This document provides safety information and instructions for operating and maintaining NPK hydraulic hammers models GH06 through GH6. It contains information on safety procedures, specifications, operation, maintenance, lubrication, and inspection of the hammers. The document emphasizes the importance of reading the full instruction manual to prevent injury and only using genuine NPK replacement parts.
This document provides safety information and instructions for operating and maintaining NPK hydraulic hammers models GH06 through GH6. It contains information on safety procedures, specifications, operation, maintenance, lubrication, and inspection of the hammers. The document emphasizes the importance of reading the full instruction manual to prevent injury and only using genuine NPK replacement parts.
This document provides safety information and instructions for operating and maintaining NPK hydraulic hammers models GH06 through GH6. It contains information on safety procedures, specifications, operation, maintenance, lubrication, and inspection of the hammers. The document emphasizes the importance of reading the full instruction manual to prevent injury and only using genuine NPK replacement parts.
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 injury.
CAUTION (yellow) notices indicate a potentially hazardous
situation, which, if not avoided, may result in minor or moderate injury.
ATTENTION (blue) notices in NPK Instruction Manuals are an
ATTENTION NPK 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 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 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.
1 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, see page 8. 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 (440) 232-7900 or Internet at www.npkce.com.
2 CONTENTS SAFETY .......................................................................................................................................................... 1 INTRODUCTION ............................................................................................................................................. 6 BASIC OPERATING INSTRUCTIONS ........................................................................................................... 6 PRECAUTIONS FOR USING THE NPK HYDRAULIC HAMMER ................................................................. 7 CARRIER MACHINE COMPATIBILITY CHART ............................................................................................ 8 HAMMER SPECIFICATIONS ......................................................................................................................... 9 STRUCTURE .................................................................................................................................................. 11 STRUCTURAL DRAWING ...................................................................................................................... 11 HAMMER SERIAL NUMBER LOCATION ...................................................................................................... 13 PRINCIPLE OF OPERATION ......................................................................................................................... 14 HYDRAULIC INSTALLATION ......................................................................................................................... 15 BACKHOE/EXCAVATOR HAMMER LINES ........................................................................................... 15 SKID STEER HAMMER LINES .............................................................................................................. 15 HAMMER CONTROL VALVE ................................................................................................................. 15 SKID STEER HAMMER FLOW CONTROL VALVE (OPTIONAL) ......................................................... 16 HYDRAULIC QUICK DISCONNECTS .................................................................................................... 18 MOUNTING INSTALLATION .......................................................................................................................... 20 BACKHOES and EXCAVATORS ............................................................................................................ 20 SKID STEERS ......................................................................................................................................... 20 REMOVAL FROM THE CARRIER .......................................................................................................... 21 REMOVAL FROM THE SKID STEER .................................................................................................... 21 MOUNTING TO THE CARRIER ............................................................................................................. 21 MOUNTING TO THE SKID STEER ........................................................................................................ 22 LUBRICATION ................................................................................................................................................ 23 GREASING PROCEDURE ..................................................................................................................... 23 CORRECT FUNCTION OF GREASING AND GREASE INTERVALS ................................................... 24 FUNCTION OF GREASING .................................................................................................................... 24 GREASE INTERVALS ............................................................................................................................ 24 CORRECT GREASE FOR HYDRAULIC HAMMERS ............................................................................ 24 NPK HAMMER GREASE ........................................................................................................................ 25 AUTO LUBE SYSTEMS .......................................................................................................................... 26 AUTO LUBE GREASE LINE PRE-FILLING............................................................................................ 27 PRIMING THE GREASE LINE ................................................................................................................ 27 HAMMER MOUNTED AUTO LUBE GREASE LINE PRE-FILLING ....................................................... 30 PRIMING THE GREASE LINE ................................................................................................................ 30 HIGH HEAT APPLICATION ............................................................................................................................ 35 ROUTINE INSPECTION AND MAINTENANCE ............................................................................................. 36 WEEKLY INSPECTION .................................................................................................................................. 37 TROUBLESHOOTING .................................................................................................................................... 38 TROUBLESHOOTING CHART ............................................................................................................... 38 CHECKING THE HYDRAULIC PRESSURES ................................................................................................ 39 CHECKING THE HYDRAULIC FLOW AT RATED PRESSURE .................................................................... 41 OIL LEAKAGE ................................................................................................................................................. 43 GAS LEAKAGE ............................................................................................................................................... 44 EXCESS OIL IN THE GAS HEAD INSPECTION PROCEDURE ................................................................... 45 NITROGEN GAS PRESSURE ........................................................................................................................ 46 GAS CHARGING KIT / PART NO. 7300588 .................................................................................................. 46 CHECKING THE GAS PRESSURE ............................................................................................................... 47 GAS CHARGING THE HAMMER ................................................................................................................... 49 TOOLS AND EQUIPMENT REQUIRED FOR HAMMER DISASSEMBLY .................................................... 51 NPK START-UP KIT ....................................................................................................................................... 54 NPK ASSEMBLY LUBRICANT ....................................................................................................................... 55 DISASSEMBLY PROCEDURE ....................................................................................................................... 56 DISCHARGING THE GAS PRESSURE ......................................................................................................... 57 DISASSEMBLY ............................................................................................................................................... 58 DISASSEMBLING THE MAIN BODY ............................................................................................................. 60 MODELS GH4 and GH6 ......................................................................................................................... 60 3 CONTENTS PISTON AND SLEEVE REMOVAL ......................................................................................................... 60 MODELS GH06 through GH3 ................................................................................................................. 61 DISASSEMBLY OF THE HAMMER VALVE ................................................................................................... 63 INSPECTION AND REPAIR AFTER DISASSEMBLY .................................................................................... 65 REPAIR SECTION INTRODUCTION ............................................................................................................. 66 REPAIR TOOLS AND EQUIPMENT .............................................................................................................. 66 HAMMER SLEEVE AND PISTON RECONDITIONING TOOLS .................................................................... 67 MAIN BODY BORE REPAIR .......................................................................................................................... 69 INSPECTION AND GENERAL POLISHING OF MAIN BODY ............................................................... 69 NPK RECONDITIONING TOOL ............................................................................................................. 70 REPAIR OF BODY BORE BY GRINDING AND POLISHING ................................................................ 71 REPAIRING DEEP BODY BORE SCRATCHES BY WELDING AND POLISHING ............................... 74 HONING MAIN BODY ............................................................................................................................. 77 MAIN BODY BORE DIMENSIONS ......................................................................................................... 78 PISTON ACTIVE SEAL AREA REPAIR ......................................................................................................... 79 PISTON TO SLEEVE RUNNING CLEARANCES .......................................................................................... 80 REPAIR THE STRIKING END OF PISTON ................................................................................................... 81 MAIN BODY SLEEVES................................................................................................................................... 81 REPAIR OF SLEEVE INSIDE DIAMETER ............................................................................................. 81 REPLACING THE SEALS............................................................................................................................... 82 REASSEMBLY OF THE HAMMER ................................................................................................................ 85 INSTALL SLEEVES AND PISTON INTO THE MAIN BODY .................................................................. 85 GH4 and GH6 .......................................................................................................................................... 85 ALTERNATE METHOD OF INSTALLING SLEEVES AND PISTON INTO THE MAIN BODY .............. 89 GH06 and GH3 ........................................................................................................................................ 93 MAKING SURE SLEEVES ARE IN THE PROPER POSITION .............................................................. 96 TOOL END .............................................................................................................................................. 98 GAS END ................................................................................................................................................ 101 HAMMER VALVE INSTALLATION ......................................................................................................... 104 FINAL ASSEMBLY .................................................................................................................................. 111 START-UP OPERATION ................................................................................................................................ 112 TYPES AND APPLICATIONS OF TOOL ........................................................................................................ 114 STANDARD TOOLS ............................................................................................................................... 114 TOOL IDENTIFICATION ................................................................................................................................. 115 TOOLS ............................................................................................................................................................ 116 CHANGING THE TOOL .......................................................................................................................... 116 REMOVAL ............................................................................................................................................... 116 RE-INSTALLATION ................................................................................................................................. 116 MAXIMUM TOOL TO TOOL BUSHING CLEARANCE ........................................................................... 117 TOOL INSPECTION ................................................................................................................................ 119 CHISEL TOOL SHARPENING ................................................................................................................ 120 STANDARD LENGTH FOR NPK TOOLS ............................................................................................... 121 RETAINING PIN .............................................................................................................................................. 122 TOOL BUSHING REPLACEMENT ................................................................................................................. 123 TOOL HOLDER .............................................................................................................................................. 129 NPK HYDRAULIC HAMMER IMPACT RINGS ............................................................................................... 130 REPAIR ................................................................................................................................................... 130 TIE RODS ....................................................................................................................................................... 132 TIE ROD REPLACEMENT ...................................................................................................................... 132 MAXIMUM ELONGATION OF TIE RODS ...................................................................................................... 135 TIE ROD TORQUE ......................................................................................................................................... 136 TORQUE VALUES FOR HAMMER FASTENERS ......................................................................................... 137 MOUNTING BRACKET ................................................................................................................................... 138 HARDFACING ......................................................................................................................................... 139 SURFACE PREPARATION .................................................................................................................... 139 UNDERLAYMENT ................................................................................................................................... 140 HARDFACE ............................................................................................................................................. 140 STORAGE OF HYDRAULIC HAMMER .......................................................................................................... 141 4 CONTENTS WARRANTY REGISTRATION FOR NEW UNITS.......................................................................................... 142 WARRANTY STATEMENT ............................................................................................................................. 143 DECIMAL CONVERSION CHART ................................................................................................................. 147 DECIMAL INCH TO FRACTIONS ........................................................................................................... 147 REBUILD SPECIFICATIONS CHECK SHEETS ............................................................................................ 148 NOTES AND RECORDS ................................................................................................................................ 155 SERVICE RECORD ........................................................................................................................................ 155
5 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. • 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. USE A GOOD QUALITY, HIGH TEMPERATURE EP#2 GREASE CONTAINING ANTIWEAR ADDITIVES. If machine is equipped with an AUTOLUBE System, check grease reservoir daily. • 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.
6 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 hammer. • Operate the hammer in a safe manner. 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 (440) 232-7900 or email at [email protected].
7 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.
9 HAMMER SPECIFICATIONS NITROGEN GAS PRE-CHARGE HAMMER AT AMBIENT TEMPERATURE AT OPERATING TEMPERATURE MODEL (cold before operating) (hot, after 1 to 2 hrs. operation) psi (bar) psi (bar) GH06 350 (24) 405 (28) GH07 350 (24) 405 (28) GH1 350 (24) 405 (28) GH2/GH2S/ 350 (24) 405 (28) GH2TS GH3 350 (24) 405 (28) GH4 375 (26) 435 (30) GH6 390 (27) 450 (31) * Specifications subject to change without notice.
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 this manual. 2. Circuit relief pressure is at least 500 psi (35 bar) above hammer operating pressure. Above 1,000 psi (70) bar for machines with a dual stage relief. 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 180F (60 to 80C). This is the preferred check. 5. Gas pressures listed are the maximum allowed. Use tolerance of minus 25 psi (2 bar).
10 STRUCTURE STRUCTURAL DRAWING MODELS GH06 – GH3
30 GREASE FITTING A MAIN BODY AA PLUNGER BUSHING B DRAIN PLUG BB PLUNGER C TOOL HOLDER D RETAINING PIN DD SWIVEL ELBOW E RETAINING RING F UPPER TOOL BUSHING (*GH2, GH2TS, GH3 only) G LOWER TOOL BUSHING HH TOOL J IMPACT RING (SPACER SECTION) L GAS HEAD M CHARGE VALVE N PISTON P MAIN BODY SLEEVE (B) R TOP NUT U WASHER V BOTTOM NUT W VALVE BODY Y VALVE BOTTOM CAP Z VALVE SPOOL *GH2 assembly number 132501-16 only
11 STRUCTURE STRUCTURAL DRAWING MODELS GH4 – GH6
30 GREASE FITTING A MAIN BODY AA PLUNGER BUSHING AT COLLAR B DRAIN PLUG BB PLUNGER C TOOL HOLDER D RETAINING PIN DD SWIVEL ELBOW E RETAINING RING F UPPER TOOL BUSHING G LOWER TOOL BUSHING HH TOOL J IMPACT RING L GAS HEAD M CHARGE VALVE N PISTON O MAIN BODY SLEEVE (A) P MAIN BODY SLEEVE (B) R TOP NUT U WASHER V BOTTOM NUT W VALVE BODY Y VALVE BOTTOM CAP Z VALVE SPOOL
12 HAMMER SERIAL NUMBER LOCATION SERIAL NUMBER LOCATION (sn1)
13 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 6 IN PORT
(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 spool (Z) in chamber (36) is greater than the area of the plunger (BB), the main valve spool (Z) shifts up. (3) POWER STROKE With the main valve spool (Z) in the up position, chamber (35) is closed off from the "IN" port (6) and opened to chamber (34) and the return line via passages (h4), (h5), and (h2). The piston (N) is driven downwards by the compressed nitrogen gas (37) as the oil in lower chamber (35) re-circulates to upper chamber (34). When the piston (N) opens passage (h3) to upper chamber (34), the oil in main valve spool chamber (36) is switched to low pressure and the main valve spool (Z) shifts down. (4) IMPACT The piston (N) impacts the tool (HH) and the main valve spool (Z) shifts to the down position. High pressure oil is directed to the lower chamber of the piston (35) for the start of another cycle. AUTOMATIC ENERGY RECYCLING: Extremely hard material will impart greater rebound energy to the piston (N) after it strikes the tool (HH). This will assist the incoming oil in raising the piston (N) against the gas pressure in chamber (33). This reduces upstroke time and therefore increases hammer frequency (beats per minute). The impact force of the hammer remains the same on each impact. 14 HYDRAULIC INSTALLATION
BACKHOE/EXCAVATOR HAMMER LINES
Typically, the pressure line should be arranged on the left side of the boom and routed to the hammer “IN” port (6) and the return line is routed from the hammer “OUT” port (5) on the right side. Flow to the hammer is controlled from the carrier’s auxiliary valve or from an NPK supplied flow valve. Hydraulic oil is generally routed back to the tank thru the carrier’s oil cooler and filter.
SKID STEER HAMMER LINES
Flow to the hammer (m3) is directed from an auxiliary valve on the skid steer. NPK hammer ports are marked “IN” and “OUT”. Return oil (m4) is routed back to tank through the skid steer return hydraulic circuit.
HAMMER CONTROL VALVE
There are two general types of control systems depending on the carrier model: 1. CONTROL SYSTEM USING THE CARRIER AUXILIARY OR SPARE VALVE SECTION. This type of installation utilizes an existing carrier valve. Any additional parts, such as a mechanical linkage, hydraulic pilot actuators, flow control valves, etc., are supplied by the hydraulic kit supplier. NOTE: Special pressure control valves are not required. The NPK hammer operating pressure is self-regulating. 2. CONTROL SYSTEM USING THE NPK FLOW VALVE (MULTIVALVE). For carriers not equipped with a suitable auxiliary or spare valve section, NPK can provide a solenoid operated, priority flow control valve to operate the NPK hammer. The NPK multivalve is specifically designed for the operation of boom mounted attachments.
15 HYDRAULIC INSTALLATION SKID STEER HAMMER FLOW CONTROL VALVE (OPTIONAL) On skid steers where auxiliary flow is excessive for the NPK hammer model, an NPK flow control valve (ma3) is recommended.
NOTE: Be sure that the pressure (m3) and return (m4) lines are properly routed.
Inlet pressure connects to port “P” on the NPK flow control valve. Regulated flow from valve port “H” (m5) connects to the “IN” port on the NPK hammer. The “OUT” port on the hammer connects to port “T2” (m6) on the flow control valve. Port “T1” connects to the return line (m4) on the skid steer.
16 HYDRAULIC INSTALLATION PREVENTION OF CONTAMINATION 1. A hydraulic hammer is harder on oil than using a bucket, so the oil is apt to deteriorate and breakdown sooner. Neglect of the oil system can not only damage the hydraulic hammer but also cause problems in the carrier which could result in damaged components. Care should be taken to check for contamination of the oil and to change it if it is found contaminated. Oil sampling at regular intervals is highly recommended.
❖ When the hydraulic oil shows low viscosity and bubbles, this indicates that the oil is deteriorated. If the oil is dark brown and gives off an offensive odor, it is severely deteriorated. Change the oil immediately!
❖ When the oil is clouded, or the oil filter often becomes 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 contaminated cooler fins causes reduced efficiency of the cooler, keep the cooler fins clean at all times. Check the hydraulic oil cooling system to be sure it is working effectively. The use of a heat gun is the best way to evaluate if the cooler is working properly.
5. Water in the hydraulic oil will lead to damage of the hydraulic hammer and carrier. Drain off water and foreign matter from the hydraulic tank at specified intervals. When out of service, the hydraulic hammer should be stored indoors.
CHANGING THE FILTER ELEMENT AND HYDRAULIC OIL
Change the filter element and hydraulic oil at the intervals described in the operation manual of the skid steer or excavator, when using a hydraulic implement. Another method is to set up an oil sampling schedule and change accordingly.
17 HYDRAULIC INSTALLATION HYDRAULIC QUICK DISCONNECTS NPK recommends against the use of non-NPK quick disconnects on hydraulic circuits operating NPK Products.
1. The hydraulic pulsations caused by hydraulic hammer operating can cause internal pieces of non-NPK quick disconnect to disintegrate. These pieces would migrate into the hammer causing damage.
2. If quick disconnects are not used when the hammer is removed from the excavator, the hose ends should be capped to keep them clean. If this is not done, contamination in the hose ends will be flushed into the hammer when re-connected. This, again, can cause damage.
3. Most quick disconnects create a restriction in the circuit. NPK Hammers are not backpressure sensitive, but restrictions cause unnecessary heating of the oil. Also, the pressure required to operate the hammer, plus the restriction in the quick disconnects may push an older, low pressure, carrier machine to the limit of its hydraulic system. This would interfere with proper hammer operation. However, the NPK approved quick disconnects are properly sized so that the hammer operation is not affected. NOT RECOMMENDED CONNECTION APPROVED CONNECTION (39) Non-NPK Quick Disconnects (32)
NPK APPROVED CONNECTION QUICK DISCONNECTS
CONTACT YOUR NPK DEALER FOR ADDITIONAL INFORMATION ABOUT NPK QUICK DISCONNECTS
ROFLEX COUPLING STUCCHI COUPLING
18 HYDRAULIC INSTALLATION HYDRAULIC QUICK DISCONNECTS If hydraulic quick disconnects are used with the NPK hammer, it is recommended that the following precautions be followed.
1. Periodic inspection of both male (DXm)
and female (DXf) ends is recommended to ensure the couplers are in good working condition. Failure to inspect couplers may result in pieces from a damaged or failed coupler to be injected into the hammer or parts of the coupler returned to the machine.
2. Check for dirt, dust, and debris on both
couplers before coupling.
3. Be sure that the couplers are completely
seated together (38).
4. When replacing couplers, be sure that
couplers are replaced as a set, male and female. Do not use one new end and one used end.
19 MOUNTING INSTALLATION NPK Mounting Installation Kits include the parts required to adapt the NPK HYDRAULIC HAMMER to the carrier. NPK mounting kits include the hammer mounting bracket, mounting pins (optional), flow control valve (optional), and hoses to connect to the carrier hydraulic system (optional).
BACKHOES and EXCAVATORS
AF HEX HEAD CAP SCREW (if required) DXf FEMALE QUICK DISCONNECT (if required) DXm MALE QUICK DISCONNECT (if required) g20 MALE ADAPTER (if required) m1 STICK PIN (if required) m2 LINK PIN (if required) m3 WHIP HOSE (pressure) m4 WHIP HOSE (return) m7 TOP BRACKET m8 HAMMER BOLT PACKAGE m9 KLIK PIN (if required) m12 HEX NUT (if required)
SKID STEERS
NPK Mounting Installation Kits for skid
steers include parts required to adapt the NPK HYDRAULIC HAMMER to the carrier. NPK mounting kits include the hammer mounting bracket (m7), and hoses (m3 and m4) to connect to the carrier hydraulic system. The flow control valve (ma3) is optional.
20 MOUNTING INSTALLATION REMOVAL FROM THE CARRIER BACKHOES and EXCAVATORS 1. Close pressure and return line shut-off valves (k4) if available. 2. Disconnect hydraulic hoses (m3 and m4) before laying the hammer down. 3. Cap the pressure and return lines on the carrier and connect the hammer whip hoses to the hammer bracket. 4. Position the hammer (DR) horizontal on wood blocks (t20) and remove stick (m1) and link (m2) pins.
REMOVAL FROM THE SKID STEER
1. Position the hammer (DR) horizontally onto the ground or wood blocks (t20) as shown. 2. Disconnect both inlet and outlet hoses. 3. Unlatch the mechanism holding the hammer bracket to the carrier’s coupler plate. (Consult the machine manufacturer’s operator / instruction manual for this procedure.)
The tool end of the hammer should be set lower than the head end to prevent moisture from entering the hammer through the tool area.
MOUNTING TO THE CARRIER
BACKHOES and EXCAVATORS 1. Place the hammer assembly (DR) horizontally on wood blocks (t20) as shown. 2. Align the stick pin bore (m26). Install the stick pin. Then align the link pin bore (m25). 3. Connect the pressure side hose (m3) and the return side hose (m4). 4. Open the shut-off valves (k4) if available.
21 MOUNTING INSTALLATION MOUNTING TO THE SKID STEER
1. Place the hammer (DR) horizontally
onto wood blocks (t20) as shown. 2. Align the carrier’s couple plate with the hammer bracket. Couple the two per the machine manufacturer recommendations. 3. Connect the hoses.
Consult the skid steer manufacturer’s operators manual to
review the mounting and removal process!
The hydraulic lines must be handled carefully and sealed to
prevent contamination from entering the hammer or the carrier’s hydraulic system.
22 LUBRICATION GREASING PROCEDURE Manual greasing for hammers without an Auto Lube System.
1. Place the hammer in a vertical position, applying enough down
force to push the tool up into the hammer.
2. Turn the machine off.
3. Grease the hammer until grease begins to come out around the tool (HH) and lower bushing.
4. Grease hammer at least once an hour. See “Correct
Grease and Grease Intervals” for a more exact greasing procedure.
NOTE: Use a good quality EP #2 Lithium based
grease with wear inhibiting additives, see pages 24 and 25.
23 LUBRICATION CORRECT FUNCTION OF GREASING AND GREASE INTERVALS Proper hammer maintenance requires a sufficient supply of the correct grease to the tool (chisel). It is recommended that an NPK AUTO LUBE SYSTEM be used.
FUNCTION OF GREASING To properly grease, 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, the unit 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 FOR HYDRAULIC HAMMERS
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 350°F (177°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 (440) 232- 7900.
24 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 two different temperature ranges - 350°F (177°C) and 500°F (260°C). “Universal Plus” and “Super Duty” are lithium soap based products that resists washout and contain NPK-10 additive for surface protection in friction affected areas. “Chisel Paste” is an aluminum complex soap base with 12% graphite and copper additives for extreme operating conditions.
UNIVERSAL PLUS NPK PART
350 deg NUMBER 14 oz. (.397 kg) CARTRIDGE G000-1010 120 lb. (54 kg) KEG G000-1020 35 lb. (16 kg) PAIL G000-1030 400 lb. (181 kg) DRUM G000-1040
SUPER DUTY NPK PART
500 deg NUMBER 14 oz. (.397 kg) CARTRIDGE G000-1011 120 lb. (54 kg) KEG G000-1021 35 lb. (16 kg) PAIL G000-1031 400 lb. (181 kg) DRUM G000-1041
CHISEL PASTE NPK PART
500 deg NUMBER 14 oz. (.397 kg) CARTRIDGE G000-1050 *14 oz. (.397 kg) CARTRIDGE G025-1050 35 lb. (16 kg) PAIL G000-1060 400 lb. (181 kg) DRUM G000-1070 *Hammer Mounted Auto Lube only
25 LUBRICATION AUTO LUBE SYSTEMS
An automatic greasing system is recommended to reduce hammer tool and bushing
wear. NPK offers two types of Auto Lube Systems:
“AUTO LUBE PUMP” “HAMMER MOUNTED AUTO LUBE PUMP”
The NPK Auto Lube Systems are designed to automatically provide a continuous supply of grease to the hammer tool and tool bushing, increasing tool and tool bushing life by reducing wear. The Auto Lube pumps are capable of pumping EP2 grease in cold weather. The pump output is adjustable according to the replacements of the hammer model and to compensate for tool bushing wear.
NPK PH Series Hammer models have a connection port (26) for an automatic greasing system. Refer to the NPK Auto Lube Instruction Manuals for details.
If an Auto Lube System is not used, you can grease the unit manually through the grease fitting (30).
26 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 in a vertical
position, applying enough down force to push the tool up into the hammer.
2. Turn the carrier excavator/backhoe off.
3. Fill the NPK Auto Lube pump reservoir
with a power greaser through the fill fitting (30) on the side of the pump or from the top by removing the fill cover (a1). Use a premium quality grade EP2, high temperature grease with wear inhibiting additive. (See “CORRECT GREASE”.)
4. Disconnect the grease line (29) from
the Auto Lube main pump cartridge (a4).
27 LUBRICATION AUTO LUBE GREASE LINE PRE-FILLING
5. Install NPK part number G100-8050, hose fill adapter (a13), onto the #6 JIC female end of the grease line (29) previously removed.
ITEM PART NO. DESCRIPTION
30 B160-4010 Grease Fitting – 1/4" NPT male f5 K301-6620 Male x Female Adapter - #6 JIC male x 1/4" NPT female
6. Remove the grease line (29) at the
hammer assembly (KK).
7. Attach a grease gun (t37) or power
greaser to the grease line (29) leading to the hammer.
8. Pump grease through the grease line
(29) until a steady stream of grease (28) is realized at the opposite (hammer) end.
9. Re-attach the grease line (29) to the
hammer assembly (KK).
28 LUBRICATION AUTO LUBE GREASE LINE PRE-FILLING
10. Pump twenty more shots of grease,
using a grease gun or power greaser, into the grease line (29). This will prime the hammer tool cavity and pre- lube the tool (HH). Look for grease coming out around the tool at the tool bushing (see arrow).
11. Remove the hose fill adapter (a13)
and re-connect the grease line (29) to the Auto Lube pump (FZ).
NOTE: If the Auto Lube unit has run out of grease, the above procedure should be used to purge all air out of the grease line before using the hammer. Failure to do this will result in an intermittent supply of grease to the hammer.
29 LUBRICATION HAMMER MOUNTED AUTO LUBE GREASE LINE PRE-FILLING It is mandatory that the supply line from the Auto Lube main pump to the connection on the hammer is primed with grease before it is used. Failure to do this will result in no grease being administered to the hammer tool for 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 in a vertical
position, applying enough down force to push the tool up into the hammer.
2. Turn the excavator/backhoe off.
3. Make sure there is a full grease
cartridge (a54) installed in the Hammer Mounted Auto Lube assembly. Ensure that the flat seal (a65) in the lubrication passage (176) is not damaged. Use a premium quality grade EP-2, high temperature grease with wear inhibiting additive. (See “CORRECT GREASE”.)
4. Disconnect the grease line (29) at the
hammer assembly (KK).
30 LUBRICATION AUTO LUBE GREASE LINE PRE-FILLING
5. Attach a grease gun (t37) or power
greaser to the grease fitting (30) on the front side of the Hammer Mounted Auto Lube pump assembly (FZ).
6. Pump grease through the pump to the
grease line (29) until a steady stream of grease (28) is realized at the opposite (hammer) end.
7. Re-attach the grease line (29) to the
hammer assembly (KK).
8. Pump twenty more shots of grease, using a grease gun (t37) or power greaser, into the pump assembly (FZ). This will prime the hammer tool cavity and pre-lube the tool (HH). Look for grease coming out around the tool at the tool bushing (see arrow).
NOTE: If the Auto Lube unit has run out of grease, the above procedure should be used to purge all air out of the grease line before using the hammer. Failure to do this will result in an intermittent supply of grease to the hammer.
31 LUBRICATION LUBRICANT TERMS AND DEFINITIONS TERM DEFINITION
ADHESIVE The ability of grease, gear lubricant or oil to cling to
metal. ANTI WEAR AGENTS Used to help combat metal-to-metal contact, thus reducing wear. COHESIVE The ability of grease, gear lube or oil to cling to itself, thus resisting tearing apart. CONSISTENCY Consistency of grease is its hardness or firmness. It is determined by the depth in millimeters to which the cone of a penotrometer sinks into a sample under specified conditions. Consistency of grease may be influenced by the type and amount of thickener, viscosity of oil, working and other factors. CONTAMINATION Foreign material that could damage a part. DROPPING POINT The minimum temperature at which the oil in a grease subjected to heat begins to actually drip and breakdown. EXTREME PRESSURE Additives that under extreme pressure form an adherent AGENTS film on metal surfaces, thus forming a film of protection. FILM STRENGTH Film strength is defined as the tendency of oil molecules to cling together. It is the ability of those molecules to resist separation under pressure between two metals and to hold these metal surfaces apart. FRICTION The resistance to fluid flow in a hydraulic system. (An energy loss in terms of power output.) GALLING Surface damage on mating, moving metal parts due to friction. A severe form of adhesive wear. LUBRICATION Use of a substance (grease, oil, etc.) to reduce friction between parts or objects that move against each other. NLGI A rating given to a grease from the National Lubricating Grease Institute. This rating determines the hardness of the grease and goes on from a 000 to a 6 rating. Most greases are NLGI #2 rated. OILINESS Oiliness is measured of the coefficient of friction of a lubricant. Oiliness or lubricity depends on the adhering characteristics of an oil. It is determined by the attraction between the molecules of the oil and the molecules of another material. Of two oils having the same viscosity but different degrees of fluid friction, the one with the lower friction index has the higher degree of oiliness. PUMP A device which converts mechanical force into hydraulic fluid power. Basic design types are gear, vane, and piston units.
32 LUBRICATION LUBRICANT TERMS AND DEFINITIONS TERM DEFINITION
RESERVOIR A container for keeping a supply of working fluid in a
hydraulic system. VIBRATION A quivering or trembling motion. VISCOSITY Is the actual SAE weight of the product. Example motor oils come in 10, 20, 30, 40, 50 and 15/40 SAE weight. The viscosity designation of a lubricant indicates its internal resistance to flow.
33 AUTO LUBE / UNDERWATER PORT IDENTIFICATION NPK GH2 Hammers are equipped with one port on the spacer section (J) below the main valve for use in adapting for underwater and two in the main body for adapting for auto lube use. The air port (17) will allow the connection of an airline that will allow the hammer to be used underwater. The grease ports (18), will allow for AUTO LUBE connection. NOTE: Either grease port can be used for Auto Lube. They are connected to each other.
GH2 NPK GH4 and GH6 Hammers are equipped with two ports on the spacer section (J) below the main valve for use in adapting for Auto Lube and underwater use. The air port (17) on the left will allow the connection of an air line that will allow the hammer to be used underwater. The grease port (18), located in line with the air port, on the right will allow for Auto Lube connection.
GH4 – GH6
34 HIGH HEAT APPLICATION NPK offers a high heat conversion kit for the GH3 through GH6 hammers.
HAMMER KIT PART
MODEL NUMBER GH3 GH3-9505 GH4 GH4-9501 GH6 GH6-9500
Kit includes:
AF Hex Head Cap Screw
AT Boom Pin Collar C1 Hex Nut D Retaining Pin
NOTE: No special seals are required. Standard seals will work with “MINERAL OIL” based flame retardant oil.
NOTE: Water glycol based fluid may shorten the seal life.
NOTE: Special protection for the hydraulic hoses is recommended.
35 ROUTINE INSPECTION AND MAINTENANCE 1. VISUAL INSPECTION Detect a potential problem early. TIE RODS AND FASTENERS Inspect all fasteners and retighten as necessary. On GH06 through GH4 models, inspect tie rod assemblies for loose top nuts. On the GH6 model, inspect tie rod assemblies for cracked or missing lock plates and lock rings. If these parts are missing, consult NPK Service Department at (440) 232-7900. See pages 136 and 137 for torque values. WELDS Check for cracks, repair as necessary, see page 138. HOSES AND TUBING Check for oil leaks, loose clamps and hose abrasion. RUBBER MOUNTS Inspect for damage. HYDRAULIC OIL MAINTAIN A CLEAN HYDRAULIC SYSTEM If non-petroleum oil is used, contact NPK Service Department for compatibility. Keep hoses clean and capped when dismounting or storing hammer. Change oil and filters as recommended by carrier manufacturer. Periodic oil sampling is recommended. 2. DEMOLITION TOOL LUBRICATION Important: It is imperative that grease is maintained in the tool bushing contact area at all times. This may require hourly greasing depending on job conditions. Important: The hammer must be in a vertical position with downforce applied to push the tool all the way in. This prevents grease from entering piston impact area. Pump grease into grease fitting (30) until grease is seen coming out between the tool and bushing. USE A GOOD QUALITY, HIGH TEMPERATURE EP#2 GREASE CONTAINING ANTI- WEAR ADDITIVES. NPK recommends a Lithium Base, Moly (Molybdenum Disulfide) or other surface protecting additives, EP (Extreme Pressure), NLGI #2 Grease. A high drop point (350° to 400°) grease is desirable. If machine is equipped with an AUTOLUBE System, check grease reservoir daily. 3. TOOL and TOOL BUSHING WEAR Check the tool and tool bushings for damage, wear or deformation on a regular weekly basis. Replace the tool and/or bushings when wear exceeds the maximum clearance limit. See MAXIMUM TOOL TO TOOL BUSHING CLEARANCE, see pages 117 and 118. Do not hardface or sharpen the tool point with a cutting torch. Excessive heat from torching or welding causes embrittlement, breakage, and flying pieces. Resharpen only with a lathe or milling machine using sufficient cooling. Please consult your authorized NPK Dealer or NPK Service Department for additional information. • DO NOT SUBMERGE HAMMER UNDERWATER Unless modified for underwater operation. Consult NPK Service at (440) 232-7900 or see “UNDERWATER MANUAL” for instructions.
36 WEEKLY INSPECTION 1. TIE RODS AND FASTENERS Inspect tie rod assemblies for cracked or missing lock plates and lock rings. If lock plates are missing, consult the NPK Service Department at (440) 232-7900. Inspect all fasteners and retighten as necessary, see “TORQUE VALUES FOR HAMMER FASTENERS”.
2. WELDS Check for cracks and repair as necessary, see “MOUNTING PLATE”. Consult your authorized NPK Dealer or NPK Service Department for additional information.
3. TOOL RETAINING PIN
Remove the retaining pin and inspect for peening caused by excessive blank hammering. If necessary, grind edges smooth as shown in “TOOL RETAINING PIN INSPECTION”. The retaining pin must rotate freely.
4. DEMOLITION TOOL Remove the demolition tool and inspect for peening caused by excessive blank hammering. If necessary, grind edges smooth as shown in “TOOL INSPECTION”.
5. GAS CHARGE Check and adjust, if required, see “NITROGEN GAS PRESSURE” and “CHECKING THE GAS PRESSURE”.
37 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. NPK Hydraulic Hammers are self-regulating for hydraulic pressure. 2. The NPK HYDRAULIC HAMMER energy per blow is determined by the nitrogen gas pre-charge pressure, not the pump volume. Impact energy is proportional to gas pressure. 3. The NPK HYDRAULIC HAMMER frequency (blows per minute) is determined by oil flow to the hammer. Frequency is proportional to oil volume (gallons per minute or liters per minute). The hammer circuit must be set to provide the correct flow to the hammer. TROUBLESHOOTING CHART PROBLEM CAUSE CHECK REMEDY Loss of impact power. Low gas pressure. Gas pressure Recharge gas Loss of frequency Gas pressure too high. Gas pressure Reduce gas pressure. (hammer slows down) Shut-off valve partially Valve position Open valve. closed. Carrier relief valve set too Hydraulic pressure Adjust or replace carrier low. Must be 400 to 500 psi relief valve. (27 to 34 bar) over hammer operating pressure. Hydraulic oil temperature too Oil temperature Reduce throttle. Clean or high. Should be 180⁰F add an oil cooler. (83⁰C) or below. Hydraulic pump volume too Oil flow Increase hydraulic circuit low. flow. Oil level of carrier too low. Oil level Add hydraulic oil. Erratic running or Defective hydraulic pump or Hydraulic pressure Repair or replace stops running. control valve. Hydraulic pump or control valve. Shut-off valve closed. Hydraulic pressure Open shut-off valve. Hoses reversed. Hydraulic pressure Pressure is on the left and return is on the right. Return line blocked. Hydraulic pressure Eliminate obstruction. Oil level of carrier too low. Oil level Add hydraulic oil. Gas pressure too high. Gas pressure Reduce gas pressure. Zero gas pressure. Gas pressure Check for leak and repair. Hammer main valve Hydraulic pressure Disassemble and inspect malfunctioning. valve components. Hammer piston not cycling. Hydraulic pressure Disassemble hammer and 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 in the hammer or the carrier. If the pressures and flow available to the hammer are correct, the problem is in the hammer.
38 CHECKING THE HYDRAULIC PRESSURES
Install glycerin filled gauges in the
hammer pressure and return lines. If you have an NPK Hydraulic Installation Kit with shut-off valve (k4), install the gauges in the gauge ports (k8) provided.
Each NPK shut-off valve has an “ON”
(k5) and an “OFF” (k6) position. Make sure both shut-off valves are in the “ON” position before attempting to operate your attachment.
If there is no gauge port, install a swivel run tee (f3) with a reducer (a86), test hose (t81) and 0-5000 psi gauge (g8f) in the pressure side or a 0-700 psi gauge (g8) in the return side, between the hose connection (hf1) and pressure (m3) or return (m4) hoses.
NOTE: The test hose should be long enough to be clear of the hammer and flying debris.
1. DETERMINE RETURN LINE PRESSURE
If NPK shut-off valves are present, make sure they are in the “ON” position, and then operate the hammer. NPK recommends that the return line pressure should not exceed 300 psi (21 bar). Having a higher back pressure can have an adverse effect on the carrier.
39 CHECKING THE HYDRAULIC PRESSURES 2. DETERMINE THE SYSTEM RELIEF VALVE PRESSURE
If available, turn the NPK pressure line
shut-off valve (k4) to the “OFF” position (k6).
If not available, remove the pressure side
hose (m3) and cap (AR) the swivel “T” (f3).
Energize the hammer control circuit and note the relief valve setting on the 0-5000 psi gauge (g8f). NOTE: The relief valve is used only for ultimate safety, when the hammer is removed or the shut-off valve is closed. DO NOT use to set the hammer operating pressure. Therefore, to prevent overheating, loss of flow and reduced hammer frequency, the relief pressure should be set at a minimum of 500 psi (35 bar) above the listed hammer operating pressure. Some carriers may require 1000 psi (70 bar). Call the NPK Service Department at (440) 232-7900 for details. 3. DETERMINE THE HAMMER OPERATING PRESSURE Open both shut-off valves if present. Operate the hammer and note the operating pressure. The operating pressure of the NPK Hydraulic Hammer is self-regulating and is determined by the gas pressure setting. If the operating pressure is low, check the gas pressure. See “CHECKING THE GAS PRESSURE”.
NOTE: Stay clear of hammer when checking line pressures!
40 CHECKING THE HYDRAULIC FLOW AT RATED PRESSURE 1. Installation of a Flow Meter Equipped with Pressure Loading Valve. Install the flow meter (t36) between the hammer pressure line and return as shown below.
Generally, the pressure line (m3) is on the left and the return (m4) is on the right, looking from the operator’s seat.
2. Determine Return Line Pressure (Backpressure).
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.
41 CHECKING THE HYDRAULIC FLOW AT RATED PRESSURE 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 circuit flow chart. Refer to hammer specification chart for correct flow at rated pressure for each hammer.
fm1. Load Valve
fm2. Flow/Temperature Display fm3. Flow/Temperature Switch fm4. Pressure Gauge t36. Flow Meter 5. Out 6. In
Typical flow meter with pressure loading valve.
FLOW VS. PRESSURE CHART fl FLOW GPM (lpm)
pr PRESSURE PSI (bar) TYPICAL EXAMPLE
42 OIL LEAKAGE Exceeding 180F (80C) hydraulic operating temperature reduces seal life.
A small amount of oil leakage between the tool and tool bushing at location (pr2) is considered normal.
If oil leak is significant, locate the point of origin. Oil running down the tool may be coming from a loose hose.
It is normal for a new seal to leak slightly until the seal seats with usage.
POINTS TO CHECK FOR OIL LEAKAGE
PROBLEM CAUSE REMEDY
(pr1) Leakage through vent plug. Seal in main body sleeve A. Disassemble hammer and replace seals. (Small amount is normal) (pr2) Leakage between tool and Seal in main body sleeve B. Disassemble hammer and replace seals. bushing. Small leakage is normal here. (pr3) Leakage between main O-ring between valve and body. Replace. body and valve. Loose bolts. Use thread adhesive, tighten. (pr4) Leakage between valve O-ring under valve cap. Replace. body and valve top cap. Loose bolts. Tighten. (pr5) Leakage between valve O-ring under valve cap. Replace. body and valve bottom cap. Loose bolts. Tighten. (pr6) Leakage between valve and O-ring under swivel. Replace. swivel. (pr7) Leakage between hose and Loose or damaged hose fitting. Tighten or replace. swivel. (pr8) Leakage between swivel and Seal in swivel. Replace. flange.
43 GAS LEAKAGE (If the gas pressure drops over 25 psi (2 bar) per day). Exceeding 180F (80C) hydraulic operating temperature reduces seal life.
TO LOCATE GAS LEAK, APPLY SOAPY WATER (t23) AT THE POINTS INDICATED.
PROBLEM CAUSE REMEDY
(pr1) Leakage through vent plug. Seal in main body sleeve A. Disassemble hammer and replace seals. (pr9) Leakage from top of charge O-ring in check valve. Replace. valve. Damaged check valve in charge Replace. valve. (pr10) Leakage between charge O-ring in charge valve. Replace. valve and head. Loose charge valve. Use thread adhesive, tighten. (pr11) Leakage between head and O-ring in head. Disassemble hammer and replace main body. seals.
44 EXCESS OIL IN THE GAS HEAD INSPECTION PROCEDURE As the low pressure oil piston seal in the “A” Sleeve starts to wear out, the piston may pull oil into the gas head. The gas volume is then decreased and the hydraulic oil pressure required to move the piston to its full upstroke position increases.
With the hammer suspended, check and adjust the nitrogen gas pressure to the ambient or to the hot specification shown in the chart below.
Load the hammer by pressing it against a solid object until the tool stops up inside. The gauge reading should not be much above the loaded gas pressure shown on the chart below. If the loaded gas pressure is high, there is excess oil in the gas head and the hammer must be resealed.
NOTES: 1. Cold gas charge is the initial set with the hammer at ambient temperature. 2. 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. 3. Pressures listed are maximum. Use a tolerance of minus 25 psi (2 bar).
45 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 after 1 to 2 hours of running and with a system oil temperature of 140° to 180°F (60° to 80°C). 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. DO NOT OVERCHARGE THE HAMMER! Exceeding the gas pre-charge specifications can result in damaging hammer components. The NPK WARRANTY does not cover failures resulting from exceeding the specified nitrogen gas pressure. NITROGEN GAS PRE-CHARGE HAMMER AT AMBIENT TEMPERATURE AT OPERATING TEMPERATURE MODEL (cold before operating) (hot, after 1 to 2 hrs. operation) psi (bar) psi (bar) GH06 350 (24) 405 (28) GH07 350 (24) 405 (28) GH1 350 (24) 405 (28) GH2/GH2S/ 350 (24) 405 (28) GH2TS GH3 350 (24) 405 (28) GH4 375 (26) 435 (30) GH6 390 (27) 450 (31) * Specifications subject to change without notice.
GAS CHARGING KIT / PART NO. 7300588
ALL NPK HYDRAULIC HAMMERS are furnished with the following gas charging kit. In addition, a nitrogen tank and a gas pressure regulator valve (not furnished with the hammer) are required. These can be obtained from your local welding supply house. An optional regulator valve is available from NPK.
46 CHECKING THE GAS PRESSURE Inspect the nitrogen gas pressure every 100 hours. PROCEDURE
1. The gas pre-charge is measured with
no preload on the tool (HH). Remove the tool or position the hammer (DR) with the tool fully extended.
2. Remove the charge valve cap (M1)
from the hammer charge valve (M). Do not remove the charge valve assembly!
3. Turn the NPK charge adapter T-
handle (g2) to a full counterclockwise position.
4. MODELS GH06, GH07, GH1,
GH2/GH2S/GH2TS Remove plug (g12). Install adapter (g13) part no. GH000-1000 into the female port on the gas head. Install NPK charging adapter (g1).
47 CHECKING THE GAS PRESSURE
4. MODELS GH3, GH4 and GH6 Only
Install the NPK charging adapter (g1) on the hammer charge valve located on the hammer gas head (L).
5. Tighten the charge adapter cap (g6).
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 over tighten!
7. Compare the gauge pressure with the NITROGEN GAS PRE-CHARGE chart in the NITROGEN GAS PRESSURE section. If the gas is 25 psi (2 bar) or more below the specification, proceed to the NITROGEN GAS CHARGING PROCEDURE section of the manual. If the pressure is correct, go to the next step.
8. Turn the T-handle counterclockwise until it stops, as in step 3.
9. Slowly loosen the charge adapter cap to relieve the nitrogen gas pressure trapped in the charge valve.
10. Remove the charge adapter from the hammer charge valve.
11. Replace the charge valve cap on the charge valve.
48 GAS CHARGING THE HAMMER USE NITROGEN GAS ONLY.
STAY CLEAR OF THE TOOL WHILE
CHARGING THE HAMMER WITH GAS. The tool may be impacted by the piston and forced out abruptly.
PROCEDURE 1. Carry out steps 1 thru 4 of CHECKING THE GAS PRESSURE.
2. Install a pressure regulator (g7) on a
tank (g9) of nitrogen gas.
3. Connect a hose (g4) from the
pressure regulator (g7) on the nitrogen tank (g9) to the charge adapter (g1). 4. Turn the T-handle (g2) on the charge adapter (g1) clockwise.
5. Turn the handle (g7) on the tank
regulator counterclockwise to a fully closed position. Do not over tighten! 6. Open the valve (g10) on the nitrogen tank (g9) by turning the handle counterclockwise.
49 GAS CHARGING THE HAMMER 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.
8. Charge the nitrogen gas, per the gas
charge decal (g11), until the pressure gauge (g8) on the charge adapter (g1) is at the correct setting, then turn the T-handle (g2) counterclockwise all the way out. 9. Close the nitrogen tank valve (g10), and then remove the hose (g4) from the charge adapter (g1).
50 TOOLS AND EQUIPMENT REQUIRED FOR HAMMER DISASSEMBLY HOIST The minimum hoist capacity should be determined by the hammer model. Refer to “HAMMER SPECIFICATIONS”, page 9 for hammer weights.
SLUGGING WRENCH
(Optional)
SOCKET WRENCHES
See “GAS HEAD BOLT TORQUE” and “TORQUE VALUES FOR HAMMER FASTENERS” for sizes.
51 TOOLS AND EQUIPMENT REQUIRED FOR HAMMER DISASSEMBLY LONG HEX KEY WRENCHES When repairing NPK GH Series hammers, it is sometimes necessary to remove the socket head cap screws on the main valve. NPK has available 1” drive long sockets (t24) to aid in disassembly. Use with a hex key wrench (t25) modified into a straight key by cutting off the short end of the wrench as shown.
Is used to drive piston and “A” and “B” sleeves in and out of the main body bore. NPK GAS CHARGING KIT Is part of the NPK hammer start-up kit, see “NPK START-UP KIT”. NITROGEN BOTTLE AND REGULATOR CLEANING SOLVENT NPK ASSEMBLY LUBRICANT
52 TOOLS AND EQUIPMENT REQUIRED FOR HAMMER DISASSEMBLY SUITABLE NYLON SLING
DRAIN PAN
LIFTING HOOK (t28), P/N H010-7501
For removing and installing tool holder.
53 NPK START-UP KIT All new NPK hammers are shipped with a start-up kit, part number H251-5100. This kit will contain the following:
Gas Charging Kit (Red Box) Two (2) tubes of NPK grease for start up
Manuals and Warranty Information
Also, all NPK hammers are supplied with a customer instruction CD, Operators Manual, Operating Instructions, Safety Information and Warranty Information.
54 NPK ASSEMBLY LUBRICANT NPK ASSEMBLY LUBRICANT is specially formulated to provide quick, positive lubrication. Oil rich ingredients, plus a free-flowing light lithium grease, offer top lubrication, as well as long lasting protection against rust and corrosion. NPK ASSEMBLY LUBRICANT even “creeps” into remote, normally inaccessible areas to lubricate and safeguard interior metal surfaces. NPK ASSEMBLY LUBRICANT is ideal for use on all metal-to-metal surfaces.
DIRECTIONS FOR USE
1. Wipe off exposed surfaces.
2. Shake vigorously to thoroughly mix contents. 3. Spray liberally on areas requiring lubrication.
NPK ASSEMBLY LUBRICANT contains NPK-10 Metal Treatment and is ideal for use in the assembly of all NPK products. NPK ASSEMBLY LUBRICANT comes in a 16 ounce bottle with sprayer and can be ordered using part number H010-5010.
55 DISASSEMBLY PROCEDURE A sturdy work bench is recommended for disassembly and assembly of an NPK HYDRAULIC HAMMER.
REMOVE THE HAMMER FROM THE
BRACKET 1. Place the hammer on blocks (t20). Make sure the hammer is stable.
NOTE: DO NOT REMOVE TOOL FROM
HAMMER AT THIS TIME!
2. Remove the bracket bolts (m11), nuts
(m12), and washers (m13).
3. Remove hydraulic hoses.
Plug hose ends and hammer ports to prevent contamination from entering.
4. Lift the hammer (KK) from the bracket (LL). Using a
hoist, attach a chain (t4) or strap (t27) to the hammer and lift it out of the bracket (LL).
56 DISCHARGING THE GAS PRESSURE PROCEDURE
1. Remove the charge 2. Turn the NPK charge 3. Install the NPK valve cap (M1) from the adapter T-handle (g2) to charge adapter (g1) charge valve (M). Do a full counterclockwise onto the hammer not remove the charge position. charge valve located valve assembly! on the hammer 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 cap (g6). clockwise. As the T- adapter cap (g6) handle is screwed in, a VERY SLOWLY! resistance is The gas pressure encountered. By turning will gradually the T-handle, the decrease to zero. nitrogen gas pressure When it gets to zero, will be indicated on the remove the cap. pressure gauge (g8). Stop turning the T- handle when the gauge reads pressure. Do not over tighten!
7. Remove the charge adapter (g1) from the gas charge valve on the hammer gas head (L), then, reinstall the charge valve cap.
57 DISASSEMBLY Check to see that the nitrogen gas has been completely discharged. 1. Loosen the pair “A and B” or “C and D” top nuts first. Then loosen the remaining pair uniformly until the spacer spring tension is relieved.
2. Remove the nuts (R) and lockwashers (U).
3. Remove the gas head, collars, and spacer springs.
a. Pry off the gas head (L) using b. Remove the gas head from the tie screwdrivers or pry bars as levers. rods. Care should be exercised so as not to apply undue force.
When the gas head is removed, hydraulic oil will flow out of the body bore. Therefore, have oil drain pans ready. c. Remove the collars (AT). d. Remove the spring washers (AG).
58 DISASSEMBLY
4. Sling (t27) or hook (t28) the tool holder
(C).
The tool holder must be kept level and square to the main body. 5. Loosen the tie rods (Q) with a wrench (t6) by hand. If a tie rod should fail to turn, rap the bottom nut (V) with a hammer (t29). If the tie rods are still tight, re-position the tool holder to remove the bind on the tie rods. Loosen all four tie rods before removing any of them.
6. Pull out the tie rods (Q).
7. Hoist the tool holder (C) by a crane
(t34) and hook (t28) or sling to remove it from the main body.
NOTE: NPK part number for the hook is
H010-7501.
8. Hoist the spacer section or impact ring
(J) using a sling (t27) to remove it from the main body assembly.
59 DISASSEMBLING THE MAIN BODY MODELS GH4 and GH6 PISTON AND SLEEVE REMOVAL
1. Remove the dowel pins (K) from the
main body sleeve “B” (P).
2. Remove the piston, “A” and “B”
sleeves as one unit. a. Bump a nylon bar (t3) on the end of the piston at the tool holder end (1) and drive the sleeves (O, P) and piston out.
Hydraulic oil comes out of the body
each time the sleeve moves. Direct the port of the swivel adapter downward. NOTE: Do not use a steel bar to drive out the sleeves! b. To prevent damage to the body bore, support the “A” sleeve with a sling (t27) as it comes out. NOTE: When removing the sleeves and piston as a unit, the point of balance will be on the “B” sleeve near where the “A” sleeve joins it.
60 DISASSEMBLING THE MAIN BODY MODELS GH4 and GH6 ALTERNATE PISTON AND SLEEVE REMOVAL
1. Pin a chain at the gas end (2) to
diagonally opposite tie rod holes in the main body.
2. Wrap the chain around the back of a
portable power unit as shown. (NPK part number for the unit is T000-1031.)
3. Push the piston and sleeves from the tool end (1) of the body assembly and out the gas end.
4. Keep the sleeves and piston level by
adjusting tension on the sling (t27). NOTE: When removing the sleeves and piston as a unit, the point of balance will be on the “B” sleeve near where the “A” sleeve joins it.
MODELS GH06 through GH3
NOTE: Models GH06 through GH3 have no “A” sleeve. 1. Tap the “B” sleeve (P) and the piston (N) out of the hammer body (A) towards the tool end (1) of the hammer using a nylon bar or a dead blow hammer (t2) handle as shown.
When the sleeve and piston come out
of the body, hydraulic oil flows out. Have oil drain pans ready. 61 DISASSEMBLING THE MAIN BODY DISASSEMBLING THE PISTON AND SLEEVE ASSEMBLY
1. Lay the piston, “A” sleeve (O) and
“B” sleeve (P) assembly on a piece of cardboard (t30) on a table (t31).
2. Separate the piston from the “B” sleeve by rapping the striking end of the piston with a dead blow hammer (t2). The piston and “A” sleeve will separate from the “B” sleeve.
NOTE: Do not use a steel bar to drive apart the sleeves!
3. Separate the “A” sleeve (O) from the
piston (N) by tapping the sleeve with a dead blow hammer (t2).
62 DISASSEMBLY OF THE HAMMER VALVE 1. Remove the swivel adapters (GH3 to GH6, GH4 shown). a. Remove the snap ring (AJ) and the washer (AH). b. Pull the swivel elbows (DD) off of the swivel flanges (EE). c. Remove the cap screws (OO), and then remove the swivel flanges. 2. Remove the hammer valve assembly from the main hammer body. a. Attach a 6 ft. (2 m) long extension pipe (t32) to a hex wrench (t25) and with it loosen each cap screw (OO). NOTE: There is thread adhesive on each cap screw. Use heat on the head of any cap screw that is found difficult to remove. b. Remove the cap screws (OO). c. Remove hammer valve assembly.
DO NOT HEAT EXCESSIVELY!
DO NOT HEAT THE VALVE BODY OR MAIN HAMMER BODY! 3. Remove the bottom cap (Y) from the valve body (W). a. Remove the cap screws from the bottom cap with a hex wrench (t25) and extension bar (t32). b. Remove the bottom cap. Use screwdrivers (t22) or pry bars to remove the cap.
Do not force the bottom cap
when removing it. Damage to the valve body is possible which can cause oil leakage.
63 DISASSEMBLY OF THE HAMMER VALVE 4. Remove the plunger bushing and valve spool. a. Remove the cap screws from the plunger bushing (AA) using a hex wrench (t25) and extension bar. b. Use a nylon bar (t3) in the main valve body (W) at the bottom cap end (3) and drive the plunger bushing (AA) and valve spool (Z) out of the valve body with a hammer. c. Remove the valve spool from the valve body. d. Remove the plunger (BB) from the plunger bushing (AA).
64 INSPECTION AND REPAIR AFTER DISASSEMBLY As a rule, disassembly of the hydraulic hammer is only required when a problem occurs. Periodic disassembly for inspection is not required.
1. Sealing materials - any sealing
material that is found deformed, worn or damaged as shown, must be replaced.
a. Deformed, worn, distorted, damaged or
deteriorated o-ring.
b. Worn or deformed backup ring. c. Worn or deteriorated u-cup seal.
2. Hammer Internals a. Piston - 3. Tool and Tool Bushing Wear - Check the sliding areas for damage See pages 117 and 118 of this manual, and the striking area for damage or “Maximum Tool to Tool Bushing deformation. Repair or replace, if Clearance”. necessary. b. “A” and “B” sleeves – 4. General - Check the inner surface for damage a. Check for damage, breakage, and repair or replace if necessary. deformation, wear and rust and repair Complete hammer check sheets or replace, if necessary. and fax to NPK for advice on reuse b. Check for contamination and remove, if of main components. any. c. Valve spool – Check the sliding area for damage, deformation, or wear and repair or replace, if necessary. d. Valve case – Check the inner surface for damage or wear and repair or replace, if necessary. e. Swivel adapter – Check the seal contact area for damage or wear and repair or replace, if necessary.
65 REPAIR SECTION INTRODUCTION The NPK HYDRAULIC HAMMER is a rugged boom-mounted demolition tool which, by its application, is subjected to severe repeated shock forces. Based on long years of experience, NPK has carefully selected the best materials, heat treatment, and machining to obtain the longest life possible. All critical components are 100% inspected and identified by serial number. However, as with all machines, it is necessary to perform periodic maintenance and repairs. The personal attention and cost required for maintenance will be repaid many times over in trouble-free, low cost operation.
The NPK replaceable sleeve concept is an exclusive feature that greatly extends the useful service life of the NPK HYDRAULIC HAMMER. When competitive products without this exclusive feature must be scrapped, the NPK HYDRAULIC HAMMER can be completely rebuilt. This comprehensive SERVICE MANUAL contains detailed instructions for repairing major components to achieve the extended life. Please read this SERVICE MANUAL thoroughly before attempting any major repair of the hammer.
For additional information or help with any complex problem encountered, please contact the NPK ENGINEERING DEPARTMENT at (440) 232-7900.
Whenever repair or replacement of component parts is required, only parts sold by NPK should be used. NPK is not responsible for failures resulting from substitution of parts not sold or approved by NPK.
REPAIR TOOLS AND EQUIPMENT
Air or electric handheld grinder (NPK brand air grinder is recommended, p/n NHG-65LD). NPK Assembly Lube, p/n H010-5010. Polishing wheel (available from NPK, p/n 25026030). Oil stone Emery cloth (200 grit) Cleaning solvent
66 HAMMER SLEEVE AND PISTON RECONDITIONING TOOLS When repairing NPK Hammers, it is sometimes necessary to polish the piston, sleeves or main body bore. NPK has available for purchase, a hand held, long shaft straight grinder. NPK also sells the appropriate polishing and groove cleaning wheels to be used in reconditioning these parts. The part numbers are provided below for ordering purposes.
ITEM PART NO. DESCRIPTION
t1 NHG-65LD LONG SHAFT STRAIGHT GRINDER POLISHING WHEEL – used for cleaning t7 25026050 seal grooves in sleeves. (Green) POLISHING WHEEL – used for final t8 25026030 polishing of piston, sleeves and main body bore. (Gray) GRINDING WHEEL – used to grind t9 25026020 weld. (Red) CUT-OFF WHEEL – used to clean and t10 T050-7500 repair pressure balancing grooves in the sleeve land area.
67 HAMMER SLEEVE AND PISTON RECONDITIONING TOOLS
(t7) 25026050 POLISHING WHEEL (GREEN) (t8) 25026030 FINISH POLISHING WHEEL (GRAY) USE THIS WHEEL FOR CLEANING OUT SEAL USE THIS WHEEL FOR FINAL POLISHING OF GROOVES IN NPK “A” AND “B” SLEEVES. PISTON, MAIN BODY AND GLAND RING AREA OF NPK “A” AND “B” SLEEVES.
(t9) 25026020 GRINDING STONE (RED) (t10) T050-7500 CUT-OFF WHEEL
USE THIS STONE FOR GRINDING WELD IN USE CUT-OFF WHEEL TO CLEAN AND REPAIR HAMMER MAIN BODY. PRESSURE BALANCING GROOVES IN NPK “A” AND “B” SLEEVES.
NOTE: WHEN RECONDITIONING PARTS, IF YOU ARE UNSURE OF THE
PROPER PROCEDURES, CONSULT THE NPK SERVICE MANUAL OR CONTACT THE NPK SERVICE DEPARTMENT AT (440) 232-7900.
68 MAIN BODY BORE REPAIR INSPECTION AND GENERAL POLISHING OF MAIN BODY After disassembly and cleaning of the hammer components, it is important to carefully inspect the hammer main body bore.
1. Using a light, look into the bore and identify all locations (9) of the o-rings that seal the sleeve O.D. to the body. These areas can be recognized by the black markings left in the bore from the o-rings resting in these areas.
2. If no damage is noted in the o-ring areas, use a ball hone to break the glaze in the bore of the body. DO NOT USE A FIXED HONE! USE ONLY 6 STROKES OF A BALL HONE!
REMEMBER: ONCE THE SLEEVES ARE INSTALLED, THE O-RINGS BECOME
STATIONARY AND DO NOT MOVE OUT OF THE AREA THEY REST IN.
3. If a scratch runs across several o-ring areas:
a. Polish o-ring rest areas to blend with surrounding area.
b. If scratches are not removed by use of a ball hone, see Repairing Body Bore By Grinding and Polishing.
4. If score in o-ring area is too deep to polish and blend, the body may be welded in these areas and hand ground / polished, see Repairing Body Bore By Welding and Polishing.
69 MAIN BODY BORE REPAIR NPK RECONDITIONING TOOL USING THE NPK AIR GRINDER
If cavitation erosion is found in the main body, in most instances it can be addressed by light polishing in the area of erosion. DO NOT HONE THE BODY!
1. Take an NPK polishing wheel, part no. 25026030 (gray) (t8) and taper (45) each side so that the wheel is “V” shaped. This can be done by holding the wheel against the edge of a metal surface for several seconds.
2. Using a rocking motion, polish the erosion groove until the rough edges are removed. This must be done so that the o-rings on the O.D. of the sleeves will not be damaged during installation.
3. Clean bore using a ball hone making no more than 6 strokes. DO NOT HONE USING A FIXED HONE!
4. After polishing, clean main body bore to remove all grinding debris.
NOTE: WHEN REASSEMBLING THE HAMMER, USE A LIBERAL AMOUNT OF
GREASE IN THE POLISHED AREA.
70 MAIN BODY BORE REPAIR REPAIR OF BODY BORE BY GRINDING AND POLISHING
(10) POLISHED AREA
IDENTIFY O-RING AREAS (9)
The areas (9) of the bore that are sealed by o-rings can be located by the discoloration. To prevent oil and/or gas leakage, special care must be taken to obtain a smooth finish with no pinholes, undercut, or uneven finish in the o-ring areas. If you are unsure of where the o-ring areas are located, measure these areas on the outside of the sleeves and mark in the body using a permanent marker to show o-ring areas.
If a deep score (11) or scratch (deeper than .006 inch (.15 mm), that cannot be repaired by grinding is found in the body bore, repair this by welding, see Repairing Body Bore By Welding and Polishing.
71 MAIN BODY BORE REPAIR REPAIR OF BODY BORE BY GRINDING AND POLISHING
GRIND ROUGH EDGES OF THE ENTIRE POLISH SCRATCHES IN THE O-RING
LENGTH OF THE SCRATCH. AREAS (9) TO A SMOOTH SURFACE. BLEND THIS AREA TO THE (t8) POLISHING WHEEL (GRAY) SURROUNDING SURFACE. DO NOT OVER POLISH!
CHECK BORE DIMENSION WITH A BORE GAUGE (t11), COMPARE WITH
SPECIFICATIONS SHOWN IN CHART ON PAGE 78.
72 MAIN BODY BORE REPAIR REPAIR OF BODY BORE BY GRINDING AND POLISHING
After polishing, remove all o-rings from the “B” sleeve (longest sleeve). Apply a light coat of NPK Assembly Lubricant, part no. H010-5010.
Pass the sleeve in and out through the bore to check for any high spots, which require additional polishing.
9. REPAIRED O-RING – CONTACT SURFACE
12. GROUND AREA – NO O-RINGS HERE
73 MAIN BODY BORE REPAIR REPAIRING DEEP BODY BORE SCRATCHES BY WELDING AND POLISHING If a deep score or scratch (11) (deeper than .006 inch (.15 mm), that cannot be repaired by grinding is found in the body bore, repair this by welding.
The areas of the bore that are sealed by o-rings can be located by the discoloration (9). To prevent oil and/or gas leakage, special care must be taken to obtain a smooth finish with no pinholes, undercut, or uneven finish in the o-ring areas. If you are unsure of where the o-ring areas are located, measure these areas on the outside of the sleeves and mark in the body using a permanent marker to show o-ring areas.
IDENTIFY O-RING AREAS
REPAIR PROCEDURE: 1. Carefully grind the score (11) until it is flush with the surface, especially in the o-ring rest areas, as in area (10).
(10) POLISHED AREA
74 MAIN BODY BORE REPAIR REPAIRING DEEP BODY BORE SCRATCHES BY WELDING AND POLISHING 2. Clean and mark the o-ring areas. (The weld should extend 1/2” on either side of the o-ring contact area). Preheat the area(s) to be welded to approximately 300°F (150°C). This will remove oil and insure a better weld. Weld using a small diameter welding rod such as: AWS 6013 or AWS 7018 (or equivalent). Mask the area around the location to be welded. This will prevent “spatter” damage to the remaining bore area.
Use care to prevent an undercut.
AFTER WELDING, BEFORE GRINDING AFTER GRINDING AND POLISHING
3. After welding, grind weld until almost flush with the bore. Change to a fine polishing stone and finish until flush or just below flush. The seal areas of the o-rings cannot tolerate undercut and/or rough surfaces.
DO NOT HONE BODY WITH A FIXED HONE! USE A BALL
HONE ONLY MAKING NO MORE THAN 6 PASSES.
4. After polishing area, remove all o-
rings and backup rings from the “B” sleeve (P). Push the “B” sleeve (P) through the body bore (7) to check for high spots. If the “B” sleeve (P) will not go through the body bore (7), identify high spots and continue polishing.
75 MAIN BODY BORE REPAIR REPAIRING DEEP BODY BORE SCRATCHES BY WELDING AND POLISHING 5. Remove all o-rings from the “B” sleeve (longest sleeve). Apply a light coat of NPK Assembly Lubricant, part no. H010-5010.
Pass the sleeve in and out through the bore to check for any high spots, which require additional polishing.
9. REPAIRED O-RING – CONTACT SURFACE
12. GROUND AREA – NO O-RINGS HERE
76 MAIN BODY BORE REPAIR HONING MAIN BODY Generally, honing of the main body is not recommended. This is due to trying to maintain the I.D. of the body as close to the new standard dimension as possible. However, when honing is required, the use of a ball hone is recommended. Using a fixed power hone is not recommended, (consult NPK before using a fixed power hone).
The guidelines for using a ball hone are outlined below:
1. Apply a light coat of NPK Assembly Lubricant, p/n H010-5010 or equivalent oil.
2. Using the proper size hone as shown in the following chart, push / pull the hone through the body 6 times using even strokes.
3. Clean bore of the body. Check dimensions of I.D. Compare to the chart on page 78.
If dimensions are within usable limits, reassemble the hammer. If dimensions are outside the allowable range, contact NPK for assistance.
77 MAIN BODY BORE REPAIR MAIN BODY BORE DIMENSIONS GH SERIES HAMMERS HAMMER d5 d6 d7 BALL BALL MAIN BODY MAIN BODY MODEL BORE BORE MAIN BODY HONE HONE NEW MAXIMUM* LENGTH SIZE PART in (mm) in (mm) in (mm) NUMBER GH06 2.954 (75.04) 2.965 (75.30) 15.16 (385.2) N/A N/A 2.953 (75.00) 15.15 (384.9) GH07 2.954 (75.04) 2.965 (75.30) 15.36 (390.2) N/A N/A 2.953 (75.00) 15.35 (389.9) GH1 3.545 (90.04) 3.555 (90.30) 16.93 (430.2) 4" T050-7600 3.543 (90.00) 16.92 (429.9) GH2/GH2S/ 3.939 (100.04) 3.949 (100.30) 18.55 (471.2) 4" T050-7600 GH2TS 3.937 (100.00) 18.54 (470.9) GH3 4.529 (115.04) 4.539 (115.30) 21.07 (535.2) 4-1/2" T050-7605 4.528 (115.00) 21.06 (534.9) GH4 4.923 (125.04) 4.933 (125.30) 25.29 (640.2) 6" T050-7610 4.921 (125.00) 25.20 (639.8) GH6 5.907 (150.04) 5.917 (150.30) 29.15 (740.3) 6" T050-7610 5.905 (150.00) 29.12 (739.7)
NOTE: *Body bore maximum I.D. is not to exceed .010” (.25 mm) above standard (new) dimension. If bore is at or above this dimension, call the NPK Service Department at (440) 232-7900.
78 PISTON ACTIVE SEAL AREA REPAIR
PISTON REPAIR PROCEDURE
Pistons with scratches or scoring in the active seal areas, denoted as d10 and d11 in the illustration, may be repaired by polishing as long as the damage is less than .004 (.1 mm) deep. Damage more than .004 (.1 mm) deep requires piston replacement. Note that scratches in area d12 are not as critical, but the diameter of area d12 is. After repairing a piston in areas d10, d11, or d12, measure the diameters with a micrometer and contact the NPK Service Department to confirm that the piston is still within usable specifications. Areas d8 and d9 are not critical. Light buffing to smooth out scratches is all that is required.
79 PISTON TO SLEEVE RUNNING CLEARANCES The clearances shown below are to be used in determining if the internal components of the hammer are reusable. Measure the inside diameter of the sleeve and subtract the outside diameter of the piston at each location shown. There are three critical surfaces marked d10, d12, and d11. Each surface has a corresponding “Land” in the “A” or “B” sleeve through which the piston rides. These lands can be recognized by the multiple oil control grooves.
If the measurements are smaller than the values shown in the chart below, the piston and sleeves are reusable. If any of the measurements exceed the values shown, call the NPK Service Department at (440) 232-7900, for recommendations on parts replacement.
80 REPAIR THE STRIKING END OF PISTON The NPK piston is designed for maximum fatigue resistance to failure of the striking face. The striking face can become indented and mushroomed when the hammer has been used for a long time or operated with worn-out tool bushings. To repair the piston, dress the tool striking end with a grinder.
REPAIR OF SLEEVE INSIDE DIAMETER Scoring or galling may occur when the hammer has been used for a long period of time; or operated with worn-out tool bushings, loose tie rods, overheated hydraulic system, or contaminated hydraulic oil. If the sleeve has slight scratches or scoring, then repair by polishing. Call NPK for detailed information.
If the sleeve is damaged from scoring or galling in the axial direction, the oil grooves may be filled with metallic particles. The oil grooves must be cleaned or they will cause additional scoring.
81 REPLACING THE SEALS If the gas pressure drops more than 25 psi (2 bar) a day or a large oil leak is found, replace the seals. ❖ Check the seals, seal grooves, and piston active seal areas for damage. 1. Small nicks may be removed with a suitable hone. 2. When large or deep nicks are found, replace the part. GH06 – GH3
A. BODY P. “B” SLEEVE PP. U-CUP SEAL QQ. DIRT SEAL RR. O-RING SS. BACKUP RING 1. TOOL END 2. GAS END
NOTE: GH2S has extra machining for the anti-blank firing feature.
GH4 – GH6
O. “A” SLEEVE P. “B” SLEEVE AP. WEAR BAND PP. U-CUP SEAL QQ. DIRT SEAL RR. O-RING SS. BACKUP RING 1. TOOL END 2. GAS END
82 REPLACING THE SEALS All defective seals should be replaced with new ones.
1. O-rings deformed, worn, warped, damaged or deteriorated.
2. Backup rings worn or deformed.
3. U-cup seals worn or deteriorated.
Some minor leakage may be found for a while after new oil seals are installed, the oil leak will stop when the seal seats itself in use.
83 REPLACING THE SEALS 1. INSTALLING THE U-CUP SEALS a. One method of folding u-cup seals (PP) is illustrated below. Insert flat side into groove.
HOW TO HOLD THE U-CUP SEAL
b. Installation should be performed quickly, taking care to observe the correct direction. Taking too much time might let the u-cup take a set, which could cause leaks. c. Care should be exercised as not to damage the lip when installing the u-cup seal. Installation of damaged u-cup seals will cause oil leaks. d. After installing u-cups in the sleeve, coat them with grease to assist with piston installation.
e. GH06 – GH3 only – install seal (PP) from gas end (2) of hammer body. 2. INSTALL THE O-RINGS AND BACK UP RINGS
a. Install the o-rings.
b. Curl the backup rings, as shown below, and install. c. After installing, coat the o-rings and back up rings with grease.
Inspect sleeves to verify that the o-rings, back up
rings, and u-cup seals are correctly arranged.
84 REASSEMBLY OF THE HAMMER Reassemble the hydraulic hammer in the reverse order of disassembly.
INSTALL SLEEVES AND PISTON INTO THE MAIN BODY
GH4 and GH6 1. Before reassembling, clean all parts carefully. Since the hydraulic hammer is a precision machine, dust or dirt adversely affects its performance. 2. Reassemble the main body. a. Place the main body (A) on a workbench (t31) or other secure, clean surface.
b. If previously removed, reinstall the drain plug (B). Torque to 22 ft. lbs. (30 Nm). c. If previously removed, reinstall the grease fitting (30). Torque to 22 ft. lbs. (30 Nm).
NOTE: Do not use Teflon tape on grease fitting threads.
85 REASSEMBLY OF THE HAMMER INSTALL SLEEVES AND PISTON INTO THE MAIN BODY GH4 and GH6
3. Install the “B” sleeve.
a. Check the fit of the “B” sleeve. 1. Apply hydraulic oil or NPK assembly lube into the bore (7) of the main body. Before installing the o-rings and backup rings on the sleeve, slide it through the body bore from one end to the other. The sleeve should move smoothly without binding.
b. Apply hydraulic oil on the o-rings, backup rings, piston seals and dirt seal, and then install them into sleeve “B”. (See “REPLACING THE SEALS”.) c. Using a sling (t27), push the “B” sleeve (P) into the main body bore (7) from the gas head end (2) with the “Timing” port (46), “Pressure” port (6) and “Tank” port (5) facing upward. Keep the sleeve level as it enters the bore. Push the sleeve until the seals enter the bore.
86 REASSEMBLY OF THE HAMMER INSTALL SLEEVES AND PISTON INTO THE MAIN BODY GH4 and GH6 d. Remove the sling and bump the sleeve into the body bore until only the tank port passage (h2) is still showing. Use a lock plate (S) as a stop. Watch o-rings and backup rings as they enter the bore. If a seal starts to extrude, stop and push it back into its groove.
NOTE: The use of a lock plate is to prevent the sleeve from traveling into the main body bore prematurely. 4. Install the piston. a. Apply hydraulic oil or NPK assembly lube to the inner surface of the “B” sleeve. b. Insert the striking end of the piston (N) into the “B” sleeve by moving the free end up and down.
Care should be exercised so as not to damage the “B” sleeve when moving the piston up and down. 5. Install dowel pins. a. Apply a small amount of grease on two dowel pins (K) to hold them in place. b. Install the dowel pins into the “B” sleeve (P).
87 REASSEMBLY OF THE HAMMER INSTALL SLEEVES AND PISTON INTO THE MAIN BODY GH4 and GH6 6. Install the “A” sleeve. a. Apply hydraulic oil on the o-rings, backup rings, piston seals and dirt seal, and then install them into sleeve “A”. (See “REPLACING THE SEALS”.) b. Apply hydraulic oil or NPK assembly lube to the inner surface of the sleeve. c. Align the dowel pin holes on sleeve “A” (O) with the dowel pins (K) in sleeve “B” (P), then install.
d. Push the “A” sleeve over the piston until it contacts the “B” sleeve and traps the dowel pins.
7. Push “A” sleeve, piston and “B” sleeve into position.
Be sure the “A” and “B” sleeves have no gap between them before pushing them into the main hammer body. a. Remove the lock plate from sleeve “B” (P). b. Bump sleeve “A” (O), piston and sleeve “B” (P) into position. Take care to watch o-rings and backup rings on sleeve “A” as they enter the main body bore. See “MAKING SURE SLEEVES ARE IN THE PROPER POSITION”.
88 REASSEMBLY OF THE HAMMER ALTERNATE METHOD OF INSTALLING SLEEVES AND PISTON INTO THE MAIN BODY GH4 and GH6 This is the preferred method as it keeps the piston and sleeves together as one unit. It prevents sleeve separation, which could allow the dowel pins to drop out of place. Also, the steady push of the portable power unit reduces the possibility of cutting o-rings or backup rings. 1. Before reassembly, clean all parts carefully. Since the hydraulic hammer is a precision machine, dust or dirt adversely affects its performance. 2. Reassemble the main body. a. Place the main body (A) on a workbench (t31) or other secure, clean surface.
b. If previously removed, reinstall the drain plug (B). Torque to 22 ft. lbs. (30 Nm). c. If previously removed, reinstall the grease fitting (30). Torque to 22 ft. lbs. (30 Nm).
NOTE: Do not use Teflon tape on grease fitting threads.
3. Attach a chain to the hammer main body. a. Pin a chain (t4) to diagonally opposite tie rod holes (44) in the main body at the tool end (1). Hold the chain in place with pry bars (t82) or screwdrivers.
89 REASSEMBLY OF THE HAMMER ALTERNATE METHOD OF INSTALLING SLEEVES AND PISTON INTO THE MAIN BODY GH4 and GH6 b. String the chain through the tie rod holes and wrap it around the back of the cylinder (t5).
4. Install the “B” sleeve.
a. Check the fit of the “B” sleeve. 1. Apply hydraulic oil or NPK assembly lube into the bore (7) of the main body. Before installing the o-rings and backup rings on the sleeve, slide it through the body bore from one end to the other. The sleeve should move smoothly without binding.
b. Apply hydraulic oil on the o-rings, backup rings, piston seals and dirt seal, and then install them into sleeve “B”. (See “REPLACING THE SEALS”.) c. Using a sling (t27), push the “B” sleeve (P) into the main body bore (7) from the gas head end (2) with the “Timing” port (46), “Pressure” port (6) and “Tank” port (5) facing upward. Keep the sleeve level as it enters the bore. Push the sleeve until the seals enter the bore.
90 REASSEMBLY OF THE HAMMER ALTERNATE METHOD OF INSTALLING SLEEVES AND PISTON INTO THE MAIN BODY GH4 and GH6 d. Push the “B” sleeve with a portable power unit (t33) and cylinder (t5) with a push plate (t26) into the body bore until only the tank port passage (h2) is still showing. Use a lock plate (S) as a stop. Watch o-rings and backup rings as they enter the bore. If a seal starts to extrude, stop and push it back into its groove.
NOTE: The use of a lock plate is to prevent the sleeve from traveling into the main body bore prematurely.
5. Install the piston.
a. Apply hydraulic oil or NPK assembly lube to the inner surface of the “B” sleeve. b. Insert the striking end of the piston (N) into the “B” sleeve by moving the free end up and down.
Care should be exercised so as not to damage the “B” sleeve when moving the piston up and down.
91 REASSEMBLY OF THE HAMMER ALTERNATE METHOD OF INSTALLING SLEEVES AND PISTON INTO THE MAIN BODY GH4 and GH6 6. Install dowel pins. a. Apply a small amount of grease on two dowel pins (K) to hold them in place. b. Install the dowel pins into the “B” sleeve (P).
7. Install the “A” sleeve.
a. Apply hydraulic oil on the o-rings, backup rings, piston seals and dirt seal, and then install them into sleeve “A”. (See “REPLACING THE SEALS”.) b. Apply hydraulic oil or NPK assembly lube to the inner surface of the sleeve. c. Align the dowel pin holes on sleeve “A” (O) with the dowel pins (K) in sleeve “B” (P), then install.
d. Push the “A” sleeve over the piston until it contacts the “B” sleeve and traps the dowel pins. 8. Push “A” sleeve, piston and “B” sleeve into position.
Be sure the “A” and “B” sleeves have no gap between them before pushing them into the main hammer body. a. Remove the lock plate from sleeve “B” (P). b. Use the portable power unit (t33) and cylinder (t5) with a push plate (t26) to push sleeve “A” (O), piston and sleeve “B” into position. Take care to watch o-rings and backup rings on sleeve “A” as they enter the main body bore. See “MAKING SURE SLEEVES ARE IN THE PROPER POSITION”.
92 REASSEMBLY OF THE HAMMER INSTALL SLEEVE AND PISTON INTO THE MAIN BODY GH06 and GH3 1. Before reassembly, clean all parts carefully. Since the hydraulic hammer is a precision machine, dust or dirt adversely affects its performance. 2. Reassemble the main body. a. Place the main body (A) on a workbench (t31) or other secure, clean surface.
b. If previously removed, reinstall the drain plug (B). Torque to 22 ft. lbs. (30 Nm). c. If previously removed, reinstall the grease fitting (30). Torque to 22 ft. lbs. (30 Nm).
NOTE: Do not use Teflon tape on grease fitting threads.
d. Install the piston seals at the gas end of the main body.
93 REASSEMBLY OF THE HAMMER INSTALL SLEEVE AND PISTON INTO THE MAIN BODY GH06 and GH3 3. Install the “B” sleeve. a. Check the fit of the “B” sleeve. 1. Apply hydraulic oil or NPK assembly lube into the tool end bore (7) of the main body. Before installing the o-rings and backup rings on the sleeve, slide it through the body bore from one end to the other. The sleeve should move smoothly without binding.
b. Apply hydraulic oil on the o-rings, backup rings, piston seals and dirt seal, and then install them into sleeve “B”. (See “REPLACING THE SEALS”.)
c. Apply hydraulic oil or NPK assembly lube to the inner surface of the “B” sleeve. d. Insert the striking end of the piston (N) into the “B” sleeve.
Care should be exercised so as not to damage the “B” sleeve when installing the piston.
94 REASSEMBLY OF THE HAMMER INSTALL SLEEVE AND PISTON INTO THE MAIN BODY GH06 and GH3 e. Install the “B” sleeve and piston assembly into the tool end (1) of the main hammer body with the “Timing” port (46), “Pressure” port (6) and “Tank” port (5) facing upward. Keep the sleeve level as it enters the bore. Push the sleeve until the seals enter the bore.
f. Gently tap the “B” sleeve (P) and piston assembly into the hammer body (A) using a dead blow hammer (t2) as shown.
95 REASSEMBLY OF THE HAMMER MAKING SURE SLEEVES ARE IN THE PROPER POSITION Push the piston and sleeves into the body bore until the ports in sleeve “B” line up with the ports in the body.
GH4 – GH6 GH06 – GH3
A MAIN BODY 0 MAIN BODY SLEEVE (A) P MAIN BODY SLEEVE (B) 5 OUT PORT (tank) 6 IN PORT (pressure)
Check dimension (d1) to be sure the sleeves are in their correct location.
A MAIN BODY A MAIN BODY
P MAIN BODY SLEEVE (B) 0 MAIN BODY SLEEVE (A) d1 DIMENSION BOTTOM END GAP P MAIN BODY SLEEVE (B) 1 TOOL END d1 DIMENSION BOTTOM END GAP 2 GAS END d2 DIMENSION TOP END GAP 5 OUT PORT (tank) 1 TOOL END 6 IN PORT (pressure) 2 GAS END 5 OUT PORT (tank) 6 IN PORT (pressure)
96 REASSEMBLY OF THE HAMMER MAKING SURE SLEEVES ARE IN THE PROPER POSITION Check d2 If d2 is less than the value shown, “A” sleeve (O) is not fully engaged into the “B” sleeve (P). Hold “B” sleeve and try to bump “A” sleeve into position. If that doesn’t work, the sleeves must be pushed back out of the bore until the “A” sleeve comes clear of the main body. The problem can then be identified and corrected.
1. Apply a thin coat of grease to the o-ring (RR) and push it into the body bore (7) up against the end of the sleeve “B” (P). 2. Make sure the dowel pins (K) are in place in the sleeve “B”.
3. Install the o-ring (RR) into the counter bore of the grease passage (170) of the spacer section or impact ring (J). Seal the o-ring into place with a bead of RTV Silicone.
4. Install the spacer section or impact ring (J). Align the dowel pins on the sleeve “B” with the dowel pin holes in the spacer section or impact ring. Make sure the grease passage is aligned.
98 REASSEMBLY OF THE HAMMER TOOL END 5. Make sure the spacer section or impact ring (J) is snug to the main body. If it is not square to the body, the sleeves are slightly rotated out of position. Use a dead blow hammer (t2) to sharply rap the high corner of the spacer section or impact ring. This will rotate the spacer section or impact ring and sleeves into the correct position.
6. Install the tool holder and tie rods.
a. Hoist the tool holder (C) by a crane (t34), using slings or a NPK hammer hook (t28) and install it onto the spacer section or impact ring with the retaining pin bore (178) in the position shown.
b. Apply anti-seize compound to the threads (177) of the tie rods (Q). c. Clean thoroughly the threaded bore (75) of the bottom tie rod nuts (V).
99 REASSEMBLY OF THE HAMMER TOOL END d. Install the tie rods into the hammer main body (A) from the gas end. e. Turn each of the tie rods clockwise into the bottom nuts with a hand wrench (t6) until several threads are engaged. Turn each tie rod until it bottoms in the nut, then back off 1/2 to 3/4 turn. Support the tool holder during this process.
The tool holder must be level and square to the main body and spacer section or impact ring. Do not use an air impact wrench to thread the tie rods into the bottom nuts.
100 REASSEMBLY OF THE HAMMER GAS END 1. Install spring washers (AG).
a. Apply a thin coat of grease (28) on the spring washers (AG) and install them as shown below.
NOTE: Spring washers are not used in GH06 – GH3 hammers.
2. Pour a specified amount (see chart below) of oil in past “A” sleeve or into gas head or both. Use a synthetic motor oil, grade 10W-40 or 15W-50.
101 REASSEMBLY OF THE HAMMER GAS END 3. Install the o-ring (RR) onto the boss of the gas head (L). Apply grease to the surface of the o-ring before installing it on the gas head.
4. Install the four collars (AT) into the gas head (L).
NOTE: If the gas charge valve (M) was previously removed, re-install it at this time. Torque to 52 ft. lbs. (70 Nm).
5. Install the gas head (L).
Be careful pushing the gas head into position so as not to disturb the spring washers.
6. Install the four washers (U) onto the tie rods (Q).
NOTE: Apply anti-seize compound on the lock washer faces and the tie rod threads.
102 REASSEMBLY OF THE HAMMER GAS END 7. Install the top nuts (R) and tighten by hand.
a. If a gap (d3) of about .19 to .25 inch (7 to 8mm) is formed between the main body (A) and the gas head (L) when the top nuts (R) are tightened fully by hand, the setting may be regarded as normal. If the gap is larger than the above dimension, this suggests that the spring washers have fallen out of position.
8. Tighten all four top nuts with a torque wrench to the recommended torque specification shown in CHART 1 on page 136. (It may take several passes at each top nut to achieve this.) Check that no gap is noted between the sections of the hammer. (See “TIE ROD TORQUE”.)
9. Charge with nitrogen gas and inspect for gas leaks.
a. Charge nitrogen gas to the specified gas pressure. See the “GAS CHARGING THE HAMMER” section of this manual. b. Check for gas leaks. See the “GAS LEAKAGE” section of this manual.
103 REASSEMBLY OF THE HAMMER HAMMER VALVE INSTALLATION NOTE: The hammer valve must be assembled on a work bench before it is installed on the hammer body.
1. Install the bottom cap.
a. Apply a thin coat of grease on the o-ring (RR) and backup ring (SS) then; install them on the bottom cap (Y).
NOTE: Curl the backup ring in a tight circle as shown prior to installation.
b. Insert the bottom cap (Y) into the valve body (W) by carefully tapping it with a plastic or dead blow hammer (t2).
104 REASSEMBLY OF THE HAMMER HAMMER VALVE INSTALLATION c. Tighten the bolts to the specified torque; see “TORQUE VALUES FOR HAMMER FASTENERS” in this manual.
2. Install the valve spool.
a. Apply hydraulic oil or NPK assembly lubricant to the surface of the valve spool (Z).
b. Insert the valve spool (Z) from the top side into the valve body (W).
NOTE: Make sure that the valve spool moves smoothly.
105 REASSEMBLY OF THE HAMMER HAMMER VALVE INSTALLATION 3. Install the plunger and plunger bushing.
a. Apply a thin coat of grease on the o-ring (RR) and backup ring (SS) then; install them on the plunger bushing (AA).
NOTE: Curl the backup ring in a tight circle prior to installation.
b. Apply grease to the surface of the plunger (BB). Insert grease into the plunger bore of the plunger bushing then insert the plunger into the plunger bushing.
c. Insert the plunger bushing into the valve body with the plunger operation pilot hole (8) facing upward as shown.
106 REASSEMBLY OF THE HAMMER HAMMER VALVE INSTALLATION d. Tap carefully with a dead blow hammer.
e. Tighten the bolts to the specified torque; see “TORQUE VALUES FOR HAMMER FASTENERS” in this manual.
4. Prepare for main valve installation.
a. Install the o-rings.
1. Install the o-rings (RR) and backup rings (SS) on the main hammer body.
107 REASSEMBLY OF THE HAMMER HAMMER VALVE INSTALLATION
2. Install the o-ring (RR) and backup ring (SS) on the underside of the valve body (W).
3. Apply a thin coat of grease on the o-rings and backup rings.
b. Fill the hammer assembly (KK) with hydraulic oil. Pour oil (t52) into the “IN” port (6) and the “OUT” port (5) of the hammer assembly. Let air that is trapped in the assembly purge out.
108 REASSEMBLY OF THE HAMMER HAMMER VALVE INSTALLATION 5. Install the valve body.
a. Degrease the bolts (OO) and tapped holes (49) in the main hammer body (A).
b. Install the valve body assembly onto the main hammer body.
c. Apply thread adhesive (t41) onto the bolts (OO), install them and then torque them to the specified torque, see “TORQUE VALUES FOR HAMMER FASTENERS” in this manual.
6. Install the swivel flange.
a. Apply grease to the o-ring (RR) and backup ring (SS) then install them on the swivel flange (EE).
109 REASSEMBLY OF THE HAMMER HAMMER VALVE INSTALLATION b. Install the swivel flange onto the valve body.
c. Tighten the bolts to the specified torque; see “TORQUE VALUES FOR HAMMER FASTENERS” in this manual.
d. Apply grease to the o-rings (RR) and backup rings (SS). Install them on the swivel flange (GH3, GH4) or in the swivel elbow (GH6).
e. Install the seal rings (AI) (GH6 only), the swivel elbow (DD) and the stop ring (AH) onto the swivel flange (EE).
GH3, GH4 GH6
f. Using snap ring pliers, install the snap ring (AJ) onto the swivel flange.
The JIC fitting in the swivel adapter is off set to clear the swivel flange bolts.
110 REASSEMBLY OF THE HAMMER FINAL ASSEMBLY 1. Install the tool and retaining pin, see “CHANGING THE TOOL”.
2. Grease the tie rods (GH6 only).
a. After the tie rods have been torqued, install grease fittings (30) as shown. Grease until no more grease is accepted. When completed, remove the grease fittings and install the existing plugs (g12).
3. Install the hammer into the hammer bracket.
111 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 has pre-charge is factory checked before shipment. However, it is recommended the pressure be checked before using the NPK HYDRAULIC HAMMER for the first time. For the inspection procedure, see “CHECKING THE GAS PRESSURE”, pages 47 through 50. 2. At idle (THP1), raise the hammer off the ground. Place hammer vertical and activate the hammer hydraulic circuit for 3 – 5 second intervals. Continue for an additional 3 – 4 times to ensure that all the air has been purged from the hoses and the hammer before first use. Failure to do this could result in damage to the hammer’s internal components.
3. Place hammer firmly against the material to be broken (see “PRELOAD THE TOOL BEFORE STARTING”). Operate the hammer in a vertical position for approximately 10 minutes at one-half (THP2) engine speed. Increase engine speed to three-quarters (THP3) and continue operating at this speed for another 10 to 20 minutes. Increase to full engine speed (THP4). Maintain vertical position for the duration of the operation.
112 START-UP OPERATION BEFORE STARTING THE HAMMER PRE-OPERATION INSPECTION AND WARM UP Before operating the NPK HYDRAULIC HAMMER, be sure to perform the specified ROUTINE INSPECTION, see page 36.
Warm up the NPK HYDRAULIC HAMMER, see below, and the base machine in accordance with the machine manufacturer’s instruction manual. This is especially important during cold weather operation.
DAILY START-UP PROCEDURE
Operate the NPK HYDRAULIC HAMMER in the vertical position at 3/4 engine throttle setting, for about 1 – 2 minutes. During this period, inspect the NPK HYDRAULIC HAMMER and INSTALLATION KIT for leaks or loose connections.
Do not operate on a slanted surface during the start-up operation.
113 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
OPTIONAL TOOL • Concrete breaking CORE (PC) • Highway construction for GH6 • General demolition
ACCESSORY TOOLS SPECIALTY TOOL SHAPE APPLICATIONS
FROST CUTTER • Edge of trenching
Cross cut (SX), In Line (SY) • Frost cutting for GH07 thru GH4
ADAPTER TOOL • For attachments listed
for GH07 thru GH4 below
TAMPER PLATE • Soil compaction
(use with adapter tool) • Driving sheeting 9-1/2” x 9-1/2” for GH07 12” x 12” for GH1 thru GH2/GH2S 16” x 16” for GH3 thru GH4
POST and PIPE DRIVER • Driving guard rails
(use with adapter tool) • Driving fence posts for GH1 thru GH4
TOOLS FROM H & E SERIES HAMMERS WILL NOT ALWAYS FIT
GH SERIES! CHECK PART NUMBERS!
114 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.
115 TOOLS CHANGING THE TOOL REMOVAL 1. Remove the retaining pin ring (E) by using pliers or a screwdriver (t22), see Figures 1 and 2. It will easily come out if pulled at an angle as shown in Figure 2.
Figure 1 Figure 2
2. Screw an M12 bolt or cap screw (AF)
into the retainer pin (D), see Figure 3. 3. Pull out retainer pin (D). If the retainer pin (D) is jammed, use a hammer and drift from the opposite side. 4. See “RETAINING PIN” for additional retaining pin inspection and reconditioning. Figure 3
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 4, 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 5.
Figure 4 Figure 5
116 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, then move on to the next steps.
Step 2 Remove the tool from the tool holder. Measure the diameter (d16) of the bearing surface of the tool (HH), which is located on each side of the retaining pin groove. The minimum tool diameter is compared to a new tool bushing (G) only. If the tool is at or below the charted value, the tool must be replaced.
117 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.
MAXIMUM HAMMER NEW BUSHING BUSHING INSIDE MODEL DIAMETER INSIDE DIAMETER in (mm) in (mm) GH06 1.67 (42) 1.87 (47.4) GH07 1.87 (47) 2.07 (52.6) GH1 2.26 (57) 2.46 (62.6) GH2/GH2S/ 2.61 (67) 2.82 (71.6) GH2TS GH3 3.01 (76) 3.21 (81.6) GH4 3.40 (86) 3.61 (91.6) GH6 4.2 (106) 4.55 (115.6)
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. Replacing both the tool and bushings would bring the clearance back to new.
118 TOOLS TOOL INSPECTION 1. Deformation may occur on the tool in the retaining pin contact area (15) or on 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 may cause chipping (16) in the retaining pin contact area (15). If neglected, the chipping may reduce the life or cause failure of the tool retaining pin (D). Dress the area (55) with a grinder.
3. If chipping (16) is found at the top of the tool, replace the tool. If neglected, the piston impact surface will be damaged (13 is normal, 14 needs to be replaced).
119 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 with a lathe or milling machine using sufficient coolant.
121 RETAINING PIN Deformation may occur on the retaining pin in the tool contact area (AN). If this area is mushroomed, the retaining pin may become difficult to remove. Dress areas shown (AN) with a grinder.
A. Drive out the bushing lock pin (H) for the lower tool bushing. NOTE: The lock pin has thread adhesive applied at assembly. Heat the pin before attempting to drive it out. B. The tool bushings need to be shrunk before they can be removed from the tool holder (C). The recommended procedure to shrink the bushings is to use an arc welder, using a very hot weld (t53), applying at least three layers of weld covering the inside of the bushing. Depending on the hammer size, this could take from one to three hours to complete. C. Weld a steel block (t54) into the bushing (G) as shown.
D. Allow the bushing (G) to cool, without quenching, for about one-half hour to allow the weld to contract and shrink the bushing. Using a sledge hammer (t55), drive the bushing out with a steel bar (t57) from the top end of the tool holder. Note: NPK uses an old bracket bolt welded to the steel bar used in step “C”.
E. On GH2TS, GH3, GH4 and GH6 models only, repeat steps B, C and D to remove the upper bushing (if it needs to be replaced).
123 TOOL BUSHING REPLACEMENT 2. TOOL BUSHING INSTALLATION New tool bushings can be installed with either a hydraulic press, or shrink fitted with liquid nitrogen.
A. HYDRAULIC PRESS METHOD
1. Clean the bore (111) of the tool holder (C). The surface must have no sharp edges or high spots. Grind smooth, if necessary. 2. Apply a liberal coating of an anti-seize compound to the tool bushing (G) and the tool holder bore. 3. Press the bushing all the way in. HYDRAULIC PRESS REQUIREMENT 100 ton minimum – All Models
B. LIQUID NITROGEN METHOD
Wear protective clothing, a safety face shield and heavy gloves!
1. Clean the bore (111) of the tool holder (C). The surface must have no sharp edges or high spots. Grind smooth if necessary. 2. Fill an adequately sized steel or heavy plastic bucket with liquid nitrogen. Attach two pair of vise grip type pliers to the tool bushing (G). Fully submerge the tool bushing for several minutes. Remove the bushing from the liquid nitrogen, after the nitrogen stops boiling.
3. Drop the bushing into the tool holder bore. Use a hand sledge (t56) and a steel block (t54) to firmly seat the bushing.
124 TOOL BUSHING REPLACEMENT C. GH2S, GH2TS, AND GH6 LOWER TOOL BUSHING INSTALLATION The GH2S, GH2TS scaling hammers have a different tool bushing installation orientation than the GH06, GH07, GH1, GH2, GH3, and GH4 models. In order to get any distribution of grease between the tool and bushing, the grease holes (a79) located in the bushing have to be inserted in the 12 o’clock and 6 o’clock position. There are cross drilled grease ports located in the bore of the tool holder that the bushing has to be aligned with in order to distribute grease to the tool and bushing area.
GH2S, GH2TS
GH6
D. BUSHING LOCK PIN
Immediately after the lower bushing is installed, apply a high strength adhesive to the lower tool bushing lock pin (H) and drive it into place. Install the rubber plugs (TT) also using high strength adhesive.
125 TOOL HOLDER BUSHING BORE REPAIR If the lower tool bushing bore in the tool holder becomes oversized and will no longer maintain a press fit to the tool bushing, the following repair must be made. The tool holder requires its bore to be cut oversize, then welded, then cut to original size.
1. Cut the bore oversize to Dimension d24.
HAMMER DIMENSION - d24
MODEL in (mm) GH06 2.73 (69.4) GH07 2.94 (74.7) GH1 3.84 (97.5) GH2/GH2S/ 4.06 (103.0) GH2TS GH3 4.47 (113.5) GH4 4.88 (124.0) GH6 5.96 (151.5) 2. Weld the bore undersize to Dimension d26. Pre-heat the bore to 250°F (120°C). Use one of the following wires (or rod equivalent): ❖ Cronatron Cronalloy 7940 HAMMER DIMENSION - d25 ❖ Eutectic 3010A ❖ Lincoln Lincore 33 MODEL in (mm) ❖ Postal Postalloy 2892 SPL GH06 2.36 (60) ❖ Stoody Built Up GH07 2.56 (65) ❖ Or Equal GH1 3.43 (87) GH2/GH2S/ 3.70 (94) GH2TS GH3 4.09 (104) GH4 4.49 (114) GH6 5.55 (141)
126 TOOL HOLDER BUSHING BORE REPAIR 3. Machine the bore to Dimension d25.
127 TOOL HOLDER BUSHING BORE REPAIR 5. Dimension d28 is the distance from the center of the bushing retaining pin bore to the bottom of the bushing bore. This dimension must be maintained to ensure that the retaining pin groove around the outside of the tool bushing lines up with the bushing retaining pin in the tool holder.
128 TOOL HOLDER REPAIR OF EXTERIOR When the hammer has been used for a long period of time, or operated with penetration of the tool holder into the material being broken, the exterior of the tool holder may become worn. REBUILD PROCEDURE 1. Underlayment - Underlayment weld is necessary to build up the base material or over existing hardface weld. NOTE: You cannot hardface directly over old hardfacing. ❖ Welding Rod: Airco Austex 361, Cronatron 7770, Eutectic 3205, Postalloy 205, Stoody 2110 or equal. In Canada; NCH Canada, Inc. Hi-Pact #194 or equal. ❖ Dry welding rod at 300°F + (149°C +). ❖ Pre-heat the tool holder weld area to 150°F (66°C) and maintain this temperature during the welding operation. It is very important to maintain this temperature in cold environments. ❖ Adjust weld current to rod manufacturer’s specification. ❖ Peen each layer. ❖ Cool slowly. Cover weld in cold environments. 2. Hardface - Hardface can only be applied over base material or underlayment weld. Never hardface existing hardface. ❖ Welding Rod: Airco Tubecraft 1A, Cronatron 7355, Eutectic N6006, Postalloy 214, Stoody 31 or equal. In Canada; NCH Canada, Inc. Wear-X #176 or equal. ❖ Dry welding rod at 300°F + (149°C +). ❖ Pre-heat the tool holder weld area to 350°F (177°C) and maintain this temperature during the welding operation. It is very important to maintain this temperature in cold environments. ❖ Adjust weld current to rod manufacturer’s specification. ❖ Peen each layer. Do not exceed 2-3 layers of hardface. ❖ Cool slowly. Cover weld in cold environments.
19 – RETAINING PIN BORE
20 – GRIND SMOOTH Leave sufficient clearance around the tool bushing 21 – GRIND SMOOTH (no overlapping) retaining pin bore for removal or assembly. If we2 – UNDERLYING WELD necessary, a short length of 1 inch pipe can be we3 – HARDFACING welded in position over the hole to provide clearance. Grind flush after welding. we1 – REPAIR WELDMENT (see detail) 129 NPK HYDRAULIC HAMMER IMPACT RINGS REPAIR The impact ring is the stop for the tool when down pressure is applied to the hydraulic hammer. In time, the impact ring will wear through contact with the tool. The two main wear surfaces are the center bore and the beveled stop surface. The charts below give the new and maximum dimensions. A tape measure is all that is required. You do not need a micrometer. If any measurement is at or above the maximum, contact the NPK Service Department at (440) 232-7900.
HAMMER IMPACT RING IMPACT RING IMPACT RING IMPACT RING
MODEL INSIDE DIA. INSIDE DIA. INDENT INDENT NEW MAXIMUM NEW MAXIMUM (PISTON END) (PISTON END) d77 d78 d79 d80 in (mm) in (mm) in (mm) in (mm) GH06 1.26 (32) 1.46 (37) 0 0 0.20 (5) GH07 1.46 (37) 1.65 (42) 0 0 0.20 (5) GH1 1.77 (45) 1.97 (50) 0.19 (4.8) 0.39 (10) GH2/GH2S 2.05 (52) 2.24 (57) 0.18 (4.0) 0.35 (9) GH3 2.36 (60) 2.60 (65) 0.37 (9.5) 0.59 (15) GH4 2.68 (68) 2.87 (73) 0.50 (12.8) 0.75 (19) GH6 3.31 (84) 3.50 (89) 0.62 (15.8) 0.83 (21)
130 NPK HYDRAULIC HAMMER IMPACT BUSHINGS REPAIR The impact bushing is the stop for the tool when down pressure is applied to the hydraulic hammer. In time, the impact bushing will wear through contact with the tool. The two main wear surfaces are the center bore and the beveled stop surface.
The chart below gives the new and maximum dimensions. A tape measure is all that is required. You do not need a micrometer. Any measurement, at or above the maximum, requires that the impact bushing be replaced for the hammer to operate to its designed specifications. Do not weld repair the impact bushing!
HAMMER TOOL BORE CENTER BORE
MODEL NEW - d41a MAX - d41b NEW - d17 MAX - d18 in (mm) in (mm) in (mm) in (mm) GH2TS 2.61 (66.4) 2.8 (71) 2.04 (52) 2.24 (57)
HAMMER INDENTATION MODEL NEW - d19 MAX - d20 in (mm) in (mm) GH2TS 2.43 (61.8) 2.60 (66)
131 TIE RODS TIE ROD REPLACEMENT A loose tie rod is susceptible to stretching or breakage. GH6 and larger NPK tie rods are designed with a locking plate to prevent the tie rod from turning and loosening.
REPLACEMENT PROCEDURE: If the hammer with a failed tie rod is stopped immediately, only the failed tie rod must be replaced.
If the hammer has been operated with a failed tie rod for more than one hour, the remaining tie rods should be magna-fluxed in the thread areas to check for stress cracks caused by the remaining tie rods taking the extra load when one or more tie rod(s) break.
The following procedure is for the replacement of one or more tie rod(s).
1. Discharge the gas pressure. Refer to the “DISCHARGING THE GAS
PRESSURE” section of this manual.
2. Remove all lock rings (AJ) and lock plates (S) (GH6 only).
3. Loosen all tie rods and remove the failed tie rod(s) (Q1) to be replaced.
132 TIE RODS REPLACEMENT PROCEDURE 4. The remaining three tie rods should be magna-fluxed in the thread areas at this time to check for stress cracks. Some oil may be lost from the gas head at this time. Check oil capacity in “REASSEMBLY OF HAMMER” (gas end).
5. Apply “Anti-Seize” compound to the bottom threads of the new tie rod. Assemble into the hammer body and thread into the bottom nut. Thread the tie rod in until it bottoms. Then, back the tie rod out ½ to ¾ of a turn so that it is not bottomed out in the lower nut.
6. Apply “Anti-Seize” compound to the top threads of the tie rod and on the washer face. Place the washer over the top of the tie rod. (On GH6 hammer models, a pilot diameter fits into the gas head.)
7. Using a torque wrench, tighten the top nut on the newly installed tie rod to the recommended amount per “CHART 1” in the “TIE ROD TORQUE” section of this manual.
8. Repeat the tie rod torque procedure on the remaining three tie rods.
9. Apply silicone to the underside of the lock plates (GH6 only). Install the lock plates.
10. Install the snap rings (GH6 only).
11. Recharge the hammer with nitrogen gas. See the “CHARGING THE HAMMER” section of this manual.
133 TIE RODS REPLACEMENT PROCEDURE MODEL GH6 ONLY After the hammer tie rods have been torqued, install grease fittings (30) and remove plugs (g12) as shown. Grease until no more grease is accepted.
Remove the grease fittings (30) and re-install the plugs (g12).
134 MAXIMUM ELONGATION OF TIE RODS Tie rods may become stretched due to severe operating conditions or age in normal operating conditions. When the maximum length is reached, the tie rod must be replaced. The chart below gives the new and maximum lengths. A tape measure is all that is required.
135 TIE ROD TORQUE 1. Tighten all top nuts (R) with a torque wrench (t19) to the recommended torque specification shown in “CHART 1”. (NOTE: It may take several passes at each top nut to achieve this.) Check that no gap is noted between the sections of the hammer assembly.
2. Install the lock plates (GH6 only). If a lock plate does not drop into place, tighten the top nut until it does.
3. Install the snap rings (GH6 only).
4. Charge the hammer with gas. Refer to the “GAS CHARGING THE HAMMER” section of this manual.
136 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. HAMMER VALVE CASE VALVE TOP AND SWIVEL ADAPTER MODEL BOTTOM CAPS BOLT TORQUE BOLT TORQUE BOLT TORQUE DIA. ft/lbs (Nm) DIA. ft/lbs (Nm) DIA. ft/lbs (Nm) GH06 M12 95 (129) M10 33 (45) N/A N/A N/A GH07 M12 95 (129) M10 33 (45) N/A N/A N/A GH1 M12 95 (129) M10 33 (45) N/A N/A N/A GH2/GH2S/ M12 95 (129) M12 95 (129) N/A N/A N/A GH2TS GH3 M16 185 (251) M16 185 (251) M8 21 (28) GH4 M18 260 (352) M16 185 (251) M8 21 (28) GH6 M20 290 (393) M18 260 (352) M12 95 (129) *NOTE: TORQUES OF ALL BOLTS SHOWN, ARE WITH THREADS BEING LUBRICATED. SOCKET HEAD CAP SCREW BOLT HEX SOCKET DIAMETER SIZE M8 6 mm M10 8 mm M12 10 mm M14 12 mm M16 14 mm M18 14 mm M20 17 mm
137 MOUNTING BRACKET If the hammer has been overstressed due to improper operation or installed on too large a carrier, the mounting bracket may develop a fatigue crack.
EXAMPLE OF REPAIRING A CRACKED PLATE
1. Drill 3/16” (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.
3a. For plate sizes up to 3/4” (20 mm) thick, use this weld joint:
3b. For plate sizes over 3/4” (20 mm) thick, use this weld joint:
4. Grind weld flush as shown. 22 is the direction of grinding, 23 is the direction of
principal stress.
138 MOUNTING BRACKET HARDFACING
Surfaces of your NPK hammer bracket (LL) can be hardfaced (we3). The best time to apply or rebuild is as soon as the hardface pattern is worn off or when the hammer is new.
It is suggested that you use a crosshatch pattern on the hammer bottom plate (as shown) and two straight lines up each wear bar when used.
The hardfacing procedure is comprised of three steps which should be followed.
SURFACE PREPARATION Grind the entire area until it is smooth and clean. Remove all paint, grease, oil, and dirt before welding.
139 MOUNTING BRACKET UNDERLAYMENT
Underlayment weld is necessary to build up the
base material (DH) or over the existing hardface weld.
NOTE: You cannot hardface directly over old
hardfacing!
• Welding rod: Airco Austex 361, Cronatron
7770, Eutectic 3205, Postalloy 205, Stoody 2110 or equal. In Canada: NCH Canada, Inc., Hi-Pact #194 or equal. • Dry welding rod at 300°F+ (150°C+). • Pre-heat the area to be welded to 150°F (65°C) and maintain this temperature during the welding operation. It is very important to maintain this temperature in cold environments. • Adjust weld current to rod manufacturer’s specification. • Peen each layer. • Cool slowly. Allow the welded area to normalize slowly after welding, approximately eight hours. Failure to do so may cause cracking or peeling of newly applied weld. Cover weld in cold environments.
HARDFACE Hardface (we3) can only be applied over base material (DH) or underlayment weld (we2).
NOTE: Never hardface existing hardface!
• Welding rod: Airco Tubecraft 1A, Cronatron 7355, Eutectic N6006, Postalloy 214, Stoody 31 or equal. In Canada: NCH Canada, Inc., Wear-X #176 or equal. Stoody 19, 21, or 77, McKay Hardalloy 40 Tic, Hobart Smooth Arc 16. • Dry welding rod at 300°F+ (150°C+). • Pre-heat the weld area to 350°F (175°C) and maintain this temperature during the welding operation. It is very important to maintain this temperature in cold environments. • Adjust weld current to rod manufacturer’s specification. • Peen each layer. Do not exceed 2-3 layers of hardface. • Cool slowly. Allow the weld area to normalize slowly after welding, approximately eight hours. Failure to do so may cause cracking or peeling of newly applied weld. Cover weld in cold environments.
140 STORAGE OF HYDRAULIC HAMMER For short term storage between jobs, place the hammer horizontal on wood blocks (t20) or a pallet. 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), it is recommended the gas pressure be discharged at the charge valve (M). The tool (HH) should be removed, and the piston (N) pushed all the way in. Be sure the hydraulic hoses (AO) are plugged and grease the exposed end of the piston (N). Grease and reinstall the tool (HH). Cover with a waterproof tarp (t21), not shown.
DO NOT CLEAN the tool holder bore (111) of the hammer with a steam cleaner or high-pressure washer (t58). This could cause rust to form and, in turn, cause damage to the hammer piston!
141 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.
The registration can be done in any of the following ways.
The online registration can be done by the dealer or the end user.
Dealers: In the tool bar click on “DEALER LOGIN”.
• Select the NPK Electronic Parts Catalog link. • Enter your Username and Password, log into the system. • Select the “Warranty Registration” Tab toward the top of the web page to start (For assistance, please select the “Help” tab located on the top left for a step-by-step tutorial) • If the registration is completed online, there is no need to mail or fax the warranty registration.
End users / non NPK dealers
• In the tool bar click on “DEALER LOGIN” • Select the NPK Electronic Parts Catalog link. • You do NOT need to fill in username and password. • Select the “Warranty Registration” Link. • Enter your information in each field and continue to register your NPK unit(s). • At any time, you may select the “Help” tab for step-by-step tutorial. • If the registration is completed online, there is no need to mail or fax the warranty registration.
142 WARRANTY STATEMENT
143 WARRANTY STATEMENT
144 WARRANTY STATEMENT
145 WARRANTY STATEMENT
146 DECIMAL CONVERSION CHART DECIMAL INCH TO FRACTIONS
147 REBUILD SPECIFICATIONS CHECK SHEETS When rebuilding an NPK Hydraulic Hammer, it is necessary to inspect the piston (N), hammer body (A), “A” sleeve (O), “B” sleeve (P), cylinder spacer/impact ring (J), tool (HH), and tool bushings (F and G). Check tolerances after these components have been repaired or polished.
MEASURE CRITICAL AREAS
The diagrams on the following pages show the critical locations that should be measured. Carefully measure the areas shown with bore gages and micrometers.
FAX DIMENSIONS TO NPK SERVICE DEPARTMENT
Fill in the dimensions and fax this information to the NPK Service Department at (440) 232-6294 for reusability evaluation.
A. HAMMER BODY F. IMPACT BUSHING/UPPER TOOL BUSHING G. LOWER TOOL BUSHING J. IMPACT RING/SPACER SECTION N. PISTON O. MAIN BODY “A” SLEEVE P. MAIN BODY “B” SLEEVE HH. TOOL
