HYDRAULIC HAMMER OPERATORS MANUAL
Contents
1. NPK APPROVED CONNECTION QUICK DISCONNECTS CONTACT YOUR NPK DEALER FOR ADDITIONAL INFORMATION ABOUT NPK QUICK DISCONNECTS HYDRAULIC INSTALLATION CONTINUED 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 INSPECT BOTH ENDS FOR DAMAGE and female ends is recommended OR FAILURE to ensure the couplers are in good working condition Failure to inspect couplers may result in pieces from a damaged or failed coupler to migrate into the hammer or parts of the coupler returned to ARE SUR CO CON Eee the machine CLEAR OF DIRT DUST AND DEBRIS BEFORE THEY ARE RE CONNECTED 2 Check for dirt dust and debris on both couplers before coupling SURE THAT COUPLERS ARE 3 Be sure that the couplers are ON E UER RENTEN TOENE completely seated together 4 When replacing couplers be sure that couplers are replaced as a set male and female Do not use one new end and one used end or He HIT 11 168 WHEN REPLACING COUPLERS BE SURE THAT COUPLERS ARE REPLACED AS A SET MALE AND FEMALE DO NOT USE ONE NEW END AND ONE USED END 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 con2. NPR HYDRAULIC HAMMER OPERATORS MANUAL E SERIES HAMMERS E208 E220 E210A E225 E213 E240A E216 E260A Manufacturer s 3 Certificate Use Genuine NPK Parts Copyright 2006 NPK Construction Equipment Inc www npkce com H050 9610A 7 06 7990 INDEPENDENCE DRIVE WALTON HILLS OHIO 44146 PHONE 440 232 7900 FAX 440 232 6294 CONTENTS A PE cR m me EN aaa iaia qaqapas 2 a re 4 CARRIER MACHINE COMPATIBILITY uuu uu u irren rh tr rene nn 4 HANMER SPECIFICATIONS Es u uu Sus sus Sispa uu npn miU preda uma 5 HYDRAULIC INSTALLATIONS uuu uuu tint nti igna 6 PREVENTION OF CONTAMINATION ii 7 HYDRAULIC QUICK DISCONNECTS saisissant entente 8 MOUNTINGTNSIADEATIDN uZu uu u uu kappas 10 ye S NN IO IE 11 REVIOVAL FROM THE GAISBRIEIS uu u l u PEE nave LEUTE Rete QUE 11 LUBRICATION M 12 GREASING PROCEDURES aan ne 12 CORRECT GREASE AND GREASE INTERVALS 13 NPK FANMER GREASE a meme mode dm 15 AU TOLUBE SYSTEMS aussatusatesawtastapatayatapaayatayahasatayabasatapakasqhawauscotapabauypanpios 15 LUBRICANT TERMS AND iii 16 ART UP OPEP RIO I S een te nt ee te samasaa ondes 18 HAMMERS THAT ARE NEW REBUILT OR HAVE BEEN INACTIVE 18 BEFORE
3. ATTENTION OPERATING TECHNIQUES amp PRECAUTIONS DO NOT OPERATE HAMMER UNDERWATER UNLESS HAMMER HAS BEEN MODIFIED WITH UNDERWATER KIT Do not allow parts other than the tool to be submerged in water Underwater operation will damage the hammer and allow water to enter EE SEI the hydraulic system The hammer ATW can be modified for underwater TTE TE TEE TIE ITE operation contact the NPK Dealer I EU 1 for more information DO NOT SUBMERGE A HOT TOOL IN WATER The tip of the tool may be hot from operation Submerging in water can cause the tip of the tool to become brittle and break prematurely DO NOT ALLOW THE HAMMER TOOL TO HIT THE BOOM Use caution when tucking the hammer in tight to the boom for transportation 25 ROUTINE INSPECTION AND MAINTENANCE 1 VISUAL INSPECTION Detect a potential problem early FASTENERS Inspect all fasteners Retighten as necessary Refer to HAMMER FASTENER TORQUE section for Top Bracket bolt torque WELDS Check for cracks repair as necessary HOSES AND TUBING 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 2 DE
4. Also note the amount of grease needed to re grease the tool This gives you the amount of grease and how often it must be applied An example would be that a particular hammer on a particular job requires half a tube of grease every 3 hours This would be the greasing schedule you would set up If this hammer was moved to another job another grease schedule may have to be determined Second if you can t control the grease schedule such as rental units then have the operator grease the hammer once every hour of hammer operation Again grease the hammer until grease comes out between the tool and tool bushing This is usually more often than required but is far cheaper than replacing prematurely worn tools and tool bushings 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 On the following page is a list of commonly available greases by manufacturer and brand name that meet NPK s recommendations NPK does not endorse any one brand as being superior to another If you or your customers use a brand not listed please call the NPK Service Department at 800 225 4379 LUBRICATION CONTINUED CORRECT GREASE FOR HYDRAULIC HAMMERS continued BRAND NAME LI 2M Rykotac EP Grease Amolith Grease 94601 MANUFACTURER Amalie Oil Co
5. E213 200 270 2 3 4 70 E216 200 270 3 1 8 77 E220 400 540 3 18 77 3 3 8 85 E225 400 540 Sweeney 503 Anti seize recommended NOTE Contact NPK Service Department for the torque procedure for models E240A and E260A If you have any questions call NPK Service Department at 800 225 4379 37 HAMMER FASTENER TORQUE If hammer or hammer bracket fasteners are found to be loose use the following charts Medium strength thread adhesive should be used on all the valve assembly bolts and the gas charge valve All other bolts should be lubed with anti seize compound SOCKET HEAD CAP SCREWS SHCS VALVE CASE VALVE TOP AND SWIVEL ADAPTOR SHCS TORQUE SHCS TORQUE SHCS TORQUE FEES ft Ib Nm PEE Nm FER ft Ib Nm E208 525 710 525 710 110 150 E210A 900 1220 710 960 110 150 213 900 1220 710 960 110 150 was s00 ta20 70660 Mi2 110 160 4300 750 800 1200 175 40 4300 01780 900 1220 Wt HIS wer 4300 01780 900 1200 17520 260 M27 1300 1750 M24 900 1220 M16 270 ees See HAMMER DISASSEMBLY AND ASSEMBLY TOOLS AND EQUIPMENT section of Service Manual for NPK hex key wrench part numbers HEX HEAD BOLTS HAMMER BRACKET RUBBER MOUNTS TOP ADAPTOR MODEL BRACKET
6. OR SPARE VALVE SECTION This type of installation utilizes an existing carrier valve Any additional parts such as a mechanical linkage hydraulic pilot control valve flow control valves etc are furnished in the NPK HYDRAULIC INSTALLATION KIT Special hydraulic pressure control valves are not required The NPK HYDRAULIC HAMMER operating pressure is self regulating 2 CONTROL SYSTEM USING THE NPK MULTIVALVE For carriers not equipped with a suitable auxiliary or spare valve section the NPK HYDRAULIC INSTALLATION KIT includes a solenoid operated priority flow control valve to operate the NPK HYDRAULIC HAMMER The NPK MULTIVALVE is specifically designed for the operation of boom mounted attachments HYDRAULIC INSTALLATION CONTINUED ATTENTION 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 hydraulic oil can not only damage the hydraulic hammer but also cause problems in the carrier which could result in damaged components Care should be taken to check for contamination of the oil and to change it if it is found contaminated Oil sampling at regular intervals is highly recommended When the hydraulic oil shows low viscosity and bubbles this indicates that the oil is deteriorated If the oil is dark brown and gives off an offensive odor it is severely deteriorated Change the oil immediately When the oil is cl
7. Pull out retainer pin If the retainer pin is jammed use a hammer and drift from the opposite side Retaining as Figure 2 RE INSTALLATION Clean the retainer pin housing hole and retaining ring groove Coat the surface of the tool with grease then install Apply grease to the retaining ring housing groove Coat the retaining pin with grease then install Install the retaining ring in the following manner a While deforming the retaining ring as shown in Figure 3 partially force it into the groove b Using the handle of the pliers or screwdriver press the rest of the ring into the groove see Figure 4 Na Figure 3 Figure 4 Nm TOOLS CONTINUED TOOL INSPECTION 1 Deformation may occur on the tool in the retaining pin contact area or on thrust surface If these areas are mushroomed tool may become difficult to remove from the tool holder Dress with a grinder 2 Excessive blank hammering may cause chipping in the retaining pin contact area If neglected the chipping may reduce the life of the retaining pin Dress with a grinder E K BEFORE REPAIR AFTER REPAIR 3 If chipping is found at the top of the tool replace the tool If neglected the piston impact surface will be damaged r CHIPPED AREA NORMAL CONDITION CHIPPED TOOL 34 TOOLS CONTINUED MAXIMUM TOOL TO TOOL BUSHING CLEARANCE Replace the tool bushing and or tool when the to
8. control lever or pedal to prevent unnecessary blank hammering Blank hammering is continued hammer operation after the material is broken This will overheat the hydraulic system and cause undue wear 21 OPERATION CONTINUED ATTENTION OPERATING TECHNIQUES amp PRECAUTIONS 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 This unnecessary added stress leads to the following problems 1 Premature bushing wear and or tool breakage 2 Breakage of tie rods 3 Breakage of bracket bolts 4 Decrease in transfer of energy translates to reduced production When the tool binds from incorrect working angle the sound of the hammer changes TANGENTIAL Keep the boom direction of force in DIRECTION the same direction the tool is penetrating Use the boom cylinder to preload the hammer apply downforce and use the bucket and stick cylinders for alignment Keep the tool tangent to the arc of the boom ARC OF BOOM 00 OPERATION CONTINUED ATTENTION OPERATING TECHNIQUES amp 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 all
9. the first time See CHECKING THE GAS PRESSURE section for procedure At idle raise the hammer off of the ground Place hammer vertical and activate the hammer circuit for 3 5 second intervals Continue for an additional 3 4 times to ensure that all the air has been purged from the hoses and hammer before first use Failure to do this could result in damage to internal components 3 Place hammer firmly against material to be broken Operate the hammer in a vertical position for approximately 10 minutes at one half engine speed Increase engine speed to three quarters and continue operating at this speed for another 10 to 20 minutes Increase to full engine speed Maintain vertical position for the first hour of operation START UP OPERATION CONTINUED ATTENTION BEFORE STARTING THE HAMMER PRE OPERATION INSPECTION AND WARM UP Before operating the NPK hydraulic hammer be sure to perform the specified routine inspection in the ROUTINE INSPECTION AND MAINTENANCE section of this manual Warm up the NPK hydraulic hammer see below and the carrier machine in accordance with the machine manufacturer s instruction manual This is especially important during cold weather operation DAILY START UP PROCEDURE Operate the NPK hydraulic hammer in the vertical position at 1 2 engine throttle setting for about 1 2 minutes During this period inspect the NPK hydraulic hammer and installation ki
10. Amoco Rykon Premium Grease EP Grade 94108 Rykon Premium Moly Grease Grade 94114 Amoco Molylith Grease 92006 GHD Amsoll Inc BP Oil Inc Caterpillar Bearing Gard 2 Multipurpose Molydbenum Grease MPGM Moly Lithflex CX AS Citgo Extra Range Grease Cato Oil and Grease Company CITGO Conoco Inc Super Lube M EP 2 Dryden Oil Company Moly EP 2 Exxon Ronex Extra Duty Moly NLGI 2 Fiske Brothers Refining Co Lubriplate MO LITH No 2 John Deere TY6333 TY6341 Moly High Temp Kendall L 424 Mobil Moly 372 Muscle Products Corporation MPC PL 10 Powerlift Grease LP 10 Lithium EP Plus NPK Universal Plus Lithium EP Grease Super Duty EP Grease water resistant Chisel Paste Adhezolith EP 2 Grease Philube MW Retinax AM Grease 71119 Retinax HD Grease Bearing Gard 2 Prestige Moly 2 EP Molytex EP 2 Unoba Moly HD 2 Unoba Moly HD 2 Pennzoil Phillips 66 Company Shell Standard Oil Company Sun Refining amp Marketing Company Texaco U S A Union Oil Company Unocal 14 LUBRICATION CONTINUED CORRECT GREASE FOR HYDRAULIC HAMMERS continued 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 All are compatible with Autolube systems Universal Plus and Super Duty are lithium soap based products that resists washout and contain NPK 10 additive
11. BOLT TORQUE BOLT TORQUE BOLT TORQUE DIA ft lb Nm DIA ft lb Nm KE ft Ib Nm 208 1 1 4 1100 4490 M16 155 210 550 745 E210A 1 1 4 1100 1490 155 210 550 745 F213 1 1 4 1100 1490 M16 155 210 550 745 3000 4065 M24 530 1100 1490 38 STORAGE OF HYDRAULIC HAMMER For short term storage between jobs place the hammer horizontal on wood blocks Be sure the tool is liberally greased and the hydraulic hoses are capped Cover with a waterproof tarp WHIP HOSES INSTALL PLUGS ON HOSE ENDS APPLY GREASE SS IN THIS AREA p COVER WITH TARP WOOD BLOCK temm WOOD BLOCK MH rl If the NPK HYDRAULIC HAMMER is not to be used for a long period of time months the following storage procedure is recommended 1 Discharge the gas pressure Remove the Tool and push the Piston all the way in Grease the exposed end of the Piston Grease and reinstall the Tool Plug the hydraulic hoses Cover with a waterproof tarp QI I ex QD D 39 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 40 Copyright 2006 NPK Construction Equipment Inc 7550 INDEPENDENCE DRIVE PHONE 440 232 7900 www npkce com WALTO
12. Change the filter element and hydraulic oil at the intervals described in the operation manual of the excavator when using a hydraulic implement Another method is to set up an oil sampling schedule and change accordingly HYDRAULIC INSTALLATION CONTINUED HYDRAULIC QUICK DISCONNECTS NPK recommends against the use of non NPK quick disconnects on hydraulic circuits operating NPK Products 1 The hydraulic pulsations caused by hydraulic hammer operating can cause internal pieces of non NPK quick disconnects to disintegrate These pieces would migrate into the hammer causing damage 2 If quick disconnects are used when the hammer is removed from the excavator quick disconnects should be capped to keep them clean If this is not done contamination on the disconnect will be flushed into the hammer when re connected 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 This would interfere with proper hammer operation However the NPK approved quick disconnects are properly sized so that the hammer operation is not affected APPROVED CONNECTION NOT RECOMMENDED CONNECTION Non NPK Quick Disconnects QUICK DISCONNECT
13. MOLITION TOOL LUBRICATION Important t is imperative that grease is maintained in the tool bushing contact area at all times This may require hourly greasing depending on job conditions Important The hammer must be in a vertical position with downforce applied to push the tool all the way in This prevents grease from entering piston impact area Pump grease into hammer until grease is seen coming out between the tool and bushing Use a good quality high temperature EP 2 grease containing anti wear additives see LUBRICATION section If machine is equipped with an AUTOLUBE System check grease reservoir daily 3 TOOL and TOOL BUSHING WEAR Check the tool and tool bushings for damage wear or deformation on a regular weekly basis Replace the tool and or bushings when wear exceeds the maximum clearance limit see MAXIMUM TOOL TO TOOL BUSHING CLEARANCE section 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 26 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 f
14. MPACT WORKING TOOL MODEL ENERGY FREQUENCY WEIGHT DIA WORKING CLASS LENGTH ft Ib bpm Ibs Kg in mm in mm E208 4 6 116 21 5 550 I E213 4200 1900 E216 5650 2565 5 7 146 25 5 650 65 0 126 22 B s s s 136 o 5 23 5 225 12000 300 400 7800 3540 6 5 165 29 730 E240A 15000 310 390 13000 5900 7 2 184 32 815 E260A 20000 240 330 17000 7710 8 0 204 35 5 900 4 2 HYDRAULIC CIRCUIT GAS CHARGE HAMMER OIL FLOW OPERATING RELIEF PRESSURE MODEL PRESSURE minimum gpm Llmin psi bar psi bar psi bar psi bar 208 26 48 100 180 3100 215 390 27 450 31 E210A 40 53 150 200 3150 217 390 27 ew ON 216 45 58 170 220 2500 172 3000 207 350 24 2350 162 2850 197 350 24 2850 197 365 25 2900 200 390 27 2900 200 390 27 a lt w 2500 172 _ E220 53 66 200 250 225 58 77 220 290 2350 E240A 74 92 280 350 2400 260 79 106 300 400 2400 Specifications subject to change without notice NOTES 1 Hydraulic operating pressure maximum is inlet pressure at the hammer with the oil operating temperature and with the gas charge set at the hot operating pressure See CHECKING THE HYDRAULIC PRESSURES section in Service Manual Circuit relief pressur
15. N HILLS OHIO 44146 FAX 440 232 6294 H050 9610A 7 06
16. ONTAMINATION DROPPING POINT EXTREME PRESSURE AGENTS FILM STRENGTH FRICTION GALLING LUBRICATION NLGI OILINESS PUMP AND DEFINITIONS DEFINITION EE The ability of grease gear lubricant or oil to cling to metal Used to help combat metal to metal contact thus reducing wear The ability of grease gear lube or oil to cling to itself thus resisting tearing apart Consistency of grease is its hardness or firmness It is determined by the depth in millimeters to which the cone of a penotrometer sinks into a sample under specified conditions Consistency of grease may be influenced by the type and amount of thickener viscosity of oil working and other factors subjected to heat begins to actually drip and breakdown film on metal surfaces thus forming a film of protection Film strength is defined as the tendency of oil molecules to cling together It is the ability of those molecules to resist separation under pressure between two metals and to hold these metal surfaces apart The resistance to fluid flow in a hydraulic system An energy loss in terms of power output Surface damage on mating moving metal parts due to friction A severe form of adhesive wear Use of a substance grease oil etc to reduce friction between parts or objects that move against each other A rating given to a grease from the National Lubricating Grease Institute This rating determines the hardness of the grease and goes on fro
17. S Please read this manual thoroughly to understand the NPK HAMMER and its operating principles before using it 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 CARRIER MACHINE CONMPATIBILITY These carrier weight ranges are intended as a guideline only Other factors such as stick length counterweights undercarriage etc must be taken into consideration Mounting a HAMMER that is too heavy for the carrier machine can be dangerous and can damage the carrier Verify carrier stability with HAMMER before transport or operation 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 Ibs kg HAMMER RECOMMENDED CARRIER WEIGHT RANGE MODEL Ib kg 28 000 42 000 12 00 19 000 40 000 56 000 18 000 25 000 46 000 66 000 20 000 30 000 56 000 86 000 25 000 38 000 66 000 100 000 30 000 45 000 70 000 116 000 32 000 52 000 100 000 186 000 45 000 85 000 160 000 260 000 73 000 120 000 Specifications subject to change without notice SPECIFICATIONS HAMMER I
18. STARTING THE HAMMER nm 19 DAILY STARTUP PROCEDURE 25 98 nine 19 PE ATO L uM UII 20 SAFE OPERATING INSTRUCTIONS mee nennen enne 20 OPERATING TECHNIQUES amp PRECAUTIONS u usu usu 21 ROUTINE INSPECTION AND MAINTENANCE ue 26 TAVENTYHOURINSPECTIONu either 27 GAS CHARGE mm 28 NITROGEN GAS PRESSURE ei 28 GAS CHARGING RIT mm 28 CHECKING THE GAS PRESSURE bs un 29 CHARGING THE HAMMER u 2 uu u uuu 30 DISCHARGING THE GAS PRESSURE iii 31 e 32 STANDARD TOOL m 32 CHANGING THE TOO E E E eee 33 TOOLINSPEG HON e i E ETE 34 MAXIMUM TOOL TO TOOL BUSHING CLEARANCE 35 RETAINING PIN ow HOC 36 MET u u u uu E E 37 TE ROD TOROUE Ra nn nn 37 HAMMER FASTENER TORGOUE aunt diseno etx 38 STORAGE OF HYDRAULIC HAMMER Z Z Z dS 39 NOTE SAND RECORDS u uuu uu sa naa atau VAR Ede EU 40 SAFETY Safety notices in NPK Instruction Manuals follow ISO and ANSI standards for safety warnings DANGER DANGER red notices indicate an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING WARNING orange notices indicate a potentially hazardous situation which if not avoided c
19. TION GREASING PROCEDURE Manual greasing for hammers without AUTOLUBE system IMPORTANT 1 The hammer must be in a vertical position with downforce applied to push the tool all the way in This prevents grease from entering piston impact area 2 Turn machine off 3 Grease the hammer until grease begins to come out around the tool and lower bushing APPLY DOWNFORCE TO PUSH TOOL UP INTO HAMMER NOTE USE A GOOD QUALITY EP 2 LITHIUM BASED GREASE WITH WEAR INHIBITING ADDITIVES SEE PAGES 13 14 AND 15 LUBRICATION CONTINUED CORRECT GREASE AND GREASE INTERVALS Proper hammer maintenance requires a sufficient supply of the correct grease to the tool chisel The tool must be pressed against a hard surface until it stops up inside the hammer This prevents grease from entering piston impact area and ensures proper distribution of grease between the tool and tool bushings GREASE INTERVALS If the hammer is not connected to an Autolube system see page 15 the hammer must be greased at regular intervals to get the best life from the tool and tool bushings There are two ways to determine grease intervals First grease the hammer at the beginning of the job until grease comes out between the tool and the lower tool bushing Run the hammer until the shank of the tool starts to look dry This determines the time interval for the greasing of this particular hammer on this particular job Typically this is 1 to 4 hours
20. cover failures resulting from exceeding the specified nitrogen gas pressure NITROGEN GAS PRE CHARGE SPECIFICATIONS AT AMBIENT TEMPERATURE AT OPERATING TEMPERATURE cold before operating MODEL PSI BAR PSI BAR plus 0 minus 25 plus 0 minus 25 E208 390 27 450 31 E210A E213 E220 E240A 390 27 450 31 E260A 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 Optional Regulator Valve GAS CHARGE KIT 21101050 7300588 20118010 30102050 3 Charge Adapter 30604040 4 Charge KitBox 35001030 28 GAS CHARGE CONTINUED CHECKING THE GAS PRESSURE Inspect the nitrogen gas pressure every 100 hours PROCEDURE 1 The gas pre charge is measured with no preload on the tool Remove the tool or position the hammer with the tool fully extended THE HAMMER MUST NOT BE RESTING ON THE POINT Charge valve cap 2 Remove the charge Turn the NPK charge 4 Install the NPK charge valve cap adapter T handle full adapter on the hammer counterclockwise charge valve CAUTION Remove the valve cap only not the charge valve assembly 6 Turn the T handle 5 Tighten the charge clockwise As the T adapter ca
21. e is at least 500 psi 35 bar above hammer operating pressure Cold gas charge is the initial set with the hammer at ambient temperature Hot gas charge is checked after 1 to 2 hours of running and with a system oil temperature of 140 to 180 F 60 to 80 C This is the preferred check 162 165 165 m e a m HYDRAULIC INSTALLATION NPK INSTALLATION KITS are available for virtually all compatible backhoe loaders excavators and skid steers Complete parts and instructions for the hydraulic installation of the NPK HYDRAULIC HAMMER including valving and or controls hoses and fittings accumulators boom and stick tubing and clamps are provided HAMMER LINES 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 through the carrier s oil cooler and filter ACCUMULATORS General guideline requirements Some installations may have special requirements MODEL Pressure Line Return Line Accumulator Accumulator E2080 OO E208 oe E210A E213 E216 E220 E225 E240A E260A For gear pump machines only HAMMER CONTROL VALVE NPK uses two general types of control systems depending upon the carrier model 1 CONTROL SYSTEM USING CARRIER AUXILIARY
22. for surface protection in friction effected areas Chisel Paste is an aluminum complex soap base with 12 graphite and copper additives for extreme operating conditions UNIVERSAL PLUS NPK PART 350 deg NO 14 OZ CARTRIDGE 0000 1010 120 LB KEG G000 1020 39 LB PAIL G000 1030 400 LB DRUM G000 1040 SUPER DUTY NPK PART 500 deg NO 14 OZ CARTRIDGE G000 1011 120 LB KEG G000 1021 35 LB PAIL G000 1031 eee lees hotte 400 LB DRUM G000 1041 EP2 GREASE WATER RESISTANT TEMP WATER RESISTANT CHISEL PASTE PART 2000 deg NO 14 OZ CARTRIDGE G000 1050 AUTOLUBE SYSTEMS An automatic greasing system is recommended m d to reduce hammer tool and tool bushing wear Grease Line The NPK AUTOLUBE System is designed to lt automatically provide a continuous supply of grease to the hammer tool and tool bushing increasing tool and tool bushing life by reducing lt AUTOLUBE Port wear The AUTOLUBE pump is capable of pumping EP2 grease in cold weather The pump output is adjustable according to the requirements of the hammer model and to compensate for tool bushing wear Grease Fitting for manulal lubrication NPK hammer models E208 and larger have a connection port for an automatic greasing system Refer to the NPK AUTOLUBE Instruction Manual for details LUBRICATION CONTINUED LUBRICANT TERMS TERM ADHESIVE ANTI WEAR AGENTS COHESIVE CONSISTENCY C
23. gen tank 3 Install a pressure 4 Connect a hose from the 6 Turn the handle the tank regulator on a tank of pressure regulator on the regulator counterclockwise nitrogen gas nitrogen tank to the charge to full closed adapter 7 the valve on the 5 Turn the T handle on the nitrogen tank by turning the charge adapter clockwise handle counterclockwise 8 Slowly adjust the regulator on the nitrogen tank to the correct pressure turning clockwise pressure Refer to NITROGEN GAS chart in the NITROGEN GAS PRESSURE section TOTNM 9 Charge nitrogen gas until the pressure gauge 925 pressure the on the charge adapter is at the correct setting hammer s to be then turn the T handle counterclockwise all the Way Out charged to 10 Close the nitrogen tank valve and then remove the hose from the charge adapter CAUTION Nitrogen gas may be trapped in the hose Loosen fittings slowly to release pressure 11 Remove the charge adapter from the hammer charge valve 12 Replace the charge valve cap 30 GAS CHARGE CONTINUED DISCHARGING THE GAS PRESSURE PROCEDURE Charge valve cap 1 Remove the charge valve cap adapter T handle full adapter on the hammer counterclockwise charge valve A CAUTION Remove the valve cap only not the charge valve assembly Hose from Pressure De regulator Pressure gauge Label sho
24. m a 000 to a 6 rating Most greases are NLGI 2 rated Oiliness is measured of the coefficient of friction of a lubricant Oiliness or lubricity depends on the adhering characteristics of an oil It is determined by the attraction between the molecules of the oil and the molecules of another material Of two oils having the same viscosity but different degrees of fluid friction the one with the lower friction index has the higher degree of oiliness A device which converts mechanical force into hydraulic fluid power Basic design types are gear vane and piston units LUBRICATION CONTINUED LUBRICANT TERMS AND DEFINITIONS continued TERM DEFINITION E 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 START UP HAMMERS THAT ARE NEW REBUILT OR ATTENTION HAVE BEEN INACTIVE Before using a new hammer for the first time the first time after rebuild or a hammer that has been inactive for a long period of time 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
25. ng metal pieces when driving Boom Pins lf modifications are to be made do not alter the HAMMER without authorization from NPK Engineering Use only genuine NPK replacement parts NPK specifically disclaims any responsibility for any damage or injury that results from the use of any tool or parts not sold or approved by NPK For further safety information consult the AEM Hydraulic Mounted Breakers Safety Manual AEM form MB 140 NPK P N H050 9600 which is furnished with every NPK hammer To request an additional copy please contact NPK at 800 225 4379 or Internet at www npkce com mE 71 HYDRAULIC MOUNTED FA E BREAKERS WWW aem org NT SAFETY MANUAL FOR OPERATING AND MAINTENANCE PERSONNEL INTRODUCTION NPK is a leading manufacturer of boom mounted HYDRAULIC HAMMERS and has the most complete product line available anywhere The success of NPK is due to our commitment to quality dependability and long The HYDRAULIC HAMMER has many unique designed features and it is a company philosophy that the NPK HYDRAULIC HAMMER can be brought to new condition long after competitive products are scrapped You can feel confident that you have purchased the best value available This comprehensive operators manual contains instructions for operating and maintaining NPK HYDRAULIC HAMMERS This manual includes helpful information for obtaining the full potential and efficiency from NPK HYDRAULIC HAMMER
26. ol to bushing gap reaches the maximum clearance Measure the tool to bushing gap with the hammer horizontal as illustrated below If the clearance is at or greater than the charted maximum clearance consult the NPK Hydraulic Hammer Service Manual to determine which component requires replacement inch mm 5 8 16 ZX 21 AQ TOOL DIAMETER 35 RETAINING PIN Deformation may occur on the retaining pin in the tool contact area If this area is mushroomed the retaining pin may become difficult to remove Dress with a grinder E208 thru E225 TOOL CONTACT AREA E240A and E260A TOOL CONTACT AREA 36 RODS TIE ROD TORQUE See TIE ROD REPLACEMENT section of the Service Manual for complete procedure when replacing a Tie Rod 1 Tighten all TOP NUTS with a TORQUE WRENCH to the recommended pre torque specification shown in CHART 1 It may take several passes at each top nut to achieve this Check that no gap is noted between the sections 2 Mark all the TOP NUTS and HEAD as shown in figure 1A 3 Further tighten all the TOP NUTS C 180 as shown in figure 1B 4 Further tighten all the TOP NUTS as shown in figure 1C using Chart 1 below for the appropriate number of flats D per hammer model Figure 1 HAMA00297 Chart 1 Socket Size Pre Total No of MODEL Torque Flats inch mm Ft Ibs Nm D E208 200 270 2 1 2 63 E210A 200 270 2 9 46 65
27. or additional information 3 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 section The retaining pin must rotate freely 4 DEMOLITION TOOL Remove the demolition tool and inspect for peening caused by excessive blank hammering If necessary grind edges smooth as shown in TOOL INSPECTION section 5 GAS CHARGE Check and adjust if required see GAS CHARGE section yy ac 5 NITROGEN GAS PRESSURE The nitrogen gas pressure must be measured with no preload on the tool Remove the tool or position the hammer with the tool fully extended against the tool retaining pin The hammer must not be resting vertical on the tool The gas pressure in the hammer will vary according to the gas temperature PREFERRED METHOD The preferred method to measure or charge the nitrogen gas pressure is with the hydraulic system temperature stabilized at maximum operating temperature The chart showing values for Operating Temperature should be used see below ALTERNATE METHOD The nitrogen gas pressure can be measured or charged at ambient temperature cold before operating the hammer 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
28. ouded or the oil filter has become clogged it indicates that the oil is contaminated Change the oil immediately change the contaminated hydraulic oil drain the hydraulic system completely and clean components Do not mix new oil with the old 2 Do not allow any contamination to mix with the oil Take special care in preventing contamination from entering the hydraulic system through the hose or tube connection when changing the hydraulic hammer with the bucket 3 Low oil level will cause heat build up resulting in deterioration of the oil Also it may cause cavitation due to air mixing with the oil leading to a damaged hydraulic hammer and carrier components Keep the oil at the proper level at all times 4 Do not use the hydraulic hammer at an operating temperature higher than 180 F 80 C The proper operating oil temperature range is between 120 F 50 C and 180 F 80 C Since clogged cooler fins causes reduced efficiency of the cooler keep the cooler fins clean at all times Check the hydraulic oil cooling system to be sure it is working effectively The use of a heat gun is the best way to evaluate if the cooler is working properly 5 Water in the hydraulic oil will lead to damage of the hydraulic hammer and carrier Drain off water and foreign matter from the hydraulic tank at specified intervals When out of service the hydraulic hammer should be stored indoors CHANGING THE FILTER ELEMENT AND HYDRAULIC OIL
29. ould result in death or serious injury CAUTION yellow notices indicate a potentially hazardous situation A CAUTION which if not avoided may result in minor or moderate injury ATTENTION blue notices in NPK Instruction Manuals are an NPK ATTENTION standard to alert the reader to situations which if not avoided could result in equipment damage 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 SIAY CLEAR PRESSURE VESSEL GAS PRESSURE and TOOL SHARPENING decals are installed on all NPK hammer models Keep them clean and visible NPK will provide decals free of charge as needed 1 Operator and Service personnel must read and understand the NPK INSTRUCTION MANUAL to prevent serious or fatal injury 2 FLYING DEBRIS CAN CAUSE SERIOUS OR FATAL INJURY e Keep personnel and bystanders clear of hammer while in operation e Do not operate HAMMER without an impact resistant guard between HAMMER and operator NPK recommends LEXAN or equivalent material or steel mesh Some carrier manufacturers offer demolition guards for their machine Check with the carrier manufacturer for availability If not available please call NPK AFFIX DECAL IN CAB AT LOCATION VISIBLE TO OPERATOR DO NOT AFFIX TO DOOR FLYING DEBRIS CAN CAUSE SERIOUS OR FATAL INJURY Read NPK Operators Manual O
30. ow the tool to penetrate before breaking move the hammer slightly fore and aft to create a cone shaped hole The vented hole allows trapped dust and heat to escape increases the tool penetration rate into the material and prevents overheating the tool tip DO NOT HAMMER CONTINU OUSLY IN THE SAME POSITION FOR MORE THAN 30 SECONDS If the tool cannot break or penetrate into the material after hammering in the same position for 30 seconds change the working location Hammering in the same position for a long time will reduce the working efficiency increase the hydraulic oil temperature overheat the tool tip and accelerate tool wear ALWAYS WORK BY BREAKING TO A FREE FACE The material must have somewhere to break to Start at an edge 93 2 OPERATION CONTINUED ATTENTION OPERATING TECHNIQUES amp 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 OR BRACKET TO MOVE LARGE OBJECTS Do not use the hammer bracket for purposes other than for what is was intended ee ie cS RN AVOID OPERATING THE lt HAMMER WITH CYLINDERS THE END OF STROKE Continuous operation with the boom cylinders fully retracted or extended may damage the hydraulic cylinders tete t X ode x fe 24 OPERATION CONTINUED
31. p Pressure 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 Stop turning the T handle when the gauge reads pressure Do not overtighten 7 Compare the gauge pressure with the NITROGEN GAS PRE CHARGE chart in the NITROGEN GAS PRESSURE section If the gas pressure is 25 psi 2 bar or more below specification proceed to NITROGEN GAS CHARGING PROCEDURE If the pressure is correct go to the next step 8 Turn the T handle counterclockwise until it stops as in step 3 9 Slowly loosen the charge adapter cap to relieve the nitrogen gas pressure trapped in the charge valve 10 Remove the charge adapter from the hammer charge valve 11 Replace the charge valve cap on the charge valve 29 GAS CHARGE CONTINUED CHARGING THE HAMMER Do not stand near the tool when USE NITROGEN GAS ONLY charging with nitrogen gas l z AP L STAY CLEAR OF THE TOOL WHILE CHARGING THE HAMMER WITH GAS The tool may be impacted by the piston and forced out abruptly Nitrogen tank PROCEDURE 1 Carry out steps 1 thru 4 of CHECKING THE GAS PRESSURE 2 Remove the cap from the charge adapter CAUTION Remove the valve cap only not the charge valve assembly Pressure gauge 1 Charge wd adapter Miu m Nitrogen a 7N tank i aa Nitro
32. perator must be protected by an impact resistant shield or cab window NPK bystanders away H100 7010 Warning Decal for Cab Installation 3 Do not hardface or sharpen the tool point with a cutting torch Excessive heat from torching or welding can cause embrittlement breakage and flying pieces Resharpen by milling or grinding only using sufficient coolant m SAFETY CONTINUED 10 11 12 13 14 15 Fully extend the tool while charging the HAMMER with nitrogen gas Be sure that the retaining pin is installed STAY CLEAR OF TOOL POINT WHILE CHARGING Do not disassemble a HAMMER before discharging the hammer gas pre charge USE NITROGEN GAS ONLY Store and handle nitrogen tanks per OSHA regulations Avoid high pressure fluids Escaping fluid under pressure can penetrate the skin Causing serious injury Relieve pressure before disconnecting hydraulic or other lines Operate HAMMER from operators seat only Match HAMMER size to carrier according to NPK recommendations The carrier must be stable during hammer operation and during transport See CARRIER MACHINE COMPATIBILITY section of the NPK instruction manual Do not make any alterations to the TOOL without authorization from NPK Engineering Use proper lifting equipment and tools when handling or servicing the HAMMER Wear ear protection and safety glasses when operating the hammer Consult OSHA MSHA regulations when applicable Beware of flyi
33. t for leaks or loose connections Do not operate on a slanted surface during the start up operation HAMADI29S WARNING SAFE OPERATING INSTRUCTIONS i E Slee E 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 AS A HOIST The hammer is not intended to lift an object To do so can be dangerous See ns TESTES To EE TUE DO TOUCH HOT TOOL AFTER USING 20 OPERATION CONTINUED ATTENTION OPERATING TECHNIQUES amp PRECAUTIONS PRELOAD THE TOOL BEFORE STARTING Press the tip of the demolition tool vertically against the object to be broken Be sure the object is stable before activating the NPK HYDRAULIC HAMMER APPLY DOWNFORCE ON THE 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 to the hammer will raise the carrier too high and jolt the operator when the material breaks Let the NPK HYDRAULIC APPLY DOWNFORCE HAMMER the work TO LIFT CARRIER SLIGHTLY AVOID BLANK HAMMERING As soon as the material is broken release the
34. trol valve if required and hoses to connect to the carrier hydraulic system MC Refer to HAMMER FASTENER TORQUE section for Top Bracket bolt torque Refer to NPK Installation Kit Manual for additional information MOUNTING INSTALLATION CONTINUED MOUNTING TO THE CARRIER 1 Place the hammer horizontal on SHUT OFF VALVE wood blocks as shown T 2 Align the boom pin holes Install the stick pin before the cylinder link pin 3 Clean away any dirt found on the hose connections and connect hoses Pressure line is on left return line on right side of boom 4 Open shut off valves IE REMOVAL FROM THE CARRIER The hydraulic lines must be handled carefully and ATTENTION sealed to prevent contamination from entering the hammer or the carrier hydraulic system RUBBER SHUT OFF 1 Close pressure and return line MOUNTS 2 VALVE shut off valves 2 Disconnect the hydraulic hoses lt X 606 before laying the hammer down LV gt INSTALL CAP Avoid getting hydraulic oil on rubber mounts Flush with water if necessary 3 Cap the pressure and return lines on the carrier and connect the hammer whip hoses as shown Disconnect the whip hoses with the hammer positioned as shown with the Rubber Mounts above the hose connections Couple the hoses to the blind fittings on the Hammer Bracket 4 Position hammer horizontally on wood blocks and remove the boom pins LUBRICA
35. wing the gas pressure the hammer is to be charged to 4 Tighten the charge 5 Turn the T handle 6 Loosen the charge adapter adapter cap clockwise the T cap VERY SLOWLY The handle is screwed in gas pressure will gradually a resistance 15 decrease to zero then encountered By REMOVE THE CAP turning the T handle further the nitrogen 7 Remove the charge adapter gas pressure will be from the hammer and indicated on the reinstall charge valve cap pressure gauge Stop turning the T handle when the gauge reads pressure Do not over tighten 31 TOOLS STANDARD TOOLS CHISEL Crosscut FX S E wo T awo i CORE PC LEA E mm DIFFERENCE BETWEEN FX AND FY TOOLS The crosscut FX tool cuts at right angle or crosswise excavator 32 NPK Controlled breakage of concrete Layered sedimentary rock trenching oversize General demolition Cutting casting gates Concrete structures columns etc Soft material Concrete slab bridge decking Oversize Slag removal Hard rock General demolition to the stick and boom of the TOOLS CONTINUED CHANGING THE TOOL REMOVAL 1 Remove the retaining ring by using pliers or screwdrivers see Figures 1 and 2 It will easily come out if pulled at an angle as shown in Figure 2 2 Screw an M12 bolt or cap screw into the retainer pin 3
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