. Install the NPK charging valve cap (A). charging adapter T- adapter (A) on the handle (A) full hammer charge valve (B). -
Page 43: 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, see page 41. 2. -
Page 44: Discharging The Gas Pressure
GAS CHARGE DISCHARGING THE GAS PRESSURE PROCEDURE 1. Remove the charge 2. Turn the NPK charging 3. Install the NPK charging valve cap (A). adapter T-handle (A) adapter counterclockwise until it hammer charge valve stops. (B). Remove the valve cap only, not the charge valve assembly! 4. -
Page 45: Warranty Statements
WARRANTY STATEMENTS - 44 -... - Page 46 WARRANTY STATEMENTS - 45 -...
- Page 47 WARRANTY STATEMENTS - 46 -...
- Page 48 WARRANTY STATEMENTS - 47 -...
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Page 49: Storage Of Hydraulic Hammer
Be sure the tool is liberally greased (B) and the hydraulic hoses are capped (C). Cover with a waterproof tarp (D), 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 (E). -
Page 50: 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 - 49 -... - Page 51 Copyright © 2012 NPK Construction Equipment, Inc. www.npkce.com H033-9600E E200 - E207 Hyd Ham Operators Manual 11/12...
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