Hydraulic Hammer Service Manual-Books Pdf

HYDRAULIC HAMMER SERVICE MANUAL
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Safety notices in NPK Instruction Manuals follow ISO and ANSI standards for. safety warnings, DANGER red notices indicate an imminently hazardous situation. which if not avoided will result in death or serious injury. WARNING orange notices indicate a potentially hazardous. situation which if not avoided could result in death or serious. CAUTION yellow notices indicate a potentially hazardous. situation which if not avoided may result in minor or moderate. ATTENTION blue notices in NPK Instruction Manuals are an NPK. ATTENTION standard to alert the reader to situations which if not avoided. could result in equipment damage, WARNING and BASIC OPERATING INSTRUCTIONS decals are included with each. NPK hammer and installation kit Decals must be installed in the cab visible to the. operator while operating the hammer, STAY CLEAR PRESSURE VESSEL GAS PRESSURE and TOOL SHARPENING. decals are installed on all NPK hammer models Keep them clean and visible NPK will. provide decals free of charge as needed, 1 Operator and Service personnel must read and understand the NPK INSTRUCTION. MANUAL to prevent serious or fatal injury, 2 FLYING DEBRIS CAN CAUSE SERIOUS OR FATAL.
Keep personnel and bystanders clear of hammer, while in operation. Do not operate HAMMER without an impact, resistant guard between the 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. 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. 8 Operate HAMMER from operator s seat only, 9 Match HAMMER size to carrier according to NPK recommendations see page 7. The carrier must be stable during hammer operation and during transport. 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 if conditions warrant Consult OSHA regulations. 13 Wear safety glasses at all times Beware of flying debris. 14 If modifications are to be made do not alter the HAMMER without authorization. from NPK Engineering, 15 Use only genuine NPK replacement parts NPK specifically disclaims any. responsibility for any damage or injury that results from the use of any tool or parts. not sold or approved by NPK, For further safety information consult the AEM Hydraulic Mounted Breakers Safety.
Manual AEM form MB 140 NPK P N H050 9600 which is furnished with every NPK. hammer To request an additional copy please contact NPK at 800 225 4379 or. Internet at www npkce com, INTRODUCTION 5, BASIC OPERATING INSTRUCTIONS 5. PRECAUTIONS FOR USING THE NPK HYDRAULIC HAMMER 6, CARRIER MACHINE COMPATIBILITY 7. HAMMER SPECIFICATIONS 8, STRUCTURE 9, HAMMER SERIAL NUMBER LOCATION 11. PRINCIPLE OF OPERATION 12, HYDRAULIC INSTALLATION 13. MOUNTING INSTALLATION 17, ROUTINE INSPECTION AND MAINTENANCE 18.
WEEKLY INSPECTION 19, CHANGING THE TOOL 20, TROUBLESHOOTING 22. CHECKING THE HYDRAULIC PRESSURES 23, CHECKING THE HYDRAULIC FLOW TO THE HAMMER 24. OIL LEAKAGE 26, GAS LEAKAGE 27, EXCESS OIL IN THE GAS HEAD INSPECTION PROCEDURE 28. NITROGEN GAS PRESSURE 29, GAS CHARGING KIT 29, CHECKING THE GAS PRESSURE 30. GAS CHARGING THE HAMMER 32, REMOVAL AND MOUNTING OF HYDRAULIC HAMMER 33.
TOOLS REQUIRED FOR DISASSEMBLY 34, NPK START UP KIT 35. NPK ASSEMBLY LUBRICANT 36, DISASSEMBLY PROCEDURE 37. DISCHARGING GAS PRESSURE 38, DISASSEMBLING THE MAIN BODY 40. DISASSEMBLY OF MAIN VALVE 46, INSPECTION AND REPAIR AFTER DISASSEMBLY 48. REPAIR SECTION INTRODUCTION 49, REPAIR TOOLS AND EQUIPMENT 49.
HAMMER SLEEVE AND PISTON RECONDITIONING TOOLS 50, MAIN BODY BORE REPAIR 52. PISTON ACTIVE SEAL AREA REPAIR 62, PISTON TO SLEEVE RUNNING CLEARANCES 63. REPAIR THE STRIKING END OF PISTON 64, MAIN BODY SLEEVES 64. REPLACING THE SEALS 65, REASSEMBLY OF THE HAMMER 67. STANDARD TOOLS 83, ACCESSORY TOOLS 83, MAXIMUM TOOL TO TOOL BUSHING CLEARANCE 84.
NPK HYDRAULIC HAMMER IMPACT BUSHINGS 86, TOOL INSPECTION 87. CHISEL TOOL RESHARPENING 88, STANDARD LENGTH FOR NPK TOOLS 89. RETAINING PIN 90, LUBRICATION 91, AUTOLUBE UNDERWATER PORT IDENTIFICATION 94. TOOL BUSHING REPLACEMENT 95, TOOL HOLDER BUSHING BORE REPAIR 98. TOOL HOLDER 101, REPLACEMENT OF TIE RODS 102, MAXIMUM ELONGATION OF TIE RODS 104.
TORQUE CHART 105, TORQUE VALUES FOR HAMMER FASTENERS 106. MOUNTING PLATE 107, WARRANTY REGISTRATION FOR NEW UNITS 108. WARRANTY STATEMENT 109, STORAGE OF HYDRAULIC HAMMER 110. DECIMAL CONVERSION CHART 111, REBUILD SPECIFICATIONS CHECK SHEETS 112. SERVICE RECORD 119, 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 instruction manual contains instructions for repairing 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, BASIC OPERATING INSTRUCTIONS. READ OPERATORS MANUAL, Do not pry with tool, Apply down force perpendicular to work surface.
Avoid blank hammering, Do not hammer continuously in the same position for more. than 30 seconds, 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, 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, USE A GOOD QUALITY HIGH TEMPERATURE EP 2 GREASE CONTAINING. ANTIWEAR ADDITIVES, If machine is equipped with an AUTOLUBE System check grease reservoir.
PERFORM VISUAL INSPECTIONS DAILY, Do not operate with loose or missing fasteners tie rods etc. MAINTAIN A CLEAN HYDRAULIC SYSTEM, Keep hoses clean and capped when dismounting or storing hammer. Change oil and filters as recommended by carrier manufacturer. DO NOT SUBMERGE HAMMER UNDERWATER, Unless modified for underwater operation. PRECAUTIONS FOR USING THE NPK, HYDRAULIC HAMMER, Perform daily inspections. Avoid blank hammering, Do not hammer continuously in the same position for more than 30 seconds.
Do not use the hammer to move material pry material or as a 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 specified intervals, Operate the hammer carefully Do not hit the boom of the carrier with the. Operate the hammer in a safe manor Read the NPK Hydraulic Hammer. Operators Manual, If additional safety information is needed consult the AEM Hydraulic Mounted Safety. Manual To request a free copy please contact NPK at 800 225 4379 or e mail us at. www npkce com, CARRIER MACHINE COMPATIBILITY CHART.
These carrier weight ranges are intended as a guideline only Other factors such as. stick length counterweights undercarriage etc must be taken into consideration. Mounting a HAMMER that is too heavy for the carrier machine. can be dangerous and damage the machine Verify carrier. stability with hammer before transport or operation. Mounting a HAMMER that is too small for the carrier machine can damage the. HAMMER cause tool breakage and void Warranties Please consult NPK. Engineering for specific detailed information, CARRIER WEIGHT lbs kg. HAMMER MOUNTING RECOMMENDED RANGE, MODEL STYLE lb kg. GH06 Excavator 2 200 4 400 1 000 2 000, Skid Steer 2 400 3 500 1 100 1 600. GH07 Excavator 2 800 5 500 1 300 2 500, Skid Steer 3 000 5 500 1 350 2 500. GH1 Excavator 5 400 9 000 2 450 4 100, Skid Steer 5 000 7 500 2 300 3 400.
GH2 GHS2 Excavator 6 600 12 000 3 000 5 500, Skid Steer 6 000 9 000 2 700 4 100. GH3 Excavator 8 800 15 000 4 000 7 000, Skid Steer 8 000 14 000 3 600 6 400. GH4 Excavator 13 000 22 000 6 000 10 000, GH6 Excavator 22 000 31 000 10 000 14 000. Specifications are subject to change without notice. HAMMER SPECIFICATIONS, HAMMER IMPACT WORKING MOUNTING TOOL. MODEL ENERGY FREQUENCY WEIGHT STYLE DIA WORKING, CLASS LENGTH.
ft lb bpm lbs Kg in mm in mm, GH06 150 480 1200 500 225 Skid Steer 1 7 42 12 2 311. 235 107 Excavator, GH07 200 500 1200 550 250 Skid Steer 1 9 47 13 1 333. 270 125 Excavator, GH1 350 550 1100 750 340 Skid Steer 2 2 57 13 6 346. 450 205 Excavator, GH2 GHS2 500 500 1300 800 365 Skid Steer 2 6 66 14 4 367. 525 240 Excavator, GH3 750 500 1150 1075 490 Skid Steer 3 0 76 16 1 408.
800 365 Excavator, GH4 1300 400 1050 1250 570 Excavator 3 4 86 18 0 458. GH6 2000 500 800 2150 980 Excavator 4 2 106 20 0 500. HAMMER HYDRAULIC CIRCUIT GAS CHARGE, MODEL OPERATING RELIEF PRESSURE 5. OIL FLOW PRESSURE 1 minimum 2 Cold 3 Hot 4, gpm L min psi bar psi bar psi bar psi bar. GH06 2 5 7 10 25 1650 115 2150 150 350 24 405 28, GH07 4 9 15 35 1500 105 2000 140 350 24 405 28. GH1 7 13 25 50 1750 120 2250 155 350 24 405 28, GH2 GHS2 7 17 25 65 2250 160 2750 190 350 24 405 28.
GH3 12 26 45 100 1900 130 2400 165 350 24 405 28, GH4 13 32 50 120 2200 150 2700 185 375 26 435 30. GH6 24 40 90 150 2400 165 2900 200 390 27 450 31, Specifications are subject to change without notice. 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 this 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. STRUCTURAL DRAWING, MODELS GH06 GH3, A MAIN BODY, B DRAIN PLUG. C TOOL HOLDER, D RETAINING PIN, E RETAINING RING, F UPPER TOOL BUSHING GH3 ONLY. G LOWER TOOL BUSHING, J SPACER SECTION, L GAS HEAD.
M CHARGE VALVE, P MAIN BODY SLEEVE B, V BOTTOM NUT. W VALVE BODY, Y VALVE BOTTOM CAP, Z VALVE SPOOL, AA PLUNGER BUSHING. BB PLUNGER, DD SWIVEL ELBOW, 30 GREASE FITTING, STRUCTURAL DRAWING. MODELS GH4 GH6, A MAIN BODY, B DRAIN PLUG, C TOOL HOLDER. D RETAINING PIN, E RETAINING RING, F IMPACT BUSHING w UPPER TOOL BUSHING.
G LOWER TOOL BUSHING, J SPACER SECTION, L GAS HEAD. M CHARGE VALVE, O MAIN BODY SLEEVE A, P MAIN BODY SLEEVE B. V BOTTOM NUT, W VALVE BODY, Y VALVE BOTTOM CAP, Z VALVE SPOOL. AA PLUNGER BUSHING, BB PLUNGER, DD SWIVEL ELBOW, 30 GREASE FITTING. HAMMER SERIAL NUMBER LOCATION, SERIAL NUMBER LOCATION sn1.
PRINCIPLE OF OPERATION, OPEN VALVE, 1 UPSTROKE 2 VALVE SHIFT 3 POWER STROKE 4 IMPACT. N PISTON 33 NITROGEN GAS CHAMBER ABOVE PISTON, Z MAIN VALVE SPOOL 34 UPPER CHAMBER OF PISTON. BB PLUNGER 35 LOWER CHAMBER OF PISTON, HH TOOL 36 CHAMBER OF VALVE SPOOL. 5 OUT PORT 37 NITROGEN GAS, 1 UPSTROKE OF PISTON, Hydraulic oil supplied by the carrier machine hydraulic pump enters the NPK HAMMER. IN port 6 and is directed through port h1 to the top of the valve plunger forcing the. main valve spool Z to the down position Oil flows through the main valve spool Z to. the lower chamber of the piston 35 The oil pressure acts on the piston N raising the. piston up compressing the nitrogen gas 37 Oil in the upper chamber of the piston 34. is forced out the return line through port h2, 2 VALVE SHIFT.
As the piston N rises lower chamber 35 is opened to passage h3 and oil flows into. the chamber 36 of the main valve spool Z Since the area acting on the main valve. 1 Operator and Service personnel must read and understand the NPK INSTRUCTION MANUAL to prevent serious or fatal injury 2 FLYING DEBRIS CAN CAUSE SERIOUS OR FATAL INJURY Keep personnel and bystanders clear of hammer while in operation Do not operate HAMMER without an impact resistant guard between the HAMMER and operator NPK

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