NPK Operators Manual
NPK Operators Manual
NPK Operators Manual
OPERATORS MANUAL
GH SERIES HAMMERS
GH7 GH18
GH9 GH23
GH10 GH30
GH12 GH40
GH15 GH50
© Copyright 2016 NPK Construction Equipment, Inc. www.npkce.com H050-9630H GH7 - GH50 Hyd
Ham Operators Manual 4-16
NPK
CONTENTS
SAFETY .......................................................................................................................................................... 3
INTRODUCTION............................................................................................................................................. 5
CARRIER MACHINE COMPATIBILITY .......................................................................................................... 6
HAMMER SPECIFICATIONS ......................................................................................................................... 7
HAMMER SERIAL NUMBER LOCATION ...................................................................................................... 8
HYDRAULIC INSTALLATION......................................................................................................................... 9
PREVENTION OF CONTAMINATION ...................................................................................................... 10
HYDRAULIC QUICK DISCONNECTS ...................................................................................................... 11
MOUNTING INSTALLATION .......................................................................................................................... 13
REMOVAL FROM THE CARRIER ............................................................................................................ 14
MOUNTING TO THE CARRIER ................................................................................................................ 14
LUBRICATION ................................................................................................................................................ 15
MANUAL GREASING PROCEDURE ........................................................................................................ 15
CORRECT GREASE AND GREASE INTERVALS ................................................................................... 16
AUTO LUBE SYSTEMS ............................................................................................................................ 17
AUTO LUBE GREASE LINE PRE-FILLING .............................................................................................. 18
HAMMER MOUNTED AUTO LUBE GREASE LINE PRE-FILLING.......................................................... 21
LUBRICANT TERMS AND DEFINITIONS ................................................................................................ 23
START-UP OPERATION ................................................................................................................................ 25
HAMMERS THAT ARE NEW, REBUILT, OR HAVE BEEN INACTIVE .................................................... 25
BEFORE STARTING THE HAMMER........................................................................................................ 26
DAILY START-UP PROCEDURE ............................................................................................................. 26
OPERATION ................................................................................................................................................... 27
SAFE OPERATING INSTRUCTIONS ....................................................................................................... 27
OPERATING TECHNIQUES & PRECAUTIONS ...................................................................................... 28
IMPACT ENERGY TRANSMISSION THROUGH TOOLS ............................................................................. 33
IMPACT STRESS WAVES AT THE END OF THE TOOL ........................................................................ 34
ROUTINE INSPECTION AND MAINTENANCE ............................................................................................. 35
WEEKLY INSPECTION .................................................................................................................................. 36
TYPES AND APPLICATIONS OF TOOL........................................................................................................ 37
STANDARD TOOLS .................................................................................................................................. 37
TOOL IDENTIFICATION ................................................................................................................................. 38
TOOLS ............................................................................................................................................................ 39
CHANGING THE TOOL ............................................................................................................................ 39
MAXIMUM TOOL TO TOOL BUSHING CLEARANCE ............................................................................. 40
CHISEL TOOL SHARPENING .................................................................................................................. 42
STANDARD LENGTH FOR NPK TOOLS ................................................................................................. 43
TOOL RETAINING PIN INSPECTION ...................................................................................................... 44
TOOL INSPECTION .................................................................................................................................. 45
TOOL WARRANTY ......................................................................................................................................... 46
-1-
NPK
CONTENTS
TOOL BREAKAGE.......................................................................................................................................... 48
TOOL BREAKAGE DUE TO EXCESSIVE BENDING MOMENT ............................................................. 48
CHARACTERISTICS OF THE BROKEN SECTION ................................................................................. 48
TOOL BREAKAGE DUE TO EXCESSIVE WEAR OF THE TOOL HOLDER BUSHINGS ....................... 49
TEMPERATURE RELATED TOOL PROBLEMS ...................................................................................... 54
TOOL BREAKAGE DUE TO CORROSION .............................................................................................. 55
TOOL BREAKAGE DUE TO DEFECTIVE MATERIAL ............................................................................. 55
TORQUE VALUES FOR HAMMER FASTENERS ......................................................................................... 56
HAMMER BRACKET – GH7 THROUGH GH50........................................................................................ 57
GAS CHARGE ................................................................................................................................................ 58
NITROGEN GAS PRESSURE .................................................................................................................. 58
GAS CHARGING KIT ................................................................................................................................ 58
CHECKING THE GAS PRESSURE .......................................................................................................... 59
CHARGING THE HAMMER ...................................................................................................................... 61
DISCHARGING THE GAS PRESSURE .................................................................................................... 63
WARRANTY REGISTRATION FOR NEW UNITS ......................................................................................... 64
STORAGE OF HYDRAULIC HAMMER.......................................................................................................... 65
WARRANTY STATEMENTS .......................................................................................................................... 66
NOTES AND RECORDS ................................................................................................................................ 70
-2-
NPK
SAFETY
Safety notices in NPK Instruction Manuals follow ISO and ANSI standards for
safety warnings:
1. Operator and Service personnel must read and understand the NPK INSTRUCTION
MANUALS 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.
Warning Decal for Cab Installation
-3-
NPK
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 Service 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 Boom Pins.
14. 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-
NPK
INTRODUCTION
NPK is a leading manufacturer of boom mounted HYDRAULIC HAMMERS, and has the
most complete product line available anywhere. The success of NPK is due to our
commitment to quality, dependability and long 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 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-
NPK
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
can damage the carrier. Verify carrier stability with HAMMER before transport or
operation.
Mounting a HAMMER that is too small for the carrier machine can damage the
HAMMER, cause tool breakage and void Warranties. Please consult the NPK Sales
Department for specific detailed information.
CARRIER WEIGHT lbs (kg)
HAMMER RECOMMENDED CARRIER WEIGHT RANGE
MODEL (lbs) (kg)
GH7 28,000 - 42,000 12,700 - 19,000
GH9 40,000 - 56,000 18,000 - 25,000
GH10 46,000 - 66,000 20,000 - 30,000
GH12 56,000 - 86,000 25,000 - 38,000
GH15 66,000 - 100,000 30,000 - 45,000
GH18 70,000 - 114,000 32,000 - 52,000
GH23 100,000 - 150,000 45,000 - 68,000
GH30 100,000 - 186,000 45,000 - 84,000
GH40 160,000 - 260,000 72,000 - 117,000
(1) (1)
GH50 240,000 + 108,000 +
*Specifications subject to change without notice.
(1)
Contact the NPK Sales Department for carrier range.
-6-
NPK
HAMMER SPECIFICATIONS
IMPACT TOOL
HAMMER ENERGY FREQUENCY WORKING DIA WORKING
MODEL CLASS WEIGHT LENGTH
ft lb bpm lbs (kg) in (mm) in (mm)
GH7 2500 400 - 750 2900 (1320) 4.6 (116) 23 (583)
GH9 3000 500 - 670 3600 (1635) 5.0 (126) 24 (608)
GH10 4000 400 - 550 4200 (1900) 5.4 (136) 24.5 (620)
GH12 5500 380 - 480 5650 (2565) 5.7 (146) 25.5 (650)
GH15 8000 320 - 400 6800 (3085) 6.1 (156) 27 (690)
GH18 12000 300 - 400 7800 (3540) 6.5 (165) 29 (740)
GH23 13500 300 - 400 9240 (4190) 6.9 (174) 34.6 (880)
GH30 15000 310 - 390 13500 (6125) 7.2 (184) 32 (813)
GH40 17000 240 - 330 17000 (7710) 8.0 (204) 35.4 (899)
GH50 20000 210 - 280 24910 (11300) 8.4 (214) 39.7 (1008)
NOTES:
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 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 maximum. Use tolerance of minus 25 psi (2 bar).
-7-
NPK
HAMMER SERIAL NUMBER LOCATION
NPK HAMMER MODELS GH7 through GH50
The serial number location (sn1) is right of center on the body above the Auto Lube port.
-8-
NPK
HYDRAULIC INSTALLATION
NPK INSTALLATION KITS are available for virtually all compatible backhoe loaders,
excavators, and skid steers. Complete parts and instructions for the hydraulic
installation of the NPK HYDRAULIC HAMMER including valving and/or controls, hoses
and fittings, accumulators, boom and stick tubing, and clamps are provided.
HAMMER LINES
Typically, the pressure line (m3) is arranged on the left side of the boom and the return
line (m4) on the right side. Flow to the hammer is controlled from an auxiliary valve on
the carrier or from an NPK supplied valve. Hydraulic oil is routed back to the tank
through the carrier’s oil cooler and filter.
-9-
NPK
HYDRAULIC INSTALLATION
ATTENTION PREVENTION OF CONTAMINATION
1. A hydraulic hammer is harder on oil than using a bucket, so the oil is apt to
deteriorate and breakdown sooner. Neglect of the hydraulic oil can not only damage
the hydraulic hammer but also cause problems in the carrier, which could result in
damaged components. Care should be taken to check for contamination of the oil
and to change it if it is found contaminated. Oil sampling at regular intervals is
highly recommended.
When the hydraulic oil shows low viscosity and bubbles, this indicates that the oil
is deteriorated. If the oil is dark brown and gives off an offensive odor, it is
severely deteriorated. Change the oil immediately!
When the oil is 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 contamination to mix with the oil. Take special care in preventing
contamination from entering the hydraulic system through the hose or tube
connection when changing the hydraulic hammer with the bucket.
3. Low oil level will cause heat build-up, resulting in deterioration of the oil. Also, it may
cause cavitation due to air mixing with the oil, leading to a damaged hydraulic
hammer and carrier components. Keep the oil at the proper level at all times.
4. Do not use the hydraulic hammer at an operating temperature higher than 180°F
(80°C). The proper operating oil temperature range is between 120°F (50°C) and
180°F (80°C). Since clogged cooler fins causes reduced efficiency of the cooler,
keep the cooler fins clean at all times. Check the hydraulic oil cooling system to be
sure it is working effectively. The use of a heat gun is the best way to evaluate if the
cooler is working properly.
5. Water in the hydraulic oil will lead to damage of the hydraulic hammer and carrier.
Drain off water and foreign matter from the hydraulic tank at specified intervals.
When out of service, the hydraulic hammer should be stored indoors.
- 10 -
NPK
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 disconnects to disintegrate. These pieces would migrate
into the hammer, causing damage.
2. If hydraulic quick disconnects are used, they should be capped when the hammer is
removed from the carrier to keep them clean. Contamination can get into the
hydraulic quick disconnect and can be flushed into the hammer and/or the hydraulic
system 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 of the disconnects
may push an older, low pressure, carrier machine to the limit of its hydraulic system.
This would interfere with proper hammer operation. However, the NPK approved
quick disconnects are properly sized so that the hammer operation is not
affected.
NOT RECOMMENDED CONNECTION
APPROVED CONNECTION (39) Non-NPK Quick Disconnects (32)
- 11 -
NPK
HYDRAULIC INSTALLATION
HYDRAULIC QUICK DISCONNECTS
If hydraulic quick disconnects are used with the NPK hammer, it is recommended that
the following precautions be followed.
- 12 -
NPK
MOUNTING INSTALLATION
NPK Mounting Installation Kits include the parts required to adapt the NPK HYDRAULIC
HAMMER to the carrier. NPK mounting kits include the top bracket (m7), flow control
valve (if required), and hoses to connect to the carrier hydraulic system.
ITEM DESCRIPTION
k8 TEST PORT
m3 WHIP HOSE (PRESSURE)
m4 WHIP HOSE (RETURN)
m5 HAMMER HOSE (PRESSURE)
m6 HAMMER HOSE (RETURN)
m7 TOP BRACKET
m8 BOLT PACKAGE
m15 I.D. TAG
m16 INSIDE MALE ADAPTER FITTING
m17 OUTSIDE MALE ADAPTER FITTING
121 BRACKET PART NUMBER STAMP
Refer to HAMMER FASTENER TORQUE section for top bracket bolt torque.
Refer to NPK Installation Kit Manual for additional information.
- 13 -
NPK
MOUNTING INSTALLATION
REMOVAL FROM THE CARRIER
1. Close pressure and return line
shut-off valves (k4).
2. Disconnect the hammer whip
hoses (m3) and (m4) before laying
the hammer down. Avoid getting
hydraulic oil on rubber mounts
(AD). Flush with water if
necessary.
3. Cap (AR) the pressure and return
lines on the carrier and connect
the hammer whip hoses (m3) and
(m4) to the hammer bracket as
shown.
4. Position the hammer (DR)
horizontal on wood blocks (t20)
and remove boom pins.
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.
- 14 -
NPK
LUBRICATION
MANUAL GREASING PROCEDURE
Manual greasing procedure for hammers without an AUTO LUBE System.
- 15 -
NPK
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 17, 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.
- 16 -
NPK
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°F (177°C), 500°F
(260°C), and 2000°F (1094°C). All are compatible with Auto Lube systems.
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.
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.
- 17 -
NPK
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.
- 18 -
NPK
LUBRICATION
AUTO LUBE GREASE LINE PRE-FILLING
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 before using the hammer. Failure
to do this will result in an intermittent supply of grease to the hammer.
- 19 -
NPK
LUBRICATION
AUTO LUBE GREASE LINE PRE-FILLING
- 20 -
NPK
LUBRICATION
HAMMER MOUNTED AUTO LUBE GREASE LINE PRE-FILLING
It is mandatory that the supply line from the Hammer Mounted 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
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.
- 21 -
NPK
LUBRICATION
HAMMER MOUNTED AUTO LUBE GREASE LINE PRE-
FILLING
PRIMING THE GREASE LINE
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.
- 22 -
NPK
LUBRICATION
LUBRICANT TERMS AND DEFINITIONS
TERM DEFINITION
- 23 -
NPK
LUBRICATION
LUBRICANT TERMS AND DEFINITIONS
TERM DEFINITION
- 24 -
NPK
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. See CHECKING THE GAS PRESSURE section for procedure.
2. At idle, raise the hammer off of the ground. Place hammer vertical and activate
the hammer circuit for 3 – 5 second intervals. Continue for an additional 3 – 4 times
to ensure that all the air has been purged from the hoses and hammer before first
use. Failure to do this could result in damage to internal components.
- 25 -
NPK
START-UP OPERATION
BEFORE STARTING THE HAMMER
Warm up the NPK hydraulic hammer, see below, and the carrier machine in accordance
with the machine manufacturer’s instruction manual. This is especially important during
cold weather operation.
Do not operate on a
slanted surface during
the start-up operation.
- 26 -
NPK
OPERATION
SAFE OPERATING INSTRUCTIONS
- 27 -
NPK
OPERATION
OPERATING TECHNIQUES & PRECAUTIONS
- 28 -
NPK
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 bushing wear and/or tool breakage.
2. Breakage of tie rods.
3. Breakage of bracket bolts.
4. Decrease in transfer of energy translates to reduced production.
When the tool binds from incorrect working angle, the sound of the hammer changes.
- 29 -
NPK
OPERATION
OPERATING TECHNIQUES & PRECAUTIONS
ALWAYS WORK BY
BREAKING TO A FREE FACE
The material must have somewhere to
break to. Start at an edge.
- 30 -
NPK
OPERATION
OPERATING TECHNIQUES & PRECAUTIONS
- 31 -
NPK
OPERATION
OPERATING TECHNIQUES & PRECAUTIONS
- 32 -
NPK
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.
- 33 -
NPK
IMPACT ENERGY TRANSMISSION THROUGH
TOOLS
IMPACT STRESS WAVES AT THE END OF 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 28.
- 34 -
NPK
ROUTINE INSPECTION AND MAINTENANCE
1. VISUAL INSPECTION
Detect a potential problem early.
FASTENERS
Inspect all fasteners. Retighten as necessary. Refer to HAMMER FASTENER
TORQUE section, page 56 and 57 for Top Bracket bolt torque.
WELDS
Check for cracks, repair as necessary.
HOSES AND TUBING
Check for oil leaks, loose clamps and hose abrasion.
HYDRAULIC OIL
MAINTAIN A CLEAN HYDRAULIC SYSTEM
If non-petroleum oil is used, contact NPK Service Department for compatibility.
Keep hoses clean and capped when dismounting or storing hammer.
Change oil and filters as recommended by carrier manufacturer. Periodic oil
sampling is recommended.
2. 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 hammer until grease is seen coming out
between the tool and bushing.
Use a good quality, high temperature EP#2 grease
containing anti-wear additives, see LUBRICATION
section.
If machine is equipped with an AUTOLUBE System, check
grease reservoir daily.
Do not hardface or sharpen the tool point with a cutting torch. Excessive heat from
torching or welding causes embrittlement, breakage, and flying pieces. Re-sharpen
only with a surface grinder or milling machine using sufficient cooling.
Please consult your authorized NPK Dealer or NPK Service Department for additional
information.
- 35 -
NPK
WEEKLY INSPECTION
1. WELDS
Check for cracks, repair as necessary. Consult your authorized NPK Dealer or
NPK Service Department for additional information.
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
section.
4. GAS CHARGE
Check and adjust, if required, see GAS CHARGE section.
- 36 -
NPK
TYPES AND APPLICATIONS OF TOOL
STANDARD TOOLS
DEMOLITION TOOL SHAPE APPLICATIONS
Trenching
CHISEL (FX) Cutting casting gates
The cross cut (FX) tool Breaking oversize
cuts at right angle, or General demolition
crosswise, to the stick and
boom of the excavator.
Concrete breaking
MOIL (P) Highway construction
General demolition
Secondary breaking
BLUNT (E) Breaking oversize
Slag removal
OPTIONAL TOOL
Concrete breaking
CORE (PC) Highway construction
General demolition
- 37 -
NPK
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.
- 38 -
NPK
TOOLS
CHANGING THE TOOL
REMOVAL
1. Remove the retaining ring by using pliers or screwdrivers, see Figures 1 and 2. It
will easily come out if pulled at an angle as shown in Figure 2.
2. Screw an M12 bolt or cap screw into the retainer pin.
3. Pull out retainer pin. If the retainer pin is jammed, use a hammer and drift from the
opposite side.
NOTE: THIS PROCEDURE DOES NOT APPLY TO MODELS GH23 – GH50.
Figure 1 Figure 2
RE-INSTALLATION
1. Clean the retainer pin housing hole and retaining ring groove.
2. Coat the surface of the tool with grease, then install.
3. Apply grease to the retaining ring housing groove.
4. Coat the retaining pin with grease, then install.
5. Install the retaining ring in the following manner:
a. While deforming the retaining ring as shown in Figure 3, partially force it into the
groove.
b. Using the handle of the pliers or screwdriver, press the rest of the ring into the
groove, see Figure 4.
Figure 3 Figure 4
- 39 -
NPK
TOOLS
MAXIMUM TOOL TO TOOL BUSHING CLEARANCE
Replace the tool bushing (G), and/or tool (HH), when the tool to bushing gap reaches
the maximum clearance. To determine whether the bushing or tool requires
replacement, follow the instructions and charts shown below:
Step 1
Measure the tool to bushing gap (d15) with the hammer horizontal, as illustrated below.
If the clearance is at or greater than the charted maximum clearance, consult the NPK
Hydraulic Hammer Service Manual to determine which component requires
replacement.
HAMMER MAXIMUM
MODEL CLEARANCE
inch (mm)
GH7 3/8 (10)
GH9 3/8 (10)
GH10 3/8 (10)
GH12 1/2 (13)
GH15 1/2 (13)
GH18 1/2 (13)
GH23 5/8 (16)
GH30 5/8 (16)
GH40 5/8 (16)
GH50 5/8 (16)
Step 2
Remove the tool from the tool holder. Measure the diameter (d16) of the bearing
surface of the tool, 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 DIAMETER MINIMUM TOOL
MODEL (d16) DIAMETER
- 40 -
NPK
TOOLS
MAXIMUM TOOL TO TOOL BUSHING CLEARANCE
Step 3
Measure the inside diameter of the lower and upper tool bushings. The maximum tool
bushing inside diameter is compared to a new tool only. If the tool bushing dimensions
are at or above the charted value, the bushing must be replaced.
Step 4
Compare the tool and bushings 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. Obviously, replacing both the tool and bushings would bring
the clearance back to new.
- 41 -
NPK
TOOLS
CHISEL TOOL SHARPENING
Worn chisel tools can be sharpened by machining according to the dimensions below.
DO NOT hardface or sharpen the tool point with a cutting torch! Sharpen only by milling
or grinding, using sufficient coolant.
d16 d21
MODEL NO. inch mm inch mm
GH7 4.50 114 0.62 16
GH9 4.88 124 0.62 16
GH10 4.92 125 0.75 19
GH12 5.51 140 0.75 19
GH15 5.91 150 0.75 19
GH18 6.3 160 0.75 19
GH23 6.69 170 0.75 19
GH30 7.09 180 0.75 19
GH40 7.87 200 1.00 25
GH50 8.27 210 1.00 25
- 42 -
NPK
TOOLS
STANDARD LENGTH FOR NPK TOOLS
NOTE:
Minimum tool length is determined by the depth of material penetration that is required.
- 43 -
NPK
TOOLS
TOOL RETAINING PIN INSPECTION
The tool retaining pin (D) serves to keep the tool in the hammer when the hammer is
raised off the ground for repositioning. Additionally, the retaining pin will become worn
during normal use. Figure “A” shows the retaining pin when it is new. Note: the two
guide grooves (AN). The guide groove areas and the area (122) between the grooves
are the areas where the wear will take place. If large, flat areas are found here, the pin
must be replaced. This would indicate that the hammer is not being greased frequently
enough.
Figure “A”
Normal wear (20) will occur on the pin as shown in Figure “B”. Grind this area on a
bench grinder or with a disc grinder to remove any burrs. Reuse the pin.
Figure “B”
- 44 -
NPK
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 of the tool. Dress with a grinder.
2A. Excessive blank hammering can cause retaining pin breakage/failure. Replace
retaining pin (D).
3. If chipping (16) is found at the top of the tool, replace the tool. If neglected, the
piston impact surface will be damaged.
- 45 -
NPK
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 maybe made for breakage of the demolition or other accessory tools.
NPK Tool Warranty does not cover labor or travel expenses.
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 40, 41, 49, and 50.
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.
- 46 -
NPK
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):
A – Typical break from bending overload. B5, B6 and B7 – bending overload from
B1 and B2 – repeated blank hammering. excessive prying or slant hammering.
CAUSE B2 – bending overload due to excessive B8 and B9 – deformation from overheating
OF wear of the tool bushings. by hammering in the same position for
FAILURE B3 and B4 – corner loading due to more than 30 seconds.
excessive wear of the tool bushings. B10 and B11 – chipped, due to wrong
application, or overheating by hammering
in same position for over 30 seconds.
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).
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.
- 48 -
NPK
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 area 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).
- 49 -
NPK
TOOL BREAKAGE
TOOL BREAKAGE DUE TO EXCESSIVE WEAR OF THE TOOL
HOLDER BUSHINGS
PREVENTATIVE MEASURES
Replace the tool holder bushings when the clearance (d15) reaches the maximum limit
listed below. See pages 40 and 41 in this manual for the maximum tool bushing
diameter and the minimum tool diameter.
HAMMER MAXIMUM
MODEL CLEARANCE
inch (mm)
GH7 3/8 (10)
GH9 3/8 (10)
GH10 3/8 (10)
GH12 1/2 (13)
GH15 1/2 (13)
GH18 1/2 (13)
GH23 5/8 (16)
GH30 5/8 (16)
GH40 5/8 (16)
GH50 5/8 (16)
G. Tool Bushing
HH. Tool
d15. Clearance
d16. Tool Diameter
WARRANTY
NPK Warranty does not cover tool failure caused by worn tool holder bushings.
- 50 -
NPK
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.
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.
- 51 -
NPK
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.
- 52 -
NPK
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.
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 problems “A” through “E” above.
- 53 -
NPK
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.
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.
- 54 -
NPK
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, after 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.
WARRANTY
NPK Warranty does cover this type of failure.
- 55 -
NPK
TORQUE VALUES FOR HAMMER FASTENERS
If hammer or hammer bracket fasteners are found to be loose, use the following charts.
Medium strength thread adhesive should be used on all the valve assembly bolts and
the gas charge valve. All other bolts should be lubed with anti-seize compound.
- 56 -
NPK
HAMMER FASTENER TORQUE
HAMMER BRACKET – GH7 THROUGH GH50
The bolt torque for the lower support block bolt in Location (L2) has been reduced.
Please see the following chart showing the torque values. Bolts marked Location (L1)
are not affected and the standard torque remains the same. Lube all bolts.
NOTE: This is not required to be done to units in the field or dealer inventory
until time of rebuild.
- 57 -
NPK
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.
- 58 -
NPK
GAS CHARGE
CHECKING THE GAS PRESSURE
Inspect the nitrogen gas pressure every 100 hours.
PROCEDURE
- 59 -
NPK
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.
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.
- 60 -
NPK
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.
7. Slowly adjust the regulator on the nitrogen tank to the correct pressure by turning the
handle clockwise. Refer to the NITROGEN GAS PRE-CHARGE chart in the
NITROGEN GAS PRESSURE SECTION.
- 61 -
NPK
GAS CHARGE
CHARGING THE HAMMER
Nitrogen gas may be trapped in the hose. Loosen fittings slowly to release
pressure!
10. Remove the charge adapter from the hammer charge valve.
- 62 -
NPK
GAS CHARGE
DISCHARGING THE GAS PRESSURE
PROCEDURE
1. Remove the charge 2. Turn the NPK charge 3. Install the NPK charge
valve cap (M1) from the adapter T-handle (g2) to adapter (g1) onto the
charge valve (M). Do a full counterclockwise hammer charge valve
not remove the charge position. located on the hammer
valve assembly! gas head (L).
REMOVE THE VALVE CAP ONLY, NOT THE CHARGE VALVE ASSEMBLY!
4. Tighten the charge 5. Turn the T-handle (g2) 6. Loosen the charge adapter
adapter cap (g6). clockwise. As the T- cap (g6) VERY SLOWLY!
handle is screwed in, a The gas pressure will
resistance is gradually decrease to zero.
encountered. By turning When it gets to zero, remove
the T-handle, the the cap.
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. Remove the charge adapter (g1) from the gas charge valve on the hammer gas head
(L), then, reinstall the charge valve cap.
- 63 -
NPK
WARRANTY REGISTRATION FOR NEW UNITS
Complete and send to NPK after installation or complete online at www.npkce.com.
Online warranty 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.
- 64 -
NPK
STORAGE OF HYDRAULIC HAMMER
For short term storage between jobs, place the hammer horizontal on wood blocks
(t20). Be sure the tool (HH) is liberally greased and the hydraulic hoses (AO) 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),
the following storage procedure is recommended:
1. Discharge the gas pressure using the gas charge valve (M).
2. Remove the tool (HH) and push the piston (N) all the way in.
3. Grease the exposed end of the piston (N).
4. Grease and reinstall the tool (HH) at bushing areas.
5. Plug the hydraulic hoses (AO).
6. Cover with a waterproof tarp (t21), not shown.
7. Set the hammer on wood blocks (t20).
- 65 -
NPK
WARRANTY STATEMENTS
- 66 -
NPK
WARRANTY STATEMENTS
- 67 -
NPK
WARRANTY STATEMENTS
- 68 -
NPK
WARRANTY STATEMENTS
- 69 -
NPK
NOTES AND RECORDS
CARRIER MANUFACTURER
MODEL NUMBER
SERIES
SERIAL NUMBER
- 70 -
© Copyright 2016 NPK Construction Equipment, Inc. www.npkce.com H050-9630H GH7 - GH50
Hyd Ham Operators Manual 4-16