NPK PH1, PH2, PH4, PH3 Owner's Manual

Download

Page 1

HYDRAULIC HAMMER

OPERATORS MANUAL

PH SERIES HAMMERS

PH1 PH2 PH3 PH4

“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

Page 2

CONTENTS

SAFETY .......................................................................................................................... 3

INTRODUCTION ............................................................................................................. 5

CARRIER MACHINE COMPATIBILITY .......................................................................... 6

HAMMER SPECIFICATIONS ......................................................................................... 7

STRUCTURE .................................................................................................................. 8

STRUCTURAL DRAWING .......................................................................................... 8

HAMMER SERIAL NUMBER LOCATION ....................................................................... 9

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

HYDRAULIC INSTALLATION ....................................................................................... 10

PREVENTION OF CONTAMINATION ...................................................................... 12

HYDRAULIC QUICK DISCONNECTS ...................................................................... 13

MOUNTING INSTALLATION ........................................................................................ 15

REMOVAL FROM THE CARRIER ............................................................................ 15

REMOVAL FROM THE SKID STEER....................................................................... 16

MOUNTING TO THE CARRIER ............................................................................... 16

MOUNTING TO THE SKID STEER .......................................................................... 16

LUBRICATION .............................................................................................................. 17

GREASING PROCEDURE ....................................................................................... 17

CORRECT GREASE AND GREASE INTERVALS ................................................... 18

CORRECT GREASE FOR HYDRAULIC HAMMERS ............................................... 19

NPK HAMMER GREASE ....................................................................................... 19

AUTO LUBE SYSTEMS ......................................................................................... 19

AUTO LUBE GREASE LINE PRE-FILLING .............................................................. 20

HAMMER MOUNTED AUTO LUBE GREASE LINE PRE-FILLING .......................... 23

LUBRICATION .............................................................................................................. 25

LUBRICANT TERMS AND DEFINITIONS ................................................................ 25

START-UP OPERATION .............................................................................................. 28

HAMMERS THAT ARE NEW, REBUILT, OR HAVE BEEN INACTIVE .................... 28

BEFORE STARTING THE HAMMER ....................................................................... 29

DAILY START-UP PROCEDURE ............................................................................. 29

OPERATION ................................................................................................................. 30

OPERATING TECHNIQUES & PRECAUTIONS ...................................................... 31

IMPACT ENERGY TRANSMISSION THROUGH TOOLS ............................................ 36

IMPACT STRESS WAVES AT THE END OF THE TOOL ........................................ 37

TOOL BREAKAGE ........................................................................................................ 38

TOOL BREAKAGE DUE TO EXCESSIVE BENDING MOMENT .............................. 38

TOOL BREAKAGE DUE TO EXCESSIVE WEAR OF THE TOOL HOLDER

BUSHINGS ............................................................................................................... 39

CHIPPING IN RETAINING PIN SLOT ...................................................................... 41

DEFORMATION OF THE RETAINING PIN SLOT SIDES ........................................ 41

DEFORMATION OF THE TOOL TIP ........................................................................ 42

CHIPPING OF A MOIL POINT TOOL TIP ................................................................ 43

CHIPPING OF A CHISEL TOOL TIP ........................................................................ 43

TEMPERATURE RELATED TOOL PROBLEMS ...................................................... 44

TOOL BREAKAGE DUE TO CORROSION .............................................................. 45

TOOL BREAKAGE DUE TO DEFECTIVE MATERIAL ............................................. 45

- 1 -

Page 3

CONTENTS

ROUTINE INSPECTION AND MAINTENANCE ............................................................ 46

WEEKLY INSPECTION ................................................................................................ 47

TOOLS .......................................................................................................................... 48

STANDARD TOOLS ................................................................................................. 48

ACCESSORY TOOLS .............................................................................................. 48

TOOL IDENTIFICATION ........................................................................................... 49

CHANGING THE TOOL ............................................................................................ 50

MAXIMUM TOOL TO TOOL BUSHING CLEARANCE ............................................. 52

TOOL INSPECTION ................................................................................................. 54

CHISEL TOOL RESHARPENING ............................................................................. 55

STANDARD LENGTH FOR NPK TOOLS ................................................................. 56

TOOL RETAINING PIN INSPECTION ...................................................................... 57

GAS CHARGE .............................................................................................................. 59

NITROGEN GAS PRESSURE .................................................................................. 59

GAS CHARGING KIT ............................................................................................... 60

CHECKING THE GAS PRESSURE .......................................................................... 61

CHARGING THE HAMMER ...................................................................................... 63

DISCHARGING THE GAS PRESSURE ................................................................... 64

STORAGE OF HYDRAULIC HAMMER ........................................................................ 65

WARRANTY REGISTRATION FOR NEW UNITS ........................................................ 66

TOOL WARRANTY ....................................................................................................... 67

WARRANTY STATEMENTS ......................................................................................... 69

NOTES AND RECORDS .............................................................................................. 73

- 2 -

Page 4

SAFETY

Safety notices in NPK Instruction Manuals follow ISO and ANSI standards for safety warnings:

DANGER (red) notices indicate an imminently hazardous situation which, if not avoided, will result in death or serious injury.

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. Keep them clean and visible. NPK will provide decals free of charge as needed.

WARNING (orange) notices indicate a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION (yellow) notices indicate a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury.

ATTENTION (blue) notices in NPK Instruction Manuals are an NPK standard to alert the reader to situations which, if not avoided, could result in equipment damage.

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.

 Keep personnel and bystanders clear of hammer while in operation.

 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.

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.

- 3 -

Page 5

SAFETY

4. 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.

5. Do not disassemble a HAMMER before discharging the hammer gas pre-charge.

6. USE NITROGEN GAS ONLY! Store and handle nitrogen tanks per OSHA regulations.

7. Avoid high pressure fluids. Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or other lines.

8. Operate HAMMER from operator’s seat only.

9. 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.

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.

12. Wear ear protection and safety glasses when operating the hammer. Consult

OSHA/MSHA regulations when applicable.

13. Beware of flying metal pieces when driving mounting pins.

14. If modifications are to be made, do not alter the HAMMER without authorization

from NPK Engineering!

15. 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.

- 4 -

Page 6

INTRODUCTION

NPK is a leading manufacturer of 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 life. The HYDRAULIC HAMMER has many unique designed features and it is a company philosophy that the NPK HYDRAULIC HAMMER can be brought to "like new” condition long after competitive products are scrapped. You can feel confident that you have purchased the best value available.

This comprehensive operator’s 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 HAMMERS. 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.

This manual will also assist NPK Dealers and Customers to obtain the longest possible life from the NPK Demolition Tools.

Customers can use this manual to take corrective action when tool breakage occurs. Dealers can use this manual to determine if tool breakage can be claimed under warranty.

Refer to the NPK Demolition Tool Warranty statement found later in this manual for the specifics of the warranty coverage.

- 5 -

Page 7

CARRIER MACHINE COMPATIBILITY

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 damage the machine. 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 lbs. (kg)

HAMMER MOUNTING RECOMMENDED RANGE

MODEL STYLE lb (kg)

PH1

PH2

PH3

PH4

*Specifications are subject to change without notice.

Excavator 4,850 - 5,955 (2,200 - 2,700)

Skid Steer 4,850 - 5,955 (2,200 - 2,700)

Excavator 5,955 - 8,820 (2,700 - 4,000)

Skid Steer 5,955 - 8,820 (2,700 - 4,000)

Excavator 8,820 - 13,228 (4,000 - 6,000)

Skid Steer 8,820 - 13,228 (4,000 - 6,000)

Excavator 13,228 - 19,842 (6,000 - 9,000)

Skid Steer 13,228 - 19,842 (6,000 - 9,000)

- 6 -

Page 8

HAMMER SPECIFICATIONS

HAMMER IMPACT FREQUENCY MOUNTING WORKING TOOL

MODEL ENERGY STYLE WEIGHT DIA. WORKING

CLASS LENGTH ft. lb. bpm lbs. (kg) in. (mm) in. (mm)

PH1

PH2

PH3

PH4

HAMMER OIL FLOW HYDRAULIC OPERATING MINIMUM CIRCUIT

MODEL PRESSURE1 RELIEF2

350 550 - 1,100 Excavator 423 (192) 2.24 (57) 14.0 (356)

Skid Steer 674 (306)

500 500 - 1,200 Excavator 487 (221) 2.60 (66) 15.1 (384)

Skid Steer 735 (333)

750 500 - 1,150 Excavator 825 (374) 2.99 (76) 16.5 (419)

Skid Steer N/A

1300 400 - 1,000 Excavator 1,064 (483) 3.39 (86) 18.5 (469)

Skid Steer N/A

gpm PH1 PH2 PH3 PH4

NITROGEN GAS PRECHARGE

HAMMER AT AMBIENT TEMPERATURE

MODEL

*psi (bar) *psi (bar) PH1 PH2 PH3 PH4

*The gas charge tolerances plus 0, minus 25 psi (2 bar).

*Specifications subject to change without notice.

7 - 15

7 -16 12 - 27 13 - 32

(cold before operating)

175 (12) 220 (15) 175 (12) 220 (15) 175 (12) 220 (15) 175 (12) 220 (15)

(lpm)

(25 - 55)

(25 - 60) (45 - 100) (50 - 120)

psi

2,175 - 2,465 2,175 - 2,465 2,175 - 2,465 2,175 - 2,465

NOTES:

(bar)

(150 - 170) (150 - 170) (150 - 170) (150 - 170)

AT OPERATING TEMPERATURE (hot,

after 1 to 2 hrs. operation)

psi

2,965 2,965 2,965 2,965

(bar)

(204) (204) (204) (204)

1. Hydraulic operating pressure maximum is inlet pressure at the hammer with the oil at operating temperature and with the gas charge set at the hot operating pressure. See CHECKING THE HYDRAULIC PRESSURES section in the Service Manual.

2. Circuit relief pressure is at least 500 psi (35 bar) above hammer operating pressure.

3. Cold gas charge is the initial set with the hammer at ambient temperature.

4. 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.

5. Pressures listed are the maximum allowed. Use tolerance of minus 25 psi (2 bar).

- 7 -

Page 9

STRUCTURE

STRUCTURAL DRAWING

MODELS PH1 – PH4

30 GREASE FITTING

A MAIN BODY

BB PLUNGER

D RETAINING PIN E RETAINING RING G TOOL BUSHING

HH TOOL

L GAS HEAD

M CHARGE VALVE

N PISTON

O MAIN BODY SLEEVE (A)

P MAIN BODY SLEEVE (B) Z VALVE SPOOL

- 8 -

Page 10

HAMMER SERIAL NUMBER LOCATION

SERIAL NUMBER LOCATION (sn1)

- 9 -

Page 11

HYDRAULIC INSTALLATION

NPK can produce INSTALLATION KITS for virtually all compatible backhoe loaders, excavators, and skid steers. Complete parts and instructions for the hydraulic installation of the NPK HYDRAULIC HAMMER including valves and/or controls, hoses and fittings, boom and stick tubing, and clamps are provided.

HAMMER LINES (BACKHOE and EXCAVATOR)

Typically, the pressure line is arranged on the left side of the boom and routed to the hammer “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 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.

HAMMER LINES (SKID STEER)

Flow to the hammer (m3) is directed from an auxiliary valve on the skid steer. NPK hammer ports are marked “IN” and “OUT”. On skid steers where the auxiliary flow is excessive for the hammer model, a flow control valve (ma3) is recommended. Return oil (m4) is routed back to tank through the skid steer return circuit.

HAMMER CONTROL VALVE

NPK uses two general types of control systems, depending upon the carrier model:

1. CONTROL SYSTEM USING THE CARRIER AUXILIARY OR SPARE VALVE SECTION.

This type of installation utilizes an existing carrier valve. Any additional parts, such as a mechanical linkage, hydraulic pilot actuators, 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.

- 10 -

Page 12

HYDRAULIC INSTALLATION

SKID STEER HAMMER FLOW CONTROL VALVE (OPTIONAL)

Be sure that the pressure (m3) and return lines (m4) are properly routed. Inlet pressure connects to port “P” on the NPK flow control valve (ma3). Regulated flow

from valve port “H” (m5) connects to the “IN” port on the NPK hammer. The “OUT” port on the hammer connects to port “T2” (m6) on the flow control valve. “T1” connects to the return line (m4) on the skid steer.

- 11 -

Page 13

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. 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 clouded, or the oil filter has become clogged, it indicates that the

oil is contaminated. Change the oil immediately!

 To 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 contaminat ion 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 contaminated 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

Change the filter element and hydraulic oil at the intervals described in the operation manual of the skid steer or excavator, when using a hydraulic implement. Another method is to set up an oil sampling schedule and change accordingly.

- 12 -

Page 14

HYDRAULIC INSTALLATION

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 disconnect to disintegrate. These pieces would migrate into the hammer, causing damage.

2. If quick disconnects are not used when the hammer is removed from the excavator, the hose ends should be capped to keep them clean. If this is not done, contamination in the hose ends 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 backpressure sensitive, but restrictions cause unnecessary heating of the oil. Also, the pressure required to operate the hammer, plus the restriction in the quick 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 (39)

NOT RECOMMENDED CONNECTION

Non-NPK Quick Disconnects (32)

NPK APPROVED CONNECTION QUICK DISCONNECTS

CONTACT YOUR NPK DEALER FOR ADDITIONAL INFORMATION ABOUT

NPK QUICK DISCONNECTS (DX)

- 13 -

Page 15

HYDRAULIC INSTALLATION

HYDRAULIC QUICK DISCONNECTS

If hydraulic quick disconnects are used with the NPK Hammer, it is recommended that the following precautions be followed.

1. Periodic inspection of both male (DXm) and female (DXf) ends is recommended to ensure the couplers are in good working condition. Failure to inspect couplers may result in pieces from a damaged or failed coupler to be injected into the hammer or parts of the coupler returned to the machine.

2. Check for dirt, dust, and debris on both male and female couplers before coupling.

3. Be sure that the couplers are completely seated together (38).

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.

- 14 -

Page 16

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).

BACKHOES and EXCAVATORS

SKID STEERS

NPK Mounting Installation Kits for skid steers include parts required to adapt the NPK HYDRAULIC HAMMER to the carrier. NPK mounting kits include the hammer mounting bracket (m7), and hoses (m3 and m4) to connect to the carrier hydraulic system. The flow control valve (ma3) is optional.

AF Hex Head Cap Screw (if required) g20 Male Adapter (if required) m12 Hex Nut (if required) DXm Male Quick Disconnect (if required) DXf Female Quick Disconnect (if

required) m1 Stick Pin (if required) m2 Link Pin (if required) m3 (Whip) Pressure Hose m4 (Whip) Return Hose m7 Top Bracket m8 Hammer Bolt Package m9 Klik Pin (if required)

REMOVAL FROM THE CARRIER

BACKHOES and EXCAVATORS

1. Close pressure and return line shut-off valves (k4) if available.

2. Disconnect hydraulic hoses (m3 and m4) before laying the hammer down.

3. Cap the pressure and return lines on the carrier and connect the hammer whip hoses to the hammer bracket.

4. Position the hammer (DR) horizontal on wood blocks (t20) and remove stick (m1) and link (m2) pins.

- 15 -

Page 17

MOUNTING INSTALLATION

REMOVAL FROM THE SKID STEER

1. Position the hammer (DR) horizontally onto the ground or wood blocks (t20) as shown.

2. Disconnect both inlet and outlet hoses.

3. Unlatch the mechanism holding the hammer bracket to the carrier’s coupler plate. (Consult the machine manufacturer’s operator/instruction manual for this procedure.

The tool end of the hammer should be set lower than the head end to prevent moisture from entering the hammer through the tool area.

MOUNTING TO THE CARRIER

BACKHOES and EXCAVATORS

1. Place the hammer assembly (DR) horizontally on wood blocks (t20) as shown.

2. Align the stick pin bore (m26). Install the stick pin. Then align the link pin bore (m25).

3. Connect the pressure side hose (m3) and the return side hose (m4).

4. Open the shut-off valves (k4) if available.

MOUNTING TO THE SKID STEER

1. Place the hammer (DR) horizontally onto wood blocks (t20) as shown.

2. Align the carrier’s coupler plate with the hammer bracket. Couple the two per the machine manufacturer recommendations.

3. Connect the hoses.

Consult the skid steer manufacturer’s operators manual to review the mounting and removal process!

The hydraulic lines must be handled carefully and sealed to prevent contamination from entering the hammer or the carrier’s hydraulic system.

- 16 -

Page 18

LUBRICATION

GREASING PROCEDURE

1. Place the hammer in a vertical position, applying enough down force to push the tool up into the hammer.

2. Turn the machine off.

3. Grease the hammer until grease begins to come out around the tool and lower bushing.

4. Grease hammer at least once an hour. See “Correct Grease and Grease Intervals” for a more exact greasing procedure.

APPLY DOWN FORCE TO PUSH TOOL UP INTO HAMMER

NOTE: USE A GOOD QUALITY EP #2 LITHIUM BASED GREASE WITH WEAR INHIBITING ADDITIVES, SEE PAGES 18 AND 19.

- 17 -

Page 19

LUBRICATION

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 Auto Lube System, see page 19, 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. 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.

There are many manufacturers of grease that meet NPK’s recommendations. NPK does not endorse any one brand as being superior to another. If you or your customers question a brand to be used, please call the NPK Service Department at 800-225-4379.

- 18 -

Page 20

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 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. Chisel Paste is an aluminum complex soap base with 12% graphite and copper additives for extreme operating conditions.

UNIVERSAL PLUS NPK PART

350 deg NUMBER

14 oz. (.397 kg) CARTRIDGE G000-1010 120 lb. (54 kg) KEG G000-1020 35 lb. (16 kg) PAIL G000-1030 400 lb. (181 kg) DRUM G000-1040

AUTO LUBE SYSTEMS

14 oz. (.397 kg) CARTRIDGE G000-1011 120 lb. (54 kg) KEG G000-1021 35 lb. (16 kg) PAIL G000-1031 400 lb. (181 kg) DRUM G000-1041

14 oz. CARTRIDGE G000-1050 35 lb. (16 kg) PAIL G000-1060 400 lb. (181 kg) DRUM G000-1070

SUPER DUTY NPK PART

500 deg NUMBER

CHISEL PASTE NPK PART

2000 deg NUMBER

An automatic greasing system is recommended to reduce hammer tool and tool bushing wear. THE NPK AUTO LUBE SYSTEM is designed to automatically provide a continuous supply of grease to the hammer tool and tool bushing – increasing tool and tool bushing life by reducing wear. The AUTO LUBE 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.

26 – AUTO LUBE PORT 29 – GREASE LINE 30 – GREASE FITTING FOR MANUAL

LUBRICATION

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

- 19 -

Page 21

LUBRICATION

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. This can and will result in severe galling of the tool and tool bushing.

PRIMING THE GREASE LINE

1. Place the hammer (KK) in a vertical position, applying enough down force to push the tool up into the hammer.

2. Turn the machine off.

3. Fill the NPK Auto Lube pump reservoir with a power greaser through the fill fitting on the side of the pump, or from the top by removing the fill cover. Use a premium quality grade EP-2, high temperature grease with wear inhibiting additive.

4. Disconnect the grease line (29) from the Auto Lube main pump cartridge (a4).

5. Install part number G100-8050 hose fill adapter (a13) onto the #6 JIC end of the grease line (29) previously removed.

6. Remove the grease line (29) at the hammer (KK).

7. Attach a grease gun (t37) or power greaser to the grease line (29) leading to the hammer.

- 20 -

Page 22

LUBRICATION

AUTO LUBE 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). This will prime the hammer cavity and pre-lube the tool. Look for grease coming out around the tool (HH) at the tool bushing (see arrow).

11. Remove the hose fill adapter (a13)

and re-connect the grease line (29) to the Auto Lube pump (FZ).

NOTE: If the Auto Lube has run out of grease, the above procedure should be

used to purge all the air out of the line (29) before using the hammer. Failure to do this will result in an intermittent supply of grease to the hammer.

- 21 -

Page 23

LUBRICATION

AUTO LUBE 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

- 22 -

Page 24

LUBRICATION

HAMMER MOUNTED AUTO LUBE GREASE LINE PRE-FILLING

It is mandatory that the supply line from the Auto Lube main pump to the connection on the hammer is primed with grease before it is used. Failure to do this will result in no grease being administered to the hammer tool for a period of time. This can and will result in severe galling of the tool and tool bushing.

PRIMING THE GREASE LINE

1. Place the hammer in a vertical position, applying enough down force to push the tool up into the hammer.

2. Turn the machine off.

3. Make sure there is a full grease cartridge installed in the Auto Lube assembly. Use a premium quality grade EP-2, high temperature grease with wear inhibiting additive.

4. Remove the grease line (29) at the hammer (KK).

5. Attach a grease gun (t37) or power greaser to the grease fitting (30) on the front side of the pump assembly (FZ).

- 23 -

Page 25

LUBRICATION

HAMMER MOUNTED AUTO LUBE GREASE LINE PRE-FILLING

PRIMING THE GREASE LINE

6. Pump grease through the pump to the grease line (29) until a steady stream of grease (28) is realized at the opposite (hammer) end.

6a. It is also possible to purge the grease

line to the hammer by disconnecting it at the hammer then pumping grease through the grease fitting provided on the grease pump assembly.

7. Re-attach the grease line (29) to the hammer (KK).

8. Pump twenty more shots of grease using the grease gun (t37) or power greaser into the pump assembly (FZ). This will prime the hammer cavity and pre-lube the tool.

9. Look for grease coming out around the tool (HH) at the tool bushing (see arrow).

NOTE: If the Auto Lube has run out of grease, the above procedure should be

used to purge all the air out of the line (29) before using the hammer. Failure to do this will result in an intermittent supply of grease to the hammer.

- 24 -

Page 26

LUBRICATION

LUBRICANT TERMS AND DEFINITIONS

TERM DEFINITION

ADHESIVE ANTI WEAR AGENTS COHESIVE CONSISTENCY

CONTAMINATION DROPPING POINT

EXTREME PRESSURE AGENTS FILM STRENGTH

FRICTION GALLING LUBRICATION NLGI

OILINESS

PUMP

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 penetrometer 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. Foreign material that could damage a part. The minimum temperature at which the oil in grease subjected to heat begins to actually drip and breakdown. Additives that under extreme pressure form an adherent 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 grease from the National Lubricating Grease Institute. This rating determines the hardness of the grease and goes on from a 000 to a 6 rating. Most different brands of grease are NLGI #2 rated. Oiliness is measured of the coefficient of friction of a lubricant. Oiliness or lubricity depends on the adhering characteristics of the 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.

- 25 -

Page 27

LUBRICATION

LUBRICANT TERMS AND DEFINITIONS

TERM DEFINITION

RESERVOIR VIBRATION

VISCOSITY

A container for keeping a supply of working fluid in a hydraulic system. 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.

- 26 -

Page 28

AUTO LUBE / UNDERWATER PORT IDENTIFICATION

NPK PH Series Hammers are equipped with two ports on the main body (A) used in adapting for AUTO LUBE and underwater use. The air port (17) will allow the connection of an air line that will allow the hammer to be used underwater. The grease port (26), located in line with the air port, will allow for AUTO LUBE connection.

- 27 -

Page 29

START-UP OPERATION

HAMMERS THAT ARE NEW, REBUILT, OR 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 the first time. For the inspection procedure, see CHECKING THE GAS PRESSURE.

2. At idle (THP1), raise the hammer off the ground. Place the hammer vertical and activate the hammer hydraulic 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 the hammer before first use. Failure to do this could result in damage to the hammer’s internal components.

3. Place the hammer firmly against the material to be broken (see “PRELOAD THE TOOL BEFORE STARTING”). Operate the hammer in a vertical position for

approximately 10 minutes at one-half (THP2) engine speed. Increase the engine speed to three-quarters (THP3) and continue operating at this speed for another 10 to 20 minutes. Increase to full engine speed (THP4). Maintain vertical position for the duration of the operation.

- 28 -

Page 30

START-UP OPERATION

BEFORE STARTING THE HAMMER

PRE-OPERATION INSPECTION AND WARM UP

Before operating the NPK HYDRAULIC HAMMER, be sure to perform the specified inspection, see “ROUTINE INSPECTION AND MAINTENANCE”.

Warm up the NPK HYDRAULIC HAMMER, see below, and the base machine in accordance with the machine manufacturer’s instruction manual. This is especially important during cold weather operation.

DAILY START-UP PROCEDURE

Operate the NPK HYDRAULIC HAMMER in the vertical position, at 3/4 engine throttle setting, for about 1-2 minutes. During this period, inspect the NPK HYDRAULIC HAMMER and INSTALLATION KIT for leaks or loose connections.

Do not operate on a slanted surface during the start-up operation.

- 29 -

Page 31

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. to be thrown towards the cab.

DO NOT USE THE HAMMER AS

A HOIST

The hammer is not intended to lift an

object. To do so, can be dangerous!

DO NOT TOUCH HOT TOOL

AFTER USING

- 30 -

Page 32

OPERATION

OPERATING TECHNIQUES & 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 down force 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 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.

Blank hammering is continued hammer

operation after the material is broken.

This will overheat the hydraulic system,

and cause undue wear of hammer parts,

and result in eventual tool retaining pin

failures, see page 54.

- 31 -

Page 33

OPERATION

OPERATING TECHNIQUES & PRECAUTIONS

DO NOT SLANT HAMMER

For the most efficient demolition, align the direction of force (51) from the boom with the penetration direction (52) of the tool (HH). Failure to do this decreases the transfer of energy from the piston to the rock and increases the bending forces at the fulcrum of the tool. This unnecessary added stress leads to the following problems:

1. Premature wearing of the tool bushings and/or tool breakage.

2. Breakage of tie rods.

3. Breakage of bracket bolts.

When the tool is working at the incorrect angle, it will bind causing the sound of the hammer to change.

Keep the boom direction of force (51) in the same direction the tool is penetrating. Use the boom cylinder to preload the hammer (apply down force), and use the bucket and stick cylinders for alignment. Keep the tool tangent to the arc of the boom (54).

- 32 -

Page 34

OPERATION

OPERATING TECHNIQUES & PRECAUTIONS

DO NOT USE THE HAMMER

TOOL AS A PRY BAR

Excessive prying can cause premature

bushing wear and tool or tie rod

breakage. When hammering materials

that allow the tool to penetrate before

breaking, move the hammer slightly

fore and aft to create a cone-shaped

hole. 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. Start at an edge.

- 33 -

Page 35

OPERATION

OPERATING TECHNIQUES & PRECAUTIONS

DO NOT DROP THE HAMMER

RAPIDLY ON AN OBJECT

Remember, the hammer assembly

(DR) is heavier than an empty bucket

and will move faster than expected.

DO NOT USE THE HAMMER

ASSEMBLY (DR) TO MOVE

LARGE OBJECTS

Do not use the hammer assembly

(DR) for purposes other than for what

it was intended.

AVOID OPERATING THE

HAMMER WITH CYLINDERS

AT THE END OF STROKE

Continuous operation with the

cylinders fully closed (97) or extended

(96) may damage the hydraulic

cylinders.

- 34 -

Page 36

OPERATION

OPERATING TECHNIQUES & PRECAUTIONS

DO NOT OPERATE HAMMER

UNDERWATER

Do not allow parts, other than the

tool, to go below water level (115).

Underwater operation will damage

the hammer and allow water to enter

the carrier’s hydraulic system. The

hammer can be modified for

underwater use – 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. Submerging below

water level (115) can cause the tip of

the tool to become brittle and break

prematurely.

DO NOT ALLOW THE

HAMMER TOOL TO HIT THE

BOTTOM OF THE BOOM

ASSEMBLY

Use caution when tucking the hammer

in tight to the boom assembly for

transportation.

- 35 -

Page 37

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. The compression wave speed is equal to the speed of sound through steel, i.e., approximately 15,000 ft/sec. Therefore, if the tool is three feet long, the impact force reaches the object to be broken 1/5000 (0.0002) second after the piston hits the tool.

Impact force is transmitted as stress waves through the tool.

- 36 -

Page 38

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. However, not all the energy of the compression waves is transmitted to the material to be broken, part of it is reconverted into reverse compression, or tensile, waves that then travel back through the tool.

When the tool is not in contact with the material to be broken, the energy of the compression waves has nowhere to go and therefore, returns totally in the chisel as tensile waves. This is referred to as a “blank hammer blow”, see page 31.

The compression waves and the tensile waves travel in a complex manner in the tool during hammer operation. While these waves are gradually being attenuated by the internal friction of the tool and by the friction between the tool and the tool holder bushings, the next impact strikes the tool. Excessively heavy contact between the tool and tool bushings causes uneven stress concentrations. This leads to premature tool failure, as seen in later sections of this manual.

- 37 -

Page 39

TOOL BREAKAGE

The following is a description of tool failures, causes of tool failures, preventative measures, and application of warranty.

TOOL BREAKAGE DUE TO EXCESSIVE BENDING MOMENT

If the tool is subjected to excessive bending moment caused by slant hammering or prying, the tool will break. Tool breaks will generally resemble one of the following examples:

tb8. Starting point of crack that leads to breakage. tb9. Starting point of break. tb10. Sudden break from instant overload condition,

tb11. Galling

(face will look very dull gray).

CHARACTERISTICS OF THE BROKEN SECTION

1. The starting point of a fatigue fracture is on the surface of the tool and located at the front or rear side of the tool, with the hammer installed on the excavator and viewed from the cab.

2. The tool has galled areas on its surface. The galling initiates a surface crack from which the fatigue fracture starts. The stress cracks, combined with bending loads and impact shock, can break the tool.

PREVENTATIVE MEASURES

1. Properly position the hammer so as not to develop a bending moment in the tool.

2. Apply sufficient grease to prevent the tool from developing cracks due to galling. This will also assure longer tool bushing life.

WARRANTY

NPK Warranty does not apply to this type of failure.

- 38 -

Page 40

TOOL BREAKAGE

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. 1). This results in the impact head being chipped or broken (Fig. 2 & 3). With the tool at an angle, and in excessive side loading contact with the tool holder bushings, the shock load traveling down the tool is unevenly concentrated (Fig. 1). This can result in the tool breaking through the retaining pin slot (Fig. 4).

- 39 -

Page 41

TOOL BREAKAGE

TOOL BREAKAGE DUE TO EXCESSIVE WEAR OF THE TOOL HOLDER BUSHINGS

PREVENTATIVE MEASURES

Replace the tool bushing (BF), and/or tool (HH), when the tool to bushing gap (d15) reaches the maximum clearance. To determine whether the bushing or tool requires replacement, follow the instructions in the “MAXIMUM TOOL TO TOOL BUSHING CLEARANCE” section of this manual.

HAMMER MAXIMUM CLEARANCE

MODEL in (mm)

PH1 PH2 PH3 PH4

WARRANTY

NPK Warranty does not cover tool failure caused by worn tool holder bushings.

1/4 1/4 1/4 1/4

6 6 6 6

BF. Tool Bushing HH. Tool d15. Clearance d16. Tool Diameter

- 40 -

Page 42

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.

PREVENTATIVE MEASURES

When the material is broken, stop operating the hammer immediately. Periodically check the tool and grind smooth any chipped areas to prevent stress cracks.

B. DEFORMATION OF THE RETAINING PIN SLOT SIDES

The tool may become chipped or deformed in the area where it is in contact with the retaining pin. As the tool breaks material, it will try to follow any fracture lines in the material (Fig. 1). This causes a chisel point tool to twist in the tool holder. The retaining pin limits how far the tool can twist. If this happens often enough, the pin contact area of the tool can become chipped (Fig. 2) or deformed (Fig. 3).

Fig. 2

Fig. 1

Fig. 3

PREVENTATIVE MEASURES

The operator should place the chisel point in line with fractures or laminations in the material, not at an angle. The tool should be checked periodically for chipped areas. Grind smooth any chipped areas to prevent stress cracks in the tool.

- 41 -

Page 43

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. If the material still resists breaking, a larger hammer may be required.

- 42 -

Page 44

TOOL BREAKAGE

D. CHIPPING OF A MOIL POINT TOOL TIP

Moil (“P”) tools are intended for use on concrete or soft rock. The use of moil tools on hard rock may result in the point being chipped.

PREVENTATIVE MEASURES

Use a chisel point (“FX” or “FY”) tool or a larger size hammer.

E. CHIPPING OF A CHISEL TOOL TIP

Chisel tool tips may be chipped due to hammer being undersize for application. Overheating tool by hammering for more than 30 seconds in one spot can cause chipping.

PREVENTATIVE MEASURES

Use correct size hammer for job conditions. Do not hammer for more than 30 seconds without moving hammer.

WARRANTY

NPK Warranty does not cover types A, B, C, D and E problems.

- 43 -

Page 45

TOOL BREAKAGE

TEMPERATURE RELATED TOOL PROBLEMS

LOW TEMPERATURE

Metallic material becomes brittle in a low temperature environment and particularly sensitive to impact stress.

PREVENTATIVE MEASURES

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.

HIGH TEMPERATURE

When the tool is used in a high temperature environment, such as for slag removal from a furnace, the tool may be deformed as shown in the picture below.

PREVENTATIVE MEASURES

Use compressed air to keep the tool cool enough not to deform.

WARRANTY

NPK Warranty does not cover this type of failure.

- 44 -

Page 46

TOOL BREAKAGE

TOOL BREAKAGE DUE TO CORROSION

Corrosion on the tool surface causes stress concentrations in the corroded area and a fatigue fracture can occur. These fractures, combined with impact stress, can lead to tool breakage.

PREVENTATIVE MEASURES

After using the tool in salt water, or exposing it to a corrosive environment, or before long term storage, be sure to rinse with fresh water. 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. The picture below illustrates the broken section. The starting point of breakage (tb9) is inside the tool, not on the surface.

WARRANTY

NPK Warranty does cover this type of failure.

- 45 -

Page 47

ROUTINE INSPECTION AND MAINTENANCE

1. VISUAL INSPECTION

Detect a potential problem early.

FASTENERS

Inspect all fasteners and retighten as necessary. See page 58 for torque values.

WELDS

Check for cracks, repair as necessary, see the PH Service Manual.

HOSES AND TUBING

Check for oil leaks, loose clamps and hose abrasion.

RUBBER MOUNTS

Inspect for damage.

HYDRAULIC OIL: MAINTAIN A CLEAN HYDRAULIC SYSTEM

If non-petroleum oil is used, contact the NPK Service Department for compatibility. Keep hoses clean and capped when dismounting or storing hammer. Change oil and filters as recommended by carrier manufacturer. Periodic oil sampling is recommended.

2. DEMOLITION TOOL LUBRICATION

Important:

It 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 grease fitting until

grease is seen coming out between the tool and bushing. USE A GOOD QUALITY, HIGH TEMPERATURE EP#2 GREASE

CONTAINING ANTI-WEAR ADDITIVES. NPK recommends a Lithium Base, Moly (Molybdenum Disulfide) or other surface protecting additives, EP (Extreme Pressure), NLGI #2 Grease. A high drop point (350° to 500°) grease is desirable.

If machine is equipped with an AUTO LUBE 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, see pages 52 and 53.

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 lathe or milling machine using sufficient cooling. Please consult your authorized NPK Dealer or NPK Service Department for additional information.

4. DO NOT SUBMERGE HAMMER UNDERWATER

Unless modified for underwater operation.

- 46 -

Page 48

WEEKLY INSPECTION

1. WELDS

Check for cracks, repair as necessary. Consult your authorized NPK Dealer or NPK Service Department for additional information.

2. TOOL RETAINING PIN

Remove the retaining pin and inspect for peening caused by excessive blank hammering. If necessary, grind edges smooth as shown in TOOL RETAINING PIN INSPECTION, see page 57. The retaining pin must rotate freely.

3. 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, see page 54.

4. GAS CHARGE

Check and adjust, if required, see pages 59 through 64.

- 47 -

Page 49

TOOLS

STANDARD TOOLS

DEMOLITION TOOL SHAPE APPLICATIONS

CHISEL (FX)

The cross cut (FX) tool cuts at right angle, or crosswise, to the stick and boom of the excavator.

MOIL (P)

BLUNT (E)

 Trenching  Cutting casting gates  Breaking oversize  General demolition

 Concrete breaking  Highway construction  General demolition

 Secondary breaking  Breaking oversize  Slag removal

ACCESSORY TOOLS

SPECIALTY TOOL SHAPE APPLICATIONS

FROST CUTTER Cross cut (SX), In Line (SY) for PH1 – PH4

ADAPTER TOOL for PH1 – PH4

TAMPER PLATE

(use with adapter tool) 12” x 12” for PH1 – PH2 16” x 16” for PH3 – PH4

POST and PIPE DRIVER

(use with adapter tool) for PH1 – PH4

 Edge of trenching  Frost cutting

 For attachments

listed below

 Soil compaction  Driving sheeting

 Driving guard rails  Driving fence posts

- 48 -

Page 50

TOOLS

TOOL IDENTIFICATION

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

- 49 -

Page 51

TOOLS

CHANGING THE TOOL

TOOL REMOVAL

1. Remove the two socket head cap screws (OO) that attach the retaining pin stopper plate (GK) to the hammer bracket. Remove the retaining pin stopper plate.

Figure 1

2. Remove the retaining pin ring (E) by using a screwdriver (t22), see Figures 2 and 3. It will easily come out if pried at an angle as shown in Figure 3.

Figure 2

3. Remove the retaining pin ring (E).

4. Screw a 6mm hex head bolt (AF) or cap screw into the retaining pin (D).

5. Pull the retaining pin out. If the retaining pin is jammed, use a hammer and drift pin to drive it out from the opposite side.

Figure 3

Figure 4

Figure 5

- 50 -

Page 52

TOOLS

CHANGING THE TOOL

TOOL REMOVAL

6. Remove the tool (HH).

TOOL INSTALLATION

1. Clean the retaining pin bore.

2. Coat the surface of the tool (HH) with grease, then install.

Figure 6

Figure 7

3. Coat the retaining pin (D) with grease, then install.

4. Install the retaining pin ring (E) by using the handle of a screwdriver (t22) as shown in Figure 9.

Figure 8

Figure 9

5. Install the retaining pin stopper plate (GK). Torque bolts (OO) to 85 ft. lbs. (115 Nm).

Figure 10

- 51 -

Page 53

TOOLS

MAXIMUM TOOL TO TOOL BUSHING CLEARANCE

Replace the tool bushing (BF), and/or tool (HH), when the tool to bushing gap reaches the maximum clearance. To determine whether the bushing or tool requires replacement, follow the instructions and charts shown below:

Step 1

Measure the tool to bushing gap (d15) with the hammer horizontal, as illustrated below. If the clearance is at or greater than the charted maximum clearance, then move on to the next steps.

HAMMER MAXIMUM CLEARANCE

MODEL in (mm)

PH1 PH2 PH3 PH4

1/4 1/4 1/4 1/4

6 6 6 6

Step 2 Remove the tool from the tool holder. Measure the diameter (d16) of the bearing

surface of the tool (HH), which is located on each side of the retaining pin groove. The minimum tool diameter is compared to a new tool bushing only. If the tool is at or below the charted value, the tool must be replaced.

HAMMER NEW TOOL MINIMUM TOOL

MODEL DIAMETER DIAMETER

in (mm) in (mm) PH1 PH2

2.24

2.60

(57) (66)

2.02

2.37

(51.2) (60.2)

PH3 PH4

2.99

3.38

(76) (86)

2.76

3.16

(70.2) (80.2)

- 52 -

Page 54

TOOLS

MAXIMUM TOOL TO TOOL BUSHING CLEARANCE

Step 3

Measure the inside diameter of the tool bushing. The maximum tool bushing inside diameter is compared to a new tool only. If the tool bushing dimensions are at or above the charted value, the bushing must be replaced.

HAMMER NEW BUSHING MAXIMUM BUSHING

MODEL INSIDE DIAMETER INSIDE DIAMETER

in (mm) in (mm) PH1 PH2 PH3 PH4

Step 4

Compare the tool and bushing to the charts in Step 2 and Step 3. Choose the new component (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.

2.25

2.61

3.00

3.39

(57.2) (66.2) (76.2) (86.2)

2.48

2.83

3.23

3.62

(63) (72) (82) (92)

- 53 -

Page 55

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. Excessive blank hammering will cause chipping (16) in the retaining pin contact area (15). If neglected, the chipping may reduce the life or cause failure of the tool retaining pin. Dress with a grinder.

3. Excessive blank hammering can cause retaining pin breakage/failure. Replace retaining pin.

4. If chipping (16) is found at the top of the tool, replace the tool. If neglected, the piston impact surface will be damaged (13 is normal, 14 needs to be replaced).

- 54 -

Page 56

TOOLS

CHISEL TOOL RESHARPENING

Worn chisel tools can be re-sharpened by machining according to the dimensions below. DO NOT hardface or sharpen the tool point with a cutting torch! Re-sharpen only with a lathe or milling machine using sufficient coolant.

HAMMER

MODEL

PH1 PH2 PH3 PH4

in (mm) in (mm)

.39 (10) 2.24 (57) .39 (10) 2.60 (66) .39 (10) 2.99 (76) .79 (20) 3.39 (86)

d21 d16 (ref)

- 55 -

Page 57

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

MODEL

PH1 PH2 PH3 PH4

NOTE:

Minimum tool length is determined by the depth of material penetration that is required.

NEW TOOL

DIAMETER (d16)

in (mm) in (mm) in (mm)

2.24 (57) 23.6 (599) 14.1 (359)

2.60 (66) 25.5 (648) 15.1 (384)

2.99 (76) 28.5 (724) 16.5 (420)

3.39 (86) 33.0 (838) 18.5 (470)

NEW TOOL

LENGTH (d23)

NEW WORKING

LENGTH (d22)

- 56 -

Page 58

TOOLS

TOOL RETAINING PIN INSPECTION

Deformation may occur on the retaining pin in the tool contact area (AN). If this area is mushroomed, the retaining pin may become difficult to remove. Dress areas shown (AN) with a grinder.

- 57 -

Page 59

TORQUE VALUES FOR HAMMER FASTENERS

If hammer bracket fasteners are found to be loose, use the following chart. If repairs are to be made, see the NPK Hydraulic Hammer Service Manual.

HAMMER

MODEL

PH1 STANDARD 3/4"-10 280 (378) 5/8”-11 165 (225)

PH2 STANDARD 3/4"-10 280 (378) 5/8”-11 165 (225)

PH3 STANDARD 1”-12 500 (675) 5/8”-11 165 (225)

PH4 STANDARD 1”-12 500 (675) 5/8”-11 165 (225)

*Torque hammer bracket bolts using anti-seize compound. **DO NOT torque adapter bracket bolts using anti-seize compound.

BRACKET

TYPE

SKID STEER 3/4"-10 280 (378) N/A N/A

HEAVY DUTY 5/8”-11 150 (203) 5/8”-11 165 (225)

SCALING 5/8”-11 150 (203) 5/8”-11 165 (225)

SKID STEER 3/4"-10 280 (378) N/A N/A

HEAVY DUTY 1”-12 500 (675) 5/8”-11 165 (225)

*HAMMER BRACKET **ADAPTER BRACKET

BOLT

DIA

BOLT TORQUE

ft/lbs (Nm)

BOLT

DIA

BOLT TORQUE

ft/lbs (Nm)

- 58 -

Page 60

GAS CHARGE

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.

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

HAMMER

MODEL

AT AMBIENT TEMPERATURE

(cold, before operating)

*psi (bar)

AT OPERATING TEMPERATURE

(hot, after 1 to 2 hrs. operation)

*psi (bar)

PH1 175 (12) 220 (15) PH2 175 (12) 220 (15) PH3 175 (12) 220 (15) PH4 175 (12) 220 (15)

*The gas charge tolerance is plus 0, minus 25 psi (2 bar).

- 59 -

Page 61

GAS CHARGE

GAS CHARGING KIT

(Part Number 7300588)

ALL NPK HYDRAULIC HAMMERS are furnished with the following gas charging kit. In addition, a nitrogen tank and pressure regulator valve (not furnished with the hammer) is required. These can be obtained from your local welding supply house. An optional regulator valve, part no. 21101060, is available from NPK.

g1. CHARGE ADAPTER (PART NO. 30604040) g3. PLUG (PART NO. 30102050) g4. HOSE (PART NO. 20118010) g5. CHARGING KIT BOX (PART NO. 35001030) g7. OPTIONAL REGULATOR VALVE (PART NO. 21101060)

- 60 -

Page 62

GAS CHARGE

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 (HH). Remove the tool or position the hammer (DR) with the tool fully extended.

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).

5. Tighten the charge adapter cap (g6).

- 61 -

Page 63

GAS CHARGE

CHECKING THE GAS PRESSURE

6. Turn the T-handle (g2) clockwise. As the T-handle is screwed in, a resistance is encountered. By turning the T-handle further, the nitrogen gas pressure will be indicated on the pressure gauge (g8). Stop turning the T-handle when the gauge reads pressure. Do not overtighten!

7. Compare the gauge pressure with the NITROGEN GAS PRE-CHARGE chart in the NITROGEN GAS PRESSURE section. If the gas is 25 psi (2 bar) or more below the specification, proceed to the NITROGEN GAS CHARGING PROCEDURE section of the manual. 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.

- 62 -

Page 64

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. Install a pressure regulator (g7) on a tank (g9) of nitrogen gas.

3. Connect a hose (g4) from the pressure regulator (g7) on the nitrogen tank (g9) to the charge adapter (g1).

4. Turn the T-handle (g2) on the charge adapter (g1) clockwise.

5. Turn the handle (g7) on the tank regulator counterclockwise to a fully closed position. Do not overtighten!

6. Open the valve (g10) on the nitrogen tank (g9) by turning the handle counterclockwise.

7. Slowly adjust the regulator on the nitrogen tank to the correct pressure by turning the handle (g7) clockwise. Refer to the NITROGEN GAS PRE-CHARGE chart in the NITROGEN GAS PRESSURE SECTION.

8. Charge the nitrogen gas, per the gas charge decal (g11), until the pressure gauge (g8) on the charge adapter (g1) is at the correct setting, then turn the Thandle (g2) counterclockwise all the way out.

9. Close the nitrogen tank valve (g10), then, remove the hose (g4) from the charge adapter (g1).

- 63 -

Page 65

GAS CHARGE

DISCHARGING THE GAS PRESSURE

THE NITROGEN GAS MUST BE DISCHARGED FROM THE

PROCEDURE

HAMMER BEFORE DISASSEMBLY!

1. Remove the charge valve cap (M1) from the charge valve (M). Do not

remove the charge valve assembly!

REMOVE THE VALVE CAP ONLY, NOT THE CHARGE VALVE ASSEMBLY!

4. Tighten the charge adapter cap (g6).

2. Turn the NPK charge adapter T-handle (g2) to a full

counterclockwise

position.

5. Turn the T-handle (g2) clockwise. As the Thandle is screwed in, a resistance is encountered. By turning the T-handle, the nitrogen gas pressure will be indicated on the pressure gauge (g8). Stop turning the Thandle when the gauge reads pressure. Do not over tighten!

3. Install the NPK charge adapter (g1) onto the hammer charge valve located on the hammer gas head (L).

6. Loosen the charge adapter cap (g6) VERY SLOWLY! The gas pressure will gradually decrease to zero. When it gets to zero, remove the cap.

7. Remove the charge adapter (g1) from the gas charge valve on the hammer gas head (L), and then reinstall the charge valve cap.

- 64 -

Page 66

STORAGE OF HYDRAULIC HAMMER

For short term storage between jobs, place the hammer horizontal on a pallet (t62). Be sure that the tool end of the hammer is lower than the gas end. Also, be sure the tool (HH) is liberally greased and the hydraulic hoses (m3 and m4) are capped. Cover with a waterproof tarp (t21), not shown.

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

DO NOT CLEAN the tool holder bore (111) of the hammer with a steam cleaner or high pressure washer (t58). This could cause rust to form, then in turn, cause damage to the hammer piston!

- 65 -

Page 67

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. Mailed to:

NPKCE 7550 Independence Dr. Walton Hills Ohio 44146

2. Faxed: 440-232-6294(U.S.) (+1)(440)232-6294(outside U.S.)

3. Completed online at :

www.npkce.com

The online registration can be done by the dealer or the end user.

Dealers:

 In the tool bar click on DEALERS.  Using your user name and password, log into the system.  At the left of the next page click on REGISTRATION.  Complete the fields with an orange diamond next to them.  At the bottom of this area, click the START REGISTRATION box and continue.  If the registration is completed online, there is no need to mail or fax the warranty

registration.

End users / non NPK dealers

 In the tool bar click on DEALERS  You do NOT need to fill in user name and password.  In the left column, click on the REGISTRATION.  Complete the fields with an orange diamond next to them.  At the bottom of this area, click the START REGISTRATION box and continue.  If the registration is completed online, there is no need to mail or fax the warranty

registration.

- 66 -

Page 68

TOOL WARRANTY

STANDARD DEMOLITION and ACCESSORY TOOLS WARRANTY (30 days)

NPK Construction Equipment, Inc. (“NPK”) warrants that new Standard Demolition Tools, and other Standard Accessory Tools sold by NPK will be free from defects in material or workmanship for a period of thirty (30) days, starting from the date of installation. NPK reserves the full right to determine if, and to what extent, warranty adjustments may be made for breakage of the demolition or other accessory tools. NPK Tool Warranty does not cover labor or travel expenses.

THIS WARRANTY DOES NOT APPLY TO:

 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. Tool breakage is specifically covered ONLY for straight across breakage as shown at locations A: Note: The tool to bushing gap must be verified and reported to NPK. Failure to provide this information will make this failure non-warrantable, see pages 39 and 40.

For warranted tool failures, a prorated credit, up to 80% maximum, will be issued for tools with tip wear greater than 50 mm on chisel and moil points, or 30 mm on blunt end tools. Note: Parts replaced under warranty become the property of NPK.

- 67 -

Page 69

TOOL WARRANTY

USER RESPONSIBILITY

 Photos and all numbers from retaining pin slot must accompany all warranties

submitted to NPK. These photos can be 35 mm, Polaroid, or digital.

 The installer, user, operator, repairer, assumes responsibility to read, understand

and comply with NPK’s written INSTALLATION, OPERATOR, and SERVICE INSTRUCTIONS.

 All labor costs.  Any expense incurred by field repair.  Tool failures as shown at locations B (see NPK Operators Manual for correct

operating procedures):

CAUSE

FAILURE

tb1 – Typical break from bending overload. tb2 and tb3 – repeated blank hammering. tb3 – bending overload due to excessive wear of the tool bushings. tb4 – corner loading due to excessive wear of the tool bushings.

tb5 – bending overload from excessive prying or slant hammering. tb6 – deformation from overheating by hammering in the same position for more than 30 seconds. tb7 – chipped, due to wrong application, or overheating by hammering in same position for over 30 seconds.

THESE WARRANTIES DO NOT COVER FAILURES RESULTING FROM:

 Installation, alteration, operation, maintenance, repair or storage which NPK judges

improper.

 Inadequate lubrication.  Exceeding the tool and/or tool bushing wear limit.  Unreasonable delay in making a repair after being notified of a potential product

problem.

THESE WARRANTIES SPECIFICALLY EXCLUDE:

 Any tool which is altered, welded, hardfaced or re-sharpened.  Replacement due to tip or shank wear.  Installations not approved by NPK.  Use of parts not sold by NPK. THE USE OF “WILL FIT” PARTS WILL VOID THE

WARRANTIES OF ANY AND ALL PARTS DAMAGED AS A RESULT OF THE FAILURE OF THE “WILL FIT” PARTS.

 Parts shipping charges in excess of those which are usual and customary. (Air

freight, unless pre-approved, will not be covered).

 Duties, brokerage fees, and local taxes.

WARRANTY REPAIRS DO NOT EXTEND THE STANDARD WARRANTY PERIOD.

LIMITATIONS AND EXCLUSIONS

Violation of any federal, provincial, state or local laws, ordinances, rules or regulations, or removal or alteration of product serial numbers void NPK’s written product warranties. Application for warranty must be made within 30 days of failure.

- 68 -

Page 70