NPK GH Series Operator's Manual
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NPK GH Series Operator's Manual

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HYDRAULIC HAMMER
OPERATORS MANUAL
GH SERIES HAMMERS
GH3-2
"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 2013 NPK Construction Equipment, Inc.
www.npkce.com
H050-9650A GH3-2 Hyd Ham
Operators Manual 6-13

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  • Page 1 OPERATORS MANUAL GH SERIES HAMMERS GH3-2 “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 2013 NPK Construction Equipment, Inc. www.npkce.com H050-9650A GH3-2 Hyd Ham Operators Manual 6-13...

  • Page 2: Table Of Contents

    ACCESSORY TOOLS ....................32   TOOL IDENTIFICATION ....................33   TOOLS .......................... 34   STANDARD LENGTH FOR NPK TOOLS ..............34   CHANGING THE TOOL .................... 35   MAXIMUM TOOL TO TOOL BUSHING CLEARANCE ..........37   CHISEL TOOL RE-SHARPENING ................39  ...

  • 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.

  • Page 5: 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 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) GH3-2 500 – 1150 1075 (490) Skid Steer 3.0 (76) 16.1 (408) 800 (365) Excavator HAMMER OIL FLOW HYDRAULIC CIRCUIT GAS CHARGE...

  • Page 8: Hammer Serial Number Location

    HAMMER SERIAL NUMBER LOCATION SERIAL NUMBER LOCATION (sn1) - 7 -...

  • Page 9: 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, generally, is routed back to the tank thru the carrier’s oil cooler and filter.

  • Page 10: 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 11: 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 in the disconnects may push an older, low pressure, carrier machine to the limit of its hydraulic system.
  • Page 12 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 and female ends is recommended to ensure the couplers are in good working condition.

  • Page 13: 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, flow control valve (if required), and hoses to connect to the carrier hydraulic system.

  • Page 14: Switch Hammer To Anti-Blank Fire

    SWITCH HAMMER TO ANTI-BLANK FIRE 1. Place the hammer horizontal to the ground. 2. Turn the shut-off valves (PRESSURE and RETURN) on the carrier to the OFF position (to prevent oil flow from the carrier). 3. Exchange the long plug (AS5) with the short plug (AS4) which are both attached to the side of the hammer body.

  • Page 15: Lubrication

    LUBRICATION GREASING PROCEDURE 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 and lower bushing.

  • Page 16: 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 17 LUBRICATION CORRECT GREASE FOR HYDRAULIC HAMMERS MANUFACTURER BRAND NAME LI-2M Amalie Oil Co. Amoco Rykotac EP Grease 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)

  • Page 18: Npk Hammer Grease

    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 three different temperature ranges - 350°, 500°, and 2000°. Universal Plus and Super Duty are lithium soap based products that resists washout and contain NPK-10 additive for surface protection in friction affected areas.

  • Page 19: Lubricant Terms And Definitions

    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 20 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 Is the actual SAE weight of the product. Example motor VISCOSITY 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.

  • Page 21: 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 55.

  • Page 22: Before Starting The Hammer

    Before operating the NPK HYDRAULIC HAMMER, be sure to perform the specified ROUTINE INSPECTION, see page 30. 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 23: Operation

    OPERATION SAFE OPERATING INSTRUCTIONS DO NOT OPERATE THE HAMMER WITHOUT AN IMPACT RESISTANT CAB WINDOW OR SHIELD (128) 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 24: 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 25 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 26 OPERATION OPERATING TECHNIQUES & PRECAUTIONS DO NOT USE THE HAMMER TOOL AS A PRY BAR Excessive prying 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 27 OPERATION OPERATING TECHNIQUES & PRECAUTIONS 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 ASSEMBLY (DR) TO MOVE LARGE OBJECTS Do not use the hammer assembly for purposes other than for what it was intended.
  • Page 28 – 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 29: 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 30: 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 breaks the material.

  • Page 31: Routine Inspection And Maintenance

    Check for oil leaks, loose clamps and hose abrasion. HYDRAULIC OIL MAINTAIN A CLEAN HYDRAULIC SYSTEM If non-petroleum oil is used, contact 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 32: 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 40.

  • Page 33: Types And Applications Of Tool

    16” x 16” for GH3 thru GH4  Driving guard rails POST and PIPE DRIVER  Driving fence posts (use with adapter tool) for GH1 thru GH4 TOOLS FROM H & E SERIES HAMMERS WILL NOT FIT GH SERIES! - 32 -...

  • Page 34: Tool Identification

    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. - 33 -...

  • Page 35: 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 DIAMETER (d16)

  • Page 36: Changing The Tool

    TOOLS CHANGING THE TOOL REMOVAL 1. Remove the four socket head cap screws (OO) that attach retaining pin stopper plate (GK) to the hammer bracket. Remove the retaining pin stopper plate. 2. Remove the retaining pin stopper (GL). 3. Screw an M12 hex head bolt (AF) or cap screw into the retaining pin (D).
  • Page 37 TOOLS CHANGING THE TOOL REINSTALLATION 1. Clean the retaining pin housing hole. 2. Coat the surface of the tool (HH) with grease, then install. 3. Coat the retaining pin (D) with grease and install. 4. Install the retaining pin stopper (GL).

  • Page 38: Maximum Tool To Tool Bushing Clearance

    TOOLS MAXIMUM TOOL TO TOOL BUSHING CLEARANCE Replace the tool bushing (F,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.
  • Page 39 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...

  • Page 40: Chisel Tool Re-Sharpening

    TOOLS CHISEL TOOL RE-SHARPENING 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 by milling or grinding, using sufficient coolant. MODEL NO. inch inch GH3-2...

  • Page 41: 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. HAMMER MODEL GH3-2 - 40 -...

  • Page 42: 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 43  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 44  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.

  • Page 45: 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. - 44 -...
  • Page 46 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 47 HOLDER BUSHINGS PREVENTATIVE MEASURES Replace the tool holder bushings when the clearance (d15) reaches the maximum limit listed below. See the NPK Hydraulic Hammer Service Manual for minimum tool (HH) diameter and tool bushing (G) maximum diameter wear charts. MAXIMUM CLEARANCE...
  • Page 48 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 49 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 50 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. - 49 -...
  • Page 51 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 52 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 53: 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 54: 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 55: 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) is required. These can be obtained from your local welding supply house. An optional regulator valve, part no.

  • Page 56: Checking The Gas Pressure

    2. Remove the charge valve cap (M1) from the hammer charge valve (M). Do not remove the charge valve assembly! 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).
  • Page 57 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 58: 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 59: Discharging The Gas Pressure

    GAS CHARGE DISCHARGING THE GAS PRESSURE PROCEDURE 1. Remove charge 2. Turn the NPK charge 3. Install the NPK charge valve (M1) from the adapter T-handle (g2) to adapter (g1) onto the charge valve (M). a full counterclockwise hammer charge valve position.

  • Page 60: 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 61: Storage Of Hydraulic Hammer

    (HH) is liberally greased and the hydraulic hoses are capped (AO). 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 (M). The tool (HH) should be removed, and the piston (N) pushed all the way in.

  • Page 62: Warranty Statements

    WARRANTY STATEMENTS - 61 -...
  • Page 63 WARRANTY STATEMENTS - 62 -...
  • Page 64 WARRANTY STATEMENTS - 63 -...
  • Page 65 WARRANTY STATEMENTS - 64 -...

  • Page 66: 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  - 65 -...
  • Page 67 © Copyright 2013 NPK Construction Equipment, Inc. www.npkce.com H050-9650A GH3-2 Hyd Ham Operators Manual 6-13...

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