FOREWORD

NPK is world's largest manufacturer of boom 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
NPK HYDRAULIC HAMMER has a 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 instruction manual contains instructions for operating 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 HYDRAULIC 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.

−1−
 INDEX

FOREWORD...................................................................................................................................................1
SAFETY ..........................................................................................................................................................3
PRECAUTION.................................................................................................................................................4
CARRIER / MACHINE COMPATIBILITY CHART...........................................................................................5
SPECIFICATIONS OF ACCUMULATOR........................................................................................................5
HAMMER SPECIFICATIONS .........................................................................................................................6
STANDARD CHISELS ....................................................................................................................................6
STRUCTURE ..................................................................................................................................................7
PRINCIPLE OF OPERATION .........................................................................................................................8
INSTALLATION ...............................................................................................................................................9
OPERATION .................................................................................................................................................10
UNDERWATER TYPE / AUTOMATIC LUBRICATION .................................................................................11
OPERATING TECHNIQUES.........................................................................................................................12
INSTRUCTIONS FOR USE OF NPK CHISELS ...........................................................................................17
MOUNTING AND REMOVAL........................................................................................................................18
CHANGING THE CHISEL ............................................................................................................................19
INSPECTION AND MAINTENANCE: TWENTY HOURS .............................................................................20
ROUTINE INSPECTION AND MAINTENANCE: DAILY...............................................................................21
CONTAMINATION CONTROL......................................................................................................................22
CHISEL & BUSHING CLEARANCE .............................................................................................................23
GAS CHARGING KIT ...................................................................................................................................24
NITROGEN GAS PRESSURE......................................................................................................................25
GAS PRESSURE CHECKING PROCEDURE .............................................................................................26
DISCHARGING THE GAS PRESSURE .......................................................................................................27
GAS CHARGING THE HAMMER.................................................................................................................28
TROUBLESHOOTING..................................................................................................................................29
CHECKING THE PRESSURE AND FLOW ..................................................................................................30
OIL LEAKAGE...............................................................................................................................................32
GAS LEAKAGE.............................................................................................................................................33
REPLACEMENT OF SIDE BOLTS ...............................................................................................................34
TORQUE CHARTS .......................................................................................................................................39
MOUNTING PLATE ......................................................................................................................................41
BRACKET SPACER......................................................................................................................................41
NOTICE ON HYDRAULIC HOSES...............................................................................................................42
STORAGE OF HAMMER .............................................................................................................................43
NOTES..........................................................................................................................................................44

−2−
IMPORTANT SAFETY INFORMATION

1. 1. Operators and service personnel must read thoroughly understand the NPK instruction manual

DANGER
2. Keep personnel clear of the HAMMER while in operation.
3. Do not operate the HAMMER without a suitable shield in place. This protects the operator from flying debris.
4. TO PREVENT 1NJURY OR DEATH, do not disassemble the HAMMER before discharging the HAMMER gas
recharge.
5. Do not hardface or sharpen chisel with a cutting torch. Excessive heat from cutting or welding causes
embattlement, breakage, and flying pieces. Resharpen only with lathe or milling machine, using sufficient
cooling.
6. Fully extend chisel while charging the HAMMER with nitrogen. STAY CLEAR OF THE CHISEL POINT WHILE
CHARGING.
7. Use nitrogen gas only.
8. The HAMMER must not be operated unless the operator is in full control of the machine. Operate the
HAMMER from the operators seat only.

WARNING
9. Important safety and operating decals are included with each HAMMER and INSTALLATION KIT. Keep them
clean and visible.
10. Match HAMMER size to machine according to NPK recommendation.
11. Use the proper lifting equipment and tools when handling or servicing the HAMMER or components.
12. Wear ear protection if conditions warrant.
13. Service personnel must take care handling pins and bushings when exchanging the bucket for the HAMMER.
The machine operator must move the ann or boom only when directed by service personnel.
14. If it is necessary to HAMMER the pins in or out, beware of flying metal chips. Eye protection should be worn.
15. Do not make any alterations to the HAMMER without authorization from NPK engineering.
16. Use replacement parts sold by NPK only.

−3−
PRECAUTIONS FOR USING THE NPK HYDRAULIC HAMMER

• PERFORM DAILY INSPECTIONS.

• AVOID BLANK HAMMERING.

• DO NOT HAMMER IN THE SAME POSITION FOR OVER ONE MINUTE.

• DO NOT USE THE HAMMER TO MOVE MATERIAL, PRY MATERIAL, OR AS PICK ON MATERIAL.

• DO NOT USE THE HAMMER UNDERWATER UNLESS THE HAMMER HAS BEEN MODIFIED FOR
UNDERWATER OPERATION.

• PREVENT CONTAMINATION FROM ENTERING THE HYDRAULIC HOSES WHEN MOUNTING OR

DISMOUNTING THE HAMMER FROM THE CARRIER.

• MAINTAIN A CLEAN HYDRAULIC SYSTEM.

• REPLACE THE FILTER ELEMENT WITH A NEW ONE AND CHANGE HYDRAULIC OIL AT THE SPECIFIED
INTERVALS.

Filter element every 100 hrs.

Hydraulic oil every 600 hrs.

• OPERATE THE HAMMER CAREFULLY. DO NOT HIT THE BOOM OF THE CARRIER WITH THE HAMMER.

−4−
CARRIER MACHINE COMPATIBILITY CHART

These carrier weight ranges are intended as a guideline only. Other factors, such as arm length, counterweights,
undercarriage, etc., must be taken into consideration.

Mounting a HAMMER that is too heavy for the carrier can be dangerous and can damage the carrier.
Mounting a HAMMER that is too small for the carrier can damage the HAMMER and void the Warranty.

Please consult the NPK Engineering Department if there are any questions regarding the compatibility of a
particular NPK HAMMER model with a particular carrier.

CARRIER MASS [TON]

RECOMMENDED RANGE
MODEL
(ton)
E-210B 18 - 20
E-213A 20 - 21
E-216A 22 - 28
E-220 30 - 38
E-225 40 - 50

SPECIFICATIONS OF ACCUMULATOR

Initial gas volume is 1000 cm3.

PRESSURE LINE RETURN LINE

MODEL PRECHARGE PRECHARGE

PRESSURE QUANTITY PRESSURE QUANTITY
MPa (kgf/m2) MPa (kgf/m2)
E-210B
E-213A 9 (90) 1 0.2 (2) 1
E-216A
E-220
12 (120) 1 0.2(2) 2
E-225

−5−
HAMMER SPECIFICATIONS

Hydraulic Oil flow Number of Gas Mass Overall length

MODEL Pressure rate blows Pressure w/chisel w/chisel
MPa L/min b.p.m MPa kg mm
E-210B 18 150 - 200 500 - 670 1.6 - 2.7 800 2,365

E-213A 17 165 - 210 400 - 590 1.6 - 2.4 960 2,525

E-216A 17 170 - 220 400 - 500 1.6 - 2.4 1,180 2,675

E-220 17 200 - 250 350 - 430 1.6 - 2.4 1,500 2,845

E-225 17 220 - 290 300 - 400 1.6 - 2.5 1,850 2,995

STANDARD CHISELS

CHISEL TYPE SHAPE APPLICATIONS

• Concrete breaking
Chisel (PC) • Highway construction
• General demolition
• Concrete breaking
Chisel (P) • Highway construction
• General demolition
• Secondary breaking
Chisel (E) • Breaking oversize
• Slag removal
• Trenching
• Cutting casting gates
Chisel crosscut (FX)
• Breaking oversize
• General demolition

−6−
STRUCTURE

STRUCTURE DRAWING

−7−
PRINCIPLE OF OPERATION

(1) (2) (3) (4)

(1) UPSTROKE OF PISTON

Hydraulic oil supplied by the carrier hydraulic system enters the NPK HAMMER "IN" port and is directed thru
port (5) to the top of the plunger, forcing the main valve spool to the down position.
Oil flows through the main valve spool to the lower chamber of the position (C2). Oil pressure acts on the
piston, raising it up and compressing the nitrogen gas. Oil in the upper chamber of the piston (C1) is forced
out the return line thru port (4).
(2) VALVE SHIFT
As the piston rises, the lower chamber (C2) is opened to passage (3) and oil flows into chamber (C3) of the
main valve spool. Since the area acting on the main valve spool in chamber (C3) is greater than the area of
the plunger, the main valve spool shifts upward. The return line is closed with the main valve spool in the up
position.
(3) POWER STROKE
With the main valve spool in the up position, chamber (C2) is closed off from the "IN" port and opened to
chamber (C1). The piston is driven downwards by the compressed nitrogen gas as the oil in lower chamber
(C2) recalculates to upper chamber (C1). When the piston opens passage (3) to the upper chamber (C1),
the oil in main valve spool chamber (C3) is switched to low pressure and the main valves spool shifts
downward. After the piston opens passage (3) to upper chamber (C1), the main valve spool opens chamber
(C1) to the return line.
(4) IMPACT
The piston impacts the chisel and the main valve spool shifts to the full down position. High pressure oil is
directed to the lower chamber of the piston for the start of another cycle.
AUTOMATIC ENERGY RECYCLING: On extremely hard material, the piston will rebound before the valve
shifts and the frequency (blow per minute) automatically increases while maintaining the full impact energy.

AUTOMATIC ENERGY RECYCLING: On extremely hard material, the piston will rebound before the
valve shifts and the frequency (blow per minute) automatically increases while maintaining the full impact energy.

−8−
HYDRAULIC INSTALLATION

NPK INSTALLATION KITS are available for virtually all loaders and excavators. NPK provides complete pans and
instructions for the hydraulic installation of the NPK HYDRAULIC HAMMER. This includes valuing and / or controls,
hoses and fittings, boom and arm tubing, and clamp.

1- Hydraulic hammer
2- Bracket
3- Pins
4- Chisel
5- Stop valves
6- Pressure line
7- Return line
8- Accumulator
9- Hammer control valve
10- Hydraulic pump
11- Oil cooler
12- Oil tank

HAMMER KIT 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 control led from an auxiliary valve on the excavator or from an NPK supplied valve.
Hydraulic oil is routed back to the tank thru the excavator's oil cooler and filter.

HAMMER CONTROL VALVE

There are two general types of control systems used, depending upon the carrier model:

1. CONTROL SYSTEM USING THE CARRIER AUXILIARY VALVE SECTION.

This type of installation utilizes an existing carrier valve whenever possible. Any additional parts, such as a
mechanical linkage, hydraulic pilot actuators, flow control valve, etc. are furnished in the NPK HYDRAULIC
INSTALLATION KIT. Special hydraulic pressure regulators are not required because 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.

MECHANICAL INSTALLATION

The pans required for the mechanical adaptation of the NPK HYDRAULIC to the carrier's boom are furnished in the
NPK HYDRAULIC INSTALLATION KIT. The MOUNTING INSTALLATION KIT includes parts such as top bracket
for some models, bushings, spacers, and boom pins if necessary.

−9−
OPERATION

BEFORE STARTING THE HAMMER

1. CHECK THE NITROGEN GAS PRESSURE (NEW HAMMERS)
The nitrogen gas precharge 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 on page 25.
2. STOP VALVE
The NPK HYDRAULIC INSTALLATION uses two
stop valves located on the arm of the carrier.
When using the NPK HYDRAULIC HAMMER be
sure these valves are turned to the "ON" position.
3. PRE-OPERATION INSPECTION AND WARM
UP
Before operating the NPK HYDRAULIC
HAMMER, be sure to perform the specified
DAILY INSPECTION. See page 21.

Warm up the NPK HYDRAULIC HAMMER and the

backhoe or excavator in accordance with the base
machine instruction manual. This is especially
important during cold weather operation.

START-UP OPERATION

Operate the NPK HYDRAULIC HAMMER in the upright

position, at half engine throttle setting, for about one hour.
During this start-up period, inspect the NPK HYDRAULIC
HAMMER and INSTALLATION KIT for or loose
connections.

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

−10−
UNDERWATER TYPE / AUTOMATIC LUBRICATION

Wrong connection for Air Supply Port and Automatic Lubricating Port caused the trouble.
Connect with AIR marked on Cylinder for Air Supply anti GRS for Automatic lubrication.

−11−
OPERATING TECHNIQUES AND PRECAUTIONS

Press the tip of the chisel vertically against the object to

be broken. Be sure the object is stable before activating
the NPK HYDRAULIC HAMMER.

Raise the front of the machine slightly and apply down

force on the foot pedal to start the NPK HYDRAULIC
HAMMER.

CAUTION
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.

As soon as the material is broken, release the control

lever or pedal to prevent unnecessary blank
hammering.

CAUTION
Blank hammering is continued HAMMER operation
after the material is broken. This will overheat the
hydraulic system and cause undue wear.

−12−
 F: The direction of force from the boom (the direction tangent to the arc of the boom)
P: Penetration direction of the chisel
A: Fulcrum

For the most efficient demolition, align the direction of force (F) from the boom with penetration direction (P) of the
chisel. 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 chisel. This unnecessary added stress leads to the following problems:

1. Premature bushing wear and/or chisel breakage

2. Breakage of side bolts
3. Breakage of bracket front bolts
When the chisel binds or the working angle is incorrect, the sound of the HAMMER changes.

Keep the boom direction of force in the same

direction the chisel is penetrating. Use the boom
cylinder to preload the HAMMER (apply
downpressure), and use the bucket and arm
cylinder for alignment.
Keep the chisel tangent to the arc of the boom.

−13−
DO NOT USE THE CHISEL AS A PRY BAR

Excessive prying can cause premature bushing wear and

chisel or side bolt breakage.

DO NOT HAMMER CONTINUOUSLY IN THE

SAME POSITION FOR MORE THAN ONE
MINUTE

If the chisel can not break or penetrate into the material

after hammering in the same position for a minute, change
the working location. Hammering in the same position for a
long time will reduce the working efficiency, increase the
hydraulic oil temperature, and accelerate chisel wear.

ALWAYS WORK BY BREAKING TO A FREE

FACE

The material must have some where to break. Start at an

edge.

DO NOT ALLOW THE CHISEL TO HIT THE

BOOM

Use caution when tucking the HAMMER in tight to the

boom for transportation.

−14−
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 it is intended for.

AVOID OPERATING THE HAMMER WITH

CYLINDERS AT THE END OF STROKE
Continuous operation with the boom cylinder fully close or
extended may damage the hydraulic cylinder.

−15−
 DANGER
BEWARE OF FLYING PROJECTILES FROM
THE HAMMER POINT

Do not use the HAMMER in such a way as to cause rock,

etc., to be thrown towards the cab.

DANGER
DO NOT OPERATE THE HAMMER WITHOUT
THE CAB WINDOW OR SHIELD IN PLACE

Cab window or shield must be in place to protect the

operator from rock thrown out from the point.

WARNING
DO NOT USE THE HAMMER AS A HOIST

The HAMMER is not intended to lift an object.

To do so can be dangerous.

WARNING
DO NOT OPERATE HAMMER UNDERWATER

Do not allow parts, other than the chisel, to be submerged

in water. Underwater operation will damage he HAMMER
seals and allow water to enter the hydraulic system.
The HAMMER can be modified for underwater operation -
contact the NPK dealer for more information.

−16−
INSTRUCTIONS FOR USE OF NPK CHISELS

• Make certain that the chisel you are going to use is a genuine NPK product stamped "NPK". if the breaker fails to
operate normally due to the use of a chisel other than our genuine products, we do not take any responsibility for
the result.

• Since chisels are used under severe working conditions, they might be broken or chipped if used in a wrong way.
When using them, follow the handling precautions given below.

Handling precautions
1. As described in page 13, operate the breaker in such a way that the pressing force of the breaker is always
applied into the direction of driving.
If the pressing direction does not agree with the driving direction, undue flexure load is applied to the chisel,
thus causing breakage as shown in Fig. 1 or bend.

Fig. 1

2. Apply grease sufficiently.

If the chisel is used without being properly greased, the sliding surface between the bushing and chisel seizes
to cause breakage.
3. Do not cool the chisel rapidly by using water or the like during working.
If the chisel is cooled quickly, its condition of hardening changes to cause breakage or chipping.
4. Don't drive the same point for a long time.
If chisel's driving is performed for a long time, the temperature at the edge
of the chisel increases and the hardness drops to cause settling or
premature wear as shown in Fig.2.
Fig. 2
5. Avoid blank hammering as you can.
Breakage or chipping occurs in the part which is engaged with the retainer
pin as shown in Fig. 3
6. Replace the round bushing and holder bushing with new ones when they
reach their useful limits.
7. If a worn bushing continues to be used, chipping or breakage will occur on Fig. 3
the head of the chisel as shown in Fig.3.
8. Do not harden again or weld for repair.
The condition of hardening changes to cause breakage or chipping

−17−
REMOVAL AND MOUNTING OF HYDRAULIC HAMMER

REMOVAL FROM THE CARRIER

1. Close pressure and return line stop valves.
2. Disconnect hydraulic hoses before laying the
HAMMER down. See illustration.
3. Cap the pressure and return line on the carrier
and plug the HAMMER hoses.
4. Position the HAMMER horizontal on wood blocks
and remove the pins.

IMPORTANT: The hydraulic lines must be handled

carefully and sealed to prevent
contamination from entering the
HAMMER or the carrier hydraulic
system.

MOUNTING TO THE CARRIER

1. Place the HAMMER horizontal on wood blocks,
as shown.
2. Align the pin holes. Install the arm pin before the
cylinder link pin.
3. Connect hydraulic hoses. Pressure is on LEFT,
return is on RIGHT.
4. Open stop valves.

IMPORTANT: Avoid getting hydraulic oil on

cushion rubbers. Flush with water if
necessary.

−18−
CHANGING THE CHISEL

1. REMOVAL
1) Remove the donut ring by using plier. See fig. l and fig.2.
It will easily come out if pulled at an angle of 30 degrees with the center as shown in fig.2.
2) Screw an M 12 bolt or cap screw into the retainer pin.
3) Pull out retainer pin. If the retainer pin holds so tight it cannot be pulled out, HAMMER it out at its back.

Fig. 1

Fig. 2
2. REINSTALLATION
1) Clean the retainer pin housing hole and donut ring groove.
2) Coat the surface of the chisel with heat resistant grease, then install chisel.
3) Apply grease to the donut ring housing groove.
4) Coat the retainer pin with heat resistant grease, then install it.
5) Install the donut ring in the following procedure.
a. While deforming the donut ring as shown in fig.3, partially force it into the groove.
b. Using the handle of the plier, press the rest of the ring into the groove little by little. See fig.4

Fig. 3 Fig. 4

−19−
INSPECTION AND MAINTENANCE

TWENTY HOURS INSPECTION

(A) SIDE BOLT AND BOLTS

Inspect all bolts, retighten as necessary. See TORQUE CHART on page 39.

(B) WELDS
Check for cracks, repair as necessary.

(C) CHISEL
Remove the chisel and inspect for peening caused by excessive blank hammering.
If necessary, grind edges smooth.

(D) CHISEL RETAINING BAR

Remove the retaining bar and inspect for peening caused by excessive blank hammering.
If necessary, grind edges smooth.

−20−
ROUTINE INSPECTION AND MAINTENANCE

DAILY:
1. VISUAL INSPECTION
Visually inspect the HAMMER daily. Detect trouble as early as possible!
2. CHISEL LUBRICATION
Grease the chisel at least twice per shift, more often if the sliding surfaces
are dry or conditions are extremely dusty or abrasive.
3. CHISEL and HOLDER BUSHING WEAR
Check the chisel and holder bushing for damage, wear or deformation.
Replace the chisel and/or bushing when wear exceeds the maximum
clearance limit. See MAXIMUM CLEARANCE BETWEEN CHISEL AND
BUSHING on page 23.

DANGER
Do not hardface or sharpen a chisel with a cutting touch. Excessive heat from cutting or welding causes
embattlement, breakage, and flying pieces. Resharpen only with a lathe or milling machine using sufficient cooling.

4. BOLTS
Inspect al bolts, retighten as necessary. See TORQUE CHART on page 39, 40.
5. WELDS
Check for cracks, repair as necessary.
6. HOSE AND TUBING
Check for oil leaks, loose clamps and hose abrasion.
7. CUSHION RUBBER
Inspect for damage.
8. CHISEL RETAINING BAR
Inspect for damage.
9. HYDRAULIC OIL
The maximum operating temperature is 80 degrees C.
Inspect the oil in the hydraulic oil tank for level, contamination and deterioration. Add oil or change oil if
necessary. If neglected, the HAMMER will break down or the hydraulic components of the excavator will be
damaged. See CONTAMINATION CONTROL OF HYDRAULIC OIL on page 22.
Change filter element and hydraulic oil at the following intervals according to the procedures described
operation manual of the excavator.

Filter element : every 100 hrs.

Hydraulic oil : every 600 hrs.

−21−
CONTAMINATION CONTROL OF HYDRAULIC OIL

1. A hydraulic HAMMER is harder on oil than using a bucket, so the oil is apt to deteriorate and be contaminated
sooner. Neglect of contaminated oil can not only damage the hydraulic HAMMER but also cause problems in
the excavator. This could result in damaged components. Due care should be taken to check for
contamination of the oil and to change it if it is found contaminated.
• 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 offensive odor, it is severely deteriorated. Change the oil immediately.
• When the oil is clouded, or the oil filter often becomes clogged, it indicates that the oil is contaminated.
Change the oil.
• To change the contaminated hydraulic oil, drain the hydraulic system completely and clean components. Do
not mix a new oil with the old.

2. Do not allow any foreign matter to mix with the oil. Take special care in preventing foreign material from
entering the hydraulic system through the hose or pipe connection when changing the hydraulic HAMMER
with the bucket. For example: sand in the hydraulic system will cause fatal damage to the components. The
oil filter should be replaced as necessary.
3. Low oil level will cause heat built up, resulting in deterioration of the oil. Also it may cause cavitation due to
mixing with air, leading to a damaged hydraulic HAMMER and carrier components Keep a proper oil level at
all times.
4. Do not use the hydraulic HAMMER at an operating temperature higher than 80°C. The proper operating oil
temperature range is between 50°C and 80°C. Since a contaminated cooler fins causes reduced efficiency of
the cooler, keep the cooler f'ins clean at all times.
5. Water in the hydraulic oil will lead to damage of the hydraulic HAMMER. When out of service, the hydraulic
HAMMER should be stored indoors. Drain off water and foreign matter from the hydraulic tank at specified
intervals.

CHANGING OF THE FILTER ELEMENT AND HYDRAULIC OIL

Change the filter element and hydraulic oil at the following intervals and according to the procedures described
in the operation manual of the excavator :
Filter element : every 100 hrs.
Hydraulic oil : every 600 hrs.

−22−
MAXIMUM CLEARANCE BETWEEN CHISEL AND BUSHING

Replace the chisel holder bushing when the clearance reaches the maximum limit listed below.

Replace the chisel when the outside diameter is worn to the limit for the minimum chisel diameter listed below.

MAXIMUM LIMIT OF MIN.

MODEL CLEARANCE CHISEL
LIMIT DIAMETER
E-210B 10 123
E-213A 10 133
E-216A 10 143
E-220 15 153
E'225 15 162
(mm)

OPERATING THE HAMMER WITH CLEARANCES EXCEEDING THE LIMIT MAY VOID THE HAMMER
WARRANTY.

−23−
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. They can be obtained from your local
welding supply house.

1 2 3 4

1- Hose
2- Plug
3- Charging valve
4- Tool box

OPTIONAL REGULATOR VALVE

−24−
NITROGEN GAS PRESSURE

The nitrogen gas pressure must be measured with no preload on the chisel. Remove the chisel; or position the
HAMMER with the chisel fully extended against the retaining bar. The HAMMER must not be resting vertical on the
chisel. 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.

ALTERNATE METHOD:
The nitrogen gas pressure can be measured or charged at ambient temperature (cold), before operating the
HAMMER. It is recommended the pressure be verified at operating temperature.

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.

Charging Gas Pressure Range Charged Gas Pressure

At Ambient temperature For De livery
MODEL (before operating) At NPK Japan
MPa (kgf/cm2) MPa (kgf/cm2)
E-210B 1.6 - 2.7 (16 - 27) 2.0 (20)
E-213A
E-216A 1.6 - 2.4 (16 - 24) 2.0 (20)
E-220
E-225 1.6 - 2.5 (16 - 25) 2.0 (20)

−25−
CHECKING THE GAS PRESSURE

Check the nitrogen gas pressure every two weeks.

PROCEDURE
1. The gas pre-charge is measured with no preload on the chisel. Remove the chisel or position the HAMMER
with the chisel fully extended. THE HAMMER MUST NOT BE RESTING ON THE POINT.

2. Remove the adapter cap. 3. Turn the NPK charging valve 4. Install the NPK charging
T-handle counterclockwise valve on the hammer
DANGER until it stops. adapter.

Remove the adapter cap only,

not the adapter assembly!

5. Tighten the charging valve cap. 6. Turn the T-handle 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.
Stop turning the T-handle when
the gauge reads pressure. Do
not over tighten.

7. Compare the gauge pressure with the NITROGEN GAS PRESSURE CHART. See page 25. If the gas
pressure is below specification, proceed to the NITROGEN GAS CHARGING PROCEDURE.
8. Turn the T-handle counterclockwise until it stops as in step 3.
9. Slowly loosen the charging valve cap to relieve the nitrogen gas pressure trapped in the charging valve.
10. Remove the charging valve from the HAMMER adapter.
11. Replace the adapter cap on the adapter.

−26−
DISCHARGING THE GAS PRESSURE

PROCEDURE

1. Remove the adapter cap. 2. Turn the NPK charging valve 3. Install the NPK charging
T-handle counterclockwise valve on the hammer
DANGER until it stops. adapter.

Remove the adapter cap only,

not the adapter assembly!

4. Tighten the charging valve cap. 5. Turn the T-handle clockwise. 6. Loosen the charging valve
As the T-handle is screwed in, cap VERY SLOWLY. The gas
a resistance is encountered. pressure will gradually
By turning the T-handle decrease to zero; then
further, the nitrogen gas REMOVE THE CAP.
pressure will be indicated on
7. Remove the charging valve
the pressure gauge. Stop
from the hammer and reinstall
turning the T-handle when the
the adapter cap.
gauge reads pressure.
Do not over tighten.

−27−
GAS CHARGING THE HAMMER

PROCEDURE
1. Carry out steps 1 thru 4 of CHECKING THE GAS PRESSURE. See page 25.
2. Remove the cap from the charging valve.

DANGER
Remove the adapter cap only, not the adapter assembly!

3. Install a pressure regulator 4. Connect a hose from the 6. Turn the handle on the tank
on a tank of nitrogen gas. pressure regulator on the regulator counterclockwise to
nitrogen tank to the charging full closed.
valve.
7. Open the valve on the
5. Turn the T-handle on the nitrogen tank by turning the
charging valve clockwise. handle counterclockwise.

8. Slowly adjust the regulator on the nitrogen tank to the correct pressure by turning clockwise.
See NITROGEN GAS PRESSURE. See page 25.
9. Change nitrogen gas until the pressure gauge on the charging valve is at the correct setting, then turn the
T-handle counterclockwise all the way out.
10. Close the nitrogen tank valve and then remove the hose from the charging valve.

WARNING
Nitrogen gas may be trapped in the hose. Loosen
fittings slowly to release pressure.

11. Remove the charging valve from the HAMMER adapter.

12. Replace the adapter cap.

DANGER
• STAY CLEAR OF THE CHISEL WHILE CHARGING
THE HAMMER WITH GAS. The chisel may be
impacted by the piston and forced out abruptly.
• USE NITROGEN GAS ONLY.

−28−
TROUBLESHOOTING

UNDERSTAND THE BASICS:

1. The NPK HYDRAULIC HAMMER hydraulic operating pressure is determined by the nitrogen gas pre-charge
pressure in the HAMMER, not the relief valve setting of the carrier.
2. The NPK HYDRAULIC HAMMER energy per blow is determined by the nitrogen gas pre-charge pressure,
not the pump volume. Energy is proportional to gas pressure.
3. The NPK HYDRAULIC HAMMER frequency (blow per minute) is determined by oil flow to the HAMMER.
Frequency is proportional to oil volume.

TROUBLESHOOTING CHART

PROBLEM CAUSE CHECK REMEDY

Loss of impact power. Low gas pressure. Gas Pressure Recharge gas.
Gas pressure too high. Gas Pressure Reduce gas pressure.
Stop valve partially closed. Valve position Open valve.
Relief valve set too low (must be
3.0 ∼ 3.5 MPa (30 ∼ 35 kgf/cm2) Hyd Pressure Adjust or replace.
Loss of frequency. over HAMMER pressure).
(HAMMER slows down)
Hyd. temperature too high. Reduce throttle, clean or add
Oil Temperature
(over 80°C) oil cooler.
Hydraulic pump volume too low. Oil Flow Increase circuit flow.
Oil level of carrier too low. Oil Level Add hydraulic oil.
Defective pump or control valve. Hyd Pressure Repair or replace.
Stop valve closed. Hyd Pressure Open valve.
Pressure is on left.
Hoses reversed. Hyd Pressure
Return is on right.
Return line blocked. Hyd Pressure Eliminate obstruction.
Erratic running or stops Oil level of carrier too low. Oil Level Add hydraulic oil.
running.
Gas pressure too high. Gas Pressure Reduce gas pressure.
Zero gas pressure. Gas Pressure Check for leak and repair.
HAMMER main valve Disassemble and inspect
Main Valve
malfunctioning. valve components.
Disassemble HAMMER and
Piston not cycling. Hyd HAMMER
inspect piston.

DETERMINE THE CAUSE OF THE PROBLEM

Technical problems are caused by either [1] the hydraulic HAMMER or [2] the hydraulic system (carrier
hydraulics or installation kit.). Checking the hydraulic pressure and flow, and the HAMMER gas pressure, will
determine if the problem is the HAMMER or the carrier. If the pressures and flow available to the HAMMER are
correct, the problem is in the HAMMER.

−29−
CHECKING THE HYDRAULIC PRESSURE AND FLOW

1. Installation of a Flow Meter Equipped with Pressure Loading Valve.

Install the flow meter between the HAMMER pressure line and return as shown below.

Generally, the pressure line is on the left and the return is on the right.

2. Determine Return Line Pressure (Pressure Drop)

Open both stop valves and press the HAMMER foot switch.
Measure the pressure with the load valve of the pressure / flow meter in full open condition. The return line
pressure should not exceed 2 MPa (20 kgf/cm2).

3. Determine Relief Valve Pressure and Oil Flow

Measure flow and pressure with the flow meter.
Adjust the load valve to zero restriction.
Warm up the hydraulic system of the excavator to
normal operating temperature.
Set engine throttle to maximum. Press HAMMER
foot switch. Turn in the loading valve knob and
record the pressure and flow at regular intervals
on graph paper.
Record pressure on one axis of the graph and flow
on the other. Increase pressure until relief setting
is reached. This is the HAMMER usable area
shown in fig. 1 on page 31.

NOTE: The pressure-flow curve varies according

to the excavator model.

Typical flow meter equipped with pressure loading valve.

−30−
4. Check the HAMMER Operating Condition. (Example of pressure-flow curve)
The working pressure of the NPK HYDRAULIC
HAMMER is self regulating, determined by the gas
pressure.
Draw the HAMMER working range on the measured
pressure-flow graph. Use the maximum pressure and
flow values from the specification chart in this manual.

The HAMMER working pressure range should be within

the line A-B-C-D.

fig. 1

For example, the condition shown in fig. 1 is acceptable.

The condition shown in fig.2 or fig.3 is not. If condition
shown in fig.2 or fig.3 occurs, check for relief valve
failure, worn pump, or excessive HAMMER gas
pressure.

NOTE: The relief pressure should be set a minimum of

3.0 to 3.5 MPa (30 to 35 kgf/cm2) above the
HAMMER working pressure.

fig. 2

The NPK HYDRAULIC HAMMER frequency (blows per

minute) is determined by the hydraulic flow delivered to
the HAMMER. The greater the oil flow, the greater the
frequency.
Do not exceed the maximum of oil flow specifications.

fig. 3

−31−
OIL LEAKAGE

Exceeding 80 °C hydraulic operating temperature reduces seal life.

A small amount of oil leakage between the chisel and holder bushing at location (B) is considered normal.
If oil leak is significant, locate the point of origin. Oil running down the chisel may be coming from a loose hose.
It is normal for a new seal to leak slightly until the seal seats with usage.

PROBLEM CAUSE REMEDY

Disassemble HAMMER and replace
(A) Leakage thin drain hole. Seal in cylinder bushing (A).
seals.
(B) Leakage between chisel and Disassemble HAMMER and replace
Seal in cylinder bushing (B).
holder bushing. seals.
O-ring between valve case and
(C) Leakage between cylinder and cylinder. Replace.
valve case.
Lose bolts. Locktite thread, tighten.

(D) Leakage between valve case O-ring under top plate. Replace.
and plunger bushing. Loose bolts. Tighten.

(E) Leakage between valve case O-ring under bottom plate Replace.
and bottom plate. Loose bolts. Tighten.
(F) Leakage between valve case
O-ring under swivel flange. Replace.
and swivel flange.
(G) Leakage between hose fitting
Loose or damaged hose fitting. Tighten or replace.
and swivel adapter.

−32−
GAS LEAKAGE (if the gas pressure drops over 1 MPa (10 kgf/cm2) per day)

Exceeding 80 °C hydraulic operating temperature reduces seal life.

PROBLEM CAUSE REMEDY

O-ring in check valve. Replace.
(J) Leakage from top of adapter.
Damaged check valve in adapter. Replace.

(K) Leakage between adapter O-ring in adapter Replace.

and head cap. Lose charge valve. Locktite thread, tighten.
(L) Leakage between head cap Disassemble HAMMER and replace
O-ring in head cap.
and cylinder. seals.
Disassemble HAMMER and replace
(M) Leakage thru drain plug. Seal in cylinder bushing (A).
seals.

−33−
REPLACEMENT OF SIDE BOLTS

Loose side bolts are susceptible to stretching or breakage. Because the mating surfaces become seated during
initial operation, the result may be lost tension and loosening of the side bolts, even though the top nut has not
turned.

REASSEMBLING PROCEDURE
1. Completely discharge the nitrogen gas.

DANGER
2. Using a peening spanner, loosen the diagonally paired top nuts, either A and D or G and C. See fig. 1 and
fig.2.
3. Loosen the remaining two top nuts.

fig. 1 fig.2

4. Remove the lock washers. See fig.3.

5. Remove the head cap in the manner as shown in fig. 4 and fig.5.

fig. 3 fig. 4 fig. 5

−34−
6. Remove the Belleville spring. See fig.6. 7. Hang the chisel holder in the level position.
See fig.7.

fig. 6 fig. 7

8. Using a spanner that fits the width across flats of the bolts, turn each bolt, counterclockwise and remove it
from its bottom nut. See fig.8.

fig. 8

9. Pull out the bolts, and then put in new bolts.

In case the bolts are not being replaced:
1. Remove the chisel holder.
2. Remove the cylinder spacer and then remove the bolts from the cylinder.

−35−
ASSEMBLING PROCEDURE

10. Apply molybdenum disulfide filled grease to the

threaded area of each bottom nut.
11. Using the spanner on the flats of the bolts, turn
the bolts clockwise and screw the bolts into
each bottom nut.
See fig.9.

fig. 9

12. Apply petrolatum to the Belleville spring, then

install it. See fig. 10. The Belleville spring
installing position is shown in fig. 11.

fig. 11

fig. 10

13. Pour the hydraulic fluid (shown in Table) into

the interior of the cylinder bush (A).

MODEL QUANTITY
E-210B 300 cc
E-213A 400 cc
E-216A 400 cc
E-220 500 cc
E-225 700 cc
fig. 12

14. Install the head cap.

−36−
15. After making sure the end face of the bolt gets into contact with the face of the bottom nut, be sure to loosen
the bolt by turning it 90 to 180 degrees. See fig.13.

fig. 13

16. Put one of the lock washer in position, then by turning the bolts, put the lock washer in secure engagement
with the bolt and the head cap. See fig.14.
Set another lock washer in the opposite-comer position in the same manner.

17. Apply molybdenum disulfide to the treaded area of

the each bolt.

18. Install two top nuts in diagonal position, then evenly

tighten them hand tight.

fig. 14

fig. 15

−37−
19. Install the lock washer on each of the remaining bolt
See fig. 16.

20. Hand tighten the other top nuts on the

diagonally-positioned bolts.

fig. 16

21. Make sure the gap is 7 to 8mm between the cylinder and head cap. See fig.17. If the gap is found larger than
specified, check to see if the Belleville spring or the spacer is out of position.

fig. 17

22. Using a peening spanner, tighten the top nuts till the head cap is in contact with the cylinder and the cylinder
spacer with the chisel Holder.
23. Use the following nut mining manner and torque for tightening them.

−38−
TORQUE CHART

SIDE BOLT TORQUE

TURN-OF-NUT METHOD :

E-210B

E-213A, E-216A, E-220, E-225

MODEL FINAL TURN-OF-NUT ANGLE

E-210B 150 °
E-213A 180 °
E-216A 180 °
E-220 180 °
E-225 210 °

TOROUE WRENCH METHOD

SOCKET SIZE TORQUE

MODEL
mm Nm (kgf⋅m)
E-210B 65 2,000 (200)
E-213A 70 2,300 (230)
E-216A 77 3,000 (300)
E-220 77 3,500 (350)
E-225 85 4,250 (425)

−39−
 TIGHTENING OF OTHER BOLTS
NPK recommends the use of "Loctite" stud lock (red). "Loctite" should be used on the threads of the bracket
bolts, main valve bolts, and the gas charge valve. Before application, the threads must be clean and dry.

Valve Case Top Plate, Bottom Plate Swivel Adapter

MODEL Torque Torque Torque
Bolt size. Bolt size. Bolt size.
Nm (kgf-m) Nm (kgf-m) Nm (kgf-m)
E-210B M24 950 (95) M22 750 (75) M12 130 (13)
E-213A M24 950 (95) M22 750 (75) M12 130 (13)
E-216A M24 950 (95) M22 750 (75) M12 130 (13)
E-220 M27 1,400 (140) M24 950 (95) M14 200 (20)
E-225 M27 1,400 (140) M24 950 (95) M14 200 (20)

Bottom Bracket Cushion Rubber Top Bracket

MODEL Torque Torque Torque
Bolt size. Bolt size. Bolt size.
Nm (kgf-m) Nm (kgf-m) Nm (kgf-m)
E-210B 1-1/4" 900 (90) M16 280 (28) M24 950 (95)
E-213A 1-1/4" 900 (90) M16 280 (28) M24 950 (95)
E-216A 1-1/2 1,100 (110) M20 550 (55) M30 1,900 (190)
E-220 1-1/2 1,100 (110) M20 550 (55) M30 1,900 (190)
E-225 1-1/2 1,100 (110) M20 550 (55) M30 1,900 (190)

*Hydraulic hose *Bolts (for pipe support)

Hydraulic Hose fitting Spanner to Tightening Bolt dia. Spanner to Tightening
hose dia. be used Torque be used torque
in mm Nm (kgf-m) in mm Nm (kgf-m)
3/16 7/16-20UN 16 20 (2) M10 17 60 (6)
1/4 PF 1/4 19 25 (2.5) M12 19 110 (11)
3/8 PF 3/8 22 50 (5)
1/2 3/4-16UN 27 80 (8)
3/4 1-1/16-12UN 36 180 (18)
1 1-5/16-12UN 41 200 (20)
1-1/4 1-5/8-12UN 50 250 (25)

−40−
MOUNTING PLATE

If the HAMMER has been overstressed due to improper operation or installed on too large carrier, the mounting
bracket may develop a fatigue crack.

REPAIRING A CRACKED PLATE

1. Drill a 5 mm hole through the bracket at the end of the crack to prevent further crack propagation.
2. Grind out the crack and weld as shown. Use AWS E7016 or equivalent welding rod.
(JIS Z3211 D4316.DIN 515 4B(R) 10)
3-A. For plate size up to 20mm thick use this weld joint:

3-B. For plate sizes over 20 mm thick use this weld joint:

4. Grind weld flush as shown:

DIRECTION OF GRINDING

DIRECTION OF PRINCIPLE STRESS

MOUNTING BRACKET SPACER

Spacer guide the motion of the HAMMER in the mounting bracket. Replace the spacer it worn below 15 mm
thickness (over 5 mm wear). Operating the HAMMER with wear exceeding this limit can result in cushion rubber
failure.

−41−
NOTICES ON HYDRAULIC HOSES

The hydraulic hoses are recommended to be changed within two years at longest. Be sure to make close check of
the hoses every day, especially, the arm end hoses and the inner bracket hoses.

(1) APPLICATION OF HOSES

• The hoses should be used within the following range of temperature.
Service temperature of the fluid -40 °C ∼ +100 °C
Atmospheric temperature -40 °C ∼ +70 °C
• Do not make any mending, repairing and alterations to the hoses.

(2) INSTALLATION OF HOSES

• Don't twist nor extend the hoses. It is dangerous that the twisted hoses should cause burst near the fittings
when the hoses are under pressure.
• Prevent the damage outside hose.
It is dangerous that the damage outside hose should cause early burst at the bent portion of the hose.
• Fasten properly following to the specified fastening torque.
If not, it can not be sealed well, and cause to oil leakage and breakage of the fittings.

(3) MAINTENANCE AND CHECK

Be sure no damage nor exposure of reinforced layer.
Be sure no oil leakage from fittings.

(4) STORE
• Keep the hoses in the clean and dry atmosphere, where there is no hazardous gas, away from the sun
shine, and within the range of temperature, -10 °C ∼ +40 °C.

•Tightening Torque for Hydraulic Hoses

Hydraulic Hoses Fitting Width Across Flat Tightening Torque
in mm Nm (kgf-m)
3/16 7/16-2 0UN 16 20 (2)
1/4 PF 1/4 19 25 (2.5)
3/8 PF3/8 22 50 (5)
I/2 3/4-16UN 27 80 (8)
3/4 1-1/16-12UN 36 180 (18)
1 1-5/16-12UN 41 200 (20)
1-1/4 1-5/8-12UN 50 250 (25)

−42−
STORAGE OF HYDRAULIC HAMMER

For short term storage between jobs, place the HAMMER horizontal on wood blocks. Be sure the chisel is liberally
greased and the hydraulic hoses are capped. Cover with a waterproof tarp.

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. The chisel should be removed, and the piston pushed all the way in. Grease the exposed
end of the piston. Be sure the hydraulic hoses are plugged. Cover with a waterproof tarp.

−43−
NOTES

NPK HYDRAULIC HAMMER, MODEL NUMBER E ........................................

SERIAL NUMBER............................................

NPK INSTALLATION KIT NUMBER .................................................................

BRACKHOE OR EXCAVATOR MANUFACTURER ..................................................................................

MODEL NUMBER .......................................... SERIES...........................
SERIAL NUMBER ...................................................................................

DATE OF INSTALLATION .........................................................................................................................

DATE OF 20 HOUR INSPECTION............................................................................................................

SERVICE RECORD

−44−
 R

NIPPON PNEUMATIC MFG . CO., LTD.

11-5, 4-CHOME, KAMIJI, HIGASHINARI-KU, OSAKA, JAPAN
TEL: (06) 6973-9104 FAX: (06) 6974-5523
http://www.npk.co.jp
Copyright C 2001 Nippon Pneumatic Mfg. Co., Ltd. All rights reserved.