NPK HYDRAULIC HAMMER INSTRUCTION MANUAL GH-9 CP/EC GH-10 CP/EC GH-12 CP/EC GH-15 CP/EC GH-18 CP/EC NIPPON PNEUMATIC MFG. CO., LTD. Copyright © 2001 Nippon Pneumatic Mfg. Co., Ltd, All rights reserved,FOREWORD NPK is world’s largest manufacturer of HYDRAULIC HAMMERS, and has the most complete product line available anywhere. The success of NPK is due to our commitment to quality, dependability and long life. ‘The NPK HYDRAULIC HAMMER has a unique designed features and itis @ 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 conta instructions for operating NPK HYDRAULIC HAMMERS. This manual includes helpful information for obtaining the full potential and efficiency from NPK HYDRAULIC HAMMERS. Please read this manual thoroughly to understand the NPK HYDRAULIC HAMMER and its operating principles before using it. For additional information or help with any problem encountered, please contact your NPK authorised 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.INDEX FOREWORD... IMPORTANT SAFETY INFORMATION.. PRECAUTIONS FOR USING THE NPK HYDRAULIC HAMMER. CARRIER MACHINE COMPATIBILITY CHART, HAMMER SPECIFICATIONS...... STANDARD CHISELS. HYDRAULIC INSTALLATION... MECHANICAL INSTALLATION MOUNTING TO THE CARRIER... REMOVAL FROM THE CARRIER... ‘TAKING THE HAMMER OUT OF THE ENVIRO BRACKET MOUNTING THE HAMMER IN THE ENVIRO BRACKET. PRINCIPLE OF OPERATION... OPERATION vss UNDERWATER TYPE / AUTOMATIC LUBRICATION. OPERATING TECHNIQUES AND PRECAUTIONS, INSTRUCTIONS FOR USE OF NPK CHISELS. CHANGING THE CHISEL... so INSPECTION AND MAINTENANCE... i ROUTINE INSPECTION AND MAINTENANCE .. REPAIRING A CRACK IN THE BRACKET, CONTAMINATION CONTROL OF HYDRAULIC OIL... MAXIMUM CLEARANCE BETWEEN CHISEL AND BUSHING. GAS CHARGING KIT NITROGEN GAS PRESSURE... CHECKING THE GAS PRESSURE... TROUBLESHOOTING CHECKING THE HYDRAULIC PRESSURE AND FLOW. OIL LEAKAGE. GAS LEAKAGE. REPLACEMENT OF SIDE BOLTS TORQUE CHART .. NOTICES ON HYDRAULIC HOSES STORAGE OF HYDRAULIC HAMMER. NOTES.IMPORTANT SAFETY INFORMATION er and se “is ‘must read thoroughly understand the NPK. instruction manual, 2. Keep personnel clear of the HAMMER while in operation. 3. Do not operate the HAMMER without a suitable shield in place. This protects the operator from flying debris. 4, TO PREVENT INJURY OR DEATH, do not disassemble the HAMMER before discharging the HAMMER gas recharge. 5. Do not hardface or sharpen chisel with a cutting torch. Excessive heat from cutting or welding causes cembattlement, breakage, and flying pieces. Resharpen only with lathe or milling machine, using sufficient cooling. Fully extend chisel while charging the HAMMER with nitrogen. STAY CLEAR OF THE CHISEL POINT WHILE CHARGING. 7. Use nitrogen gas only. 8, ‘The HAMMER must not be operated unless the operator is in full control of the machine, Operate the HAMMER from the a seat only, 9. Important safety and operating decals are included with each HAMMER and INSTALLATION KIT. Keep them clean and visible. 10. Match HAMMER size to machine according to NPK recommendation, 11. Use the proper lifting equipment and tools when handling or servicing the HAMMER or components 12. Wear ear protection if conditions warrant. 13, Service personnel must take care handling pins and bushings when exchanging the bucket for the HAMMER. The machine operator must move the arm or boom only when directed by service personnel. 14, [fit is necessary to HAMMER the pins in or out, beware of flying metal chips. Eye protection should be worn. 15. Do not make any alterations to the HAMMER without authorisation fom NPK engineering 16. Use replacement parts sold by NPK only.PRECAUTIONS FOR USING THE NPK HYDRAULIC HAMMER ‘* PERFORM DAILY INSPECTIONS. * AVOID BLANK HAMMERING. DO NOT HAMMER IN THE SAME POSITION FOR OVER 30 SECONDS. © DONOT USE THE HAMMER TO MOVE MATERIAL, PRY MATERIAL, OR AS PICK ON, MATERIAL, * DONOT USE THE HAMMER UNDERWATER UNLESS THE HAMMER HAS BEEN MODIFIED FOR UNDERWATER OPERATION. © PREVENT CONTAMINATION FROM ENTERING THE HYDRAULIC HOSES WHEN MOUNTING OR DISMOUNTING THE HAMMER FROM THE CARRIER. * MAINTAIN A CLEAN HYDRAULIC SYSTEM, REPLACE THE FILTER ELEMENT WITH A NEW ONE AND CHANGE HYDRAULIC OIL AT THE SPECIFIED INTERVALS. Filter element every 100 hrs, Hydraulic oil ___ every 600 hrs. © OPERATE THE HAMMER CAREFULLY. DO NOT HIT THE BOOM OF THE CARRIER WITH THE HAMMER,CARRIER MACHINE COMPATIBILITY CHART ‘These carrier weight ranges are intended as a guideline only. Other factors, such as arm length, counterweights, undercarriage, ete., must be taken into consideration. Mounting a HAMMER that is too heavy for the carrier can be dangerous and can damage the carrer. Mounting a HAMMER that is too small for the carrier can damage the HAMMER and void the Warranty Please consult the NPK Engineering Department if there are any questions regarding the compatibility of a particular NPK HAMMER model with a particular carrier. CARRIER MASS [TON MODEL | RECOMMENDED RANGE con) ons 17=24 Gui.t0 21-28 Gui.t2 2438 Gtits 2a4s GH.18 3850 HAMMER SPECIFICATIONS vyaraute ] otow [Number ot] Ges | yan Shey fac teemes] Orel mover | Presse, | Rate | Blows | Preset | viout "| wit cise! | beret Pa | tinin | bpm | Mra | otmslet | mm GH9 21- 150-200 | 500-650 | 1.6-2.2-2.5 1607 840 2395 Geo | —21~ | 165-210 | 430-850 [1620-24] 1816 | 980 | 2575 GH-12 21~ 170-220 | 400-520 | 1.6-2.0-2.4 2310 1220 2777 Gis] —21~ | 200-250 | 350-450 [1620-24] 2963 | _1470_| 2988 GH-18, 21~ 220-290 | 300-400 | 1.6-2.0-2.4 3292 1800 3105 Min — Factory ~ Nia SPECIFICATIONS OF ACCUMULATOR oitiat gas volume is 1000 em’, PRESSURE LINE RETURN LINE, PRECHARGE PRECHARGE, ea PRESSURE QUANTITY. | PRESSURE QUANTITY MPa (kgffcn?) MPa (kgficm?) GH-9, GH-10,GH-12|__9(90) 1 0.2Q) 1 GH-S, GHAS, 12.(120) 1 02@) 2STANDARD CHISELS CHISEL TYPE, SHAPE APPLICATIONS Chisel (PC) a er * Concrete breaking * Highway construction * General demolition Chisel (P) << * Concrete breaking * Highway construction * General demolition Chisel (E) << * Secondary breaking * Breaking oversize * Slag removal Chisel crosscut (FX) SP * Trenching * Cutting casting gates * Breaking oversize * General demolitionHYDRAULIC INSTALLATION INSTALLATION KITS are available for virtually all loaders and excavators. ‘These includes valving and/or ‘controls, hoses and fittings, boom and arm tubing, and clamp. Obiydraulic hammer Bracket Pins Ochisel ©stop valves © Pressure tine @Retum line ®Hammer control valve @biydraulic pump @ Oil cooker © Oil tank © Accumators HAMMER KIT LINES ‘Typically, the pressure line is arranged on the left side of the boom and the return line on the right side. Flow tothe HAMMER is controlled from an auxiliary valve on the excavator or from a so-called hammer valve. Hydraulic oil is routed back to the tank through the exeavator’s oil cooler and filter. HAMMER CONTROL VALVE CONTROL SYSTEM USING THE CARRIER AUXILIARY VALVE SECTION. ‘This type of installation utilises an existing carrier valve whenever possible. Any additional parts, such as a ‘mechanical linkage, hydraulic pilot actuators, flow control valve, etc. are furnished in a HYDRAULIC INSTALLATION KIT. Special hydraulic pressure regulators are not required because the NPK HYDRAULIC HAMMER operating pressure is self-regulatingMECHANICAL INSTALLATION ‘The ENVIRO HAMMER is delivered with a flat top. Please refer to Figures for the Bolt Pitch and for structure of the Enviro Bracket, After mounting the Top Bracket or Quick Hitch with Bolts(25), Washers(27) and ith torque according Torque Chart on page 49. Nuts(26), fasten the Nuts(26 ENE Only use bolts/nuts with quality 10.9 Please note that the mentioned bolt pitch is the standard bolt pitch oH-9 ce e 6 @ &—= ® € | Parla, 4 q jo Le Ke ae @ oe 4 % 3 e e+ ae Zi © die omny/ et @ sur roeag? 6 | @ s = e “oe e ea Le | | oes ee ee se | Fig, 1-1: Bolt Pitch GH-9, GH-10 (standard) ons e Te o @ an & eH | | oe, oH | Fig. 1-2: Bolt Pitch GH-12, GH-15 (standard) PK is not responsible for failures or any damage resulting from any A WARNING orn esGH-18GH-9 in Bracket for bracket parts GH-9 Enviro 9870112 lo Ref. | Description QTY | Ref. | Description QTY | Ref. | Description gry 1_| Nao) 4 | 12 | NurPiate 2__| 23 _| Spring washer 3 2 |. =| 13 | Nur Piate 6 | 24 | screw 8 |_3__| Cushion Rubber 4 |u|. - | 25 | Top Supporter 1 4_| Spacer Plug 3_| 15 | Bot 24_| 26 | spacer 2 5_| Front Bolt 2_| 16 | Bott 3 | 27 | cover 1 6_| Supporter 1_| 17 | Bott 13_| 28 | Cap Screw 4 7_| Stopper Guide 1_| 18 _| Bott [3] 20 | Bottom Rubber 1 8_| Stopper 1} |. i - | 30 | cover 1 9 | Spacer 3_| 20 | Nut 16_| 31 _| Bushing 1 10_| Bottom Bracket 1_| 21 | Washer 24 | 32 | Bolt ia 11_| spacer 1] 22 | Washer 32133 | Washer 1GH-10 in Bracket for bracket parts GH-10 Enviro 9870108 Ref. | Description Qty | Ref. | Description Qty _| Ret. | Description gry 1_| Nu) 4 | 12 | NutPiate 2__| 23 | spring washer 3 aris =| 13 | wucPiate 6 | 24 | serew 8 3_| Cushion Rubber 4 a Bolt 6 _| 25 | top Supporter 1 4_| Spacer Plug 3_| 15 | Bot 1s_| 26 | spacer 2 S_| Front Bolt 2 | 16 | Bott 3 | 27 | Cover 1 6 | Supporter 1_| 7 | Bot 13, | 28 | Cap screw 4 7_| stopper Guide 1_| 18 | Bot 3_| 29 | Bottom Rubber 1 8_| Stopper |g |. - | 30 | Cover fo 9 | Spacer 3_| 20 | wut 16_|_31_| Bushing a 10_| Bottom Bracket t_| 21 | Washer 24_| 32 | Bott 1 11 | Spacer t_| 22 | Washer 32_| 33 | washer iGH-12 in Bracket for bracket parts GH-12 Enviro 870109 lf i | 1 = i] | <= | 8 ° |, He [ Ema = l ~o Ret. | Description QTY] Ret. |Description [QTY [Ret | Deserption | rv 1 [wut 2 [12 [NutPiate 2 [3 | soning washer 3 2_ | Nut (H) 1 13__| Nut Plate 6 24 | Screw 8 3_| Cushion Rubber 4 14 | Bolt. 6 25__| Top Supporter 1 4 | spacerPiug 3_| 1s [Bott 18_| 26 | spacer 2 | Front Bott 2 | 16 | Bott 3-27 [cover 1 a | sumer [ar [pot 10_| 28 | cap serew 4 1_| Stopper Guide [is [pot 2 | 29 [Botom Rubser | 1 8 _| Stopper, 1 19 |. - 30_| Cover 1 9_| Spacer 2 20_| Nut 12 31_| Bushing z 10_| Bottom Bracket 1 21_| Washer 24 32_| Bolt. 7 11_| Spacer 1 22_| Washer 24 33__| Washer 2GH-15 in Bracket for bracket parts GH-15 Enviro 9870110 Ref. | Description QTY | Ref. | Deseription QTY | Ret. | Description gry 1_| Nut @) 2 | 12 | nutPiate 2__| 23 | spring washer 3 2 | nwap 2 | 13 | nutPiate 6_| 24 | screw 8 3._| Cushion Rubber 4_| 14 | Bot 6 _| 25 | Top Supporter 1 4_| Spacer Plug 3_| 15 | Bort 18_| 26 | Spacer 5_| Front Bott 2 | 16 | Bort 3_| 27 | cover 6_| Supporter 1_| 17 | Bott 10_| 28 | Cap Serew 1_| Stopper Guide 1_| 18 | Bott 29 | Bottom Rubber 8_| Stopper 1_| 19 | Bott 30_| Cover 9_| Spacer 3_| 20 | nut 12_| 31_| Bushing 10 _| Bottom Bracket 1_| 21 | Washer 24_| 32 | Bott 11_| spacer 1_ | 22 | Washer 26_| 33, | washer 13GH-18 in Bracket for bracket parts d GH-18 Enviro 9870111 Ref. [ Deseription ary | Ret. | Description ary | ref. | Description 1_| Nur@ 2 | 12 | nur Plate 2 | 23 | spring washer | 3 2 | Nuc 2 | 13 | ur Plate 6 | 24 | scrow 8 3 [cushion Rubber | 4 | 14 | Bote 6 _| 25 | Top supporer 1 4 | Spacer Plug 3_ [is | Bor 18_| 26 | spacer 2 5_| Front Bolt 2 | 16 [Bor 3_| 27 [cover 1 6_| Supporter 1_| 17 [Bor 1o_| 28 | cap screw 4 7_| Stopper Guide 1 | is [Bor 2 | 29 | Bottom Rubber 1 8_| Stopper 1 | 19 [Bor 2_| 30 | Cover 1 9 | spacer 3] 20 | Nu 12 | 31 | Bushing 7 10 | Bottom Bracket t_| 21 | washer 24_| 32 [por 1 11 | spacer 1 [22 [washer 26 [33 | washer 7MOUNTING TO THE CARRIER 1. Place the HAMMER horizontal on wood blocks, as shown. 2. Align the pinholes. Install the arm pin before the cylinder link pin. 3. Connect hydraulic hoses. Pressure ison LEFT, return is on RIGHT. 4. Open stop valves. IMPORTANT: Avoid getting hydraulic oil in Bracket. Flush with water if necessary. Pigs ‘Stop valve Si Cap “e Hydraulic Hydrauli| hose hammer Bucket REMOVAL FROM THE CARRIER REMOVAL FROM THE CARRIER 1. Close pressure and return line stop valves. 2. Disconnect hydraulic hoses before laying the HAMMER down. See illustration. 3. Cap the pressure and return line on the eatrier and plug the HAMMER hoses. 4, Position the HAMMER horizontal on wood blocks and remove the pins. IMPORTANT: Remove the hoses with hammer positioned as shown below Stop valve Install cap Hydraulic hose Install plug ‘The hydraulic lines must be handled carefully and sealed to prevent contamination from entering the HAMMER or the carrier hydraulic system.TAKING THE HAMMER OUT OF THE ENVIRO BRACKET. (See Fig. 2: tructure of the Enviro Bracket, pages 10, 11, 12, 13, 14) 1. Follow the instructions as described on page 1S: REMOVAL FROM THE CARRIER. 2, Remove the Chisel see page 28: REMOVAL. For GH-9, GH-10, GH-12; Remove 3x Bolts(18), 3x Nuts(20), 6x Washers(22) to take off Top Supporter(25). For GH-15, GH-I8: Remove 2x Bolts(18), 2x Nuts(20), 4x Washers(22), 2x Bolts(19), and 2x Washers(22), to take off Top Supporter(25).. 4. Remove Bolts(17), Nuts(20) and Washers(22) in order to take off Top Bracket Quick Hitch. Remove Bolts(32), Bushings(31) and Washers(33) and remove Cover(30), 6. For GH-9, GH-10: Remove Nuts(D), one by one and take out the Front Bolts(5) For GH-12, GH-15, GH-18; Remove Nuts(G) and Nuts(H), one by one and take out the Front Bolts(5). Use plastic hammer if necessary ‘Take out Supporter(6) with a lifting cord, together with Spacer (11) and Spacer Plug(4) 8. For GH-9: Remove Bolts(15) and Washers(21) and take out Cushion Rubbers(3). For GH-10, GH-12, GH-15, GH-18: Remove Bolts(14), Bolts(15) and Washers(21) and take out Cushion Rubbers(3). 9. Attach a lifting cord to the Swivel (in- and outlet) and slide the hammer to the open side of the Bottom Bracket until the swivels block. Than unscrew and remove the complete swivel. 10. Attach the lifting cord to the top of the hammer and lift and slide the hammer out of the Bottom Bracket, ‘Take good care that nobody or any part of the body is beneath the lifted hammer. 11. Lower the bare hammer on two wooden blocks. 12, Inspect Bottom Rubber(29), Spacers(26), Spacers(9), Spacer(11) and Spacer Plugs(4) for wear and replace when necessary. 13. Replace Spacers when they are worn to 15 mm (thickness) or less. Operating the HAMMER with wear ‘exceeding this limit can result in cushion rubber failure. Some Spacers are mounted with rubber Spacer Plugs(4), 14, Check the inside ofthe bracket for any irregularities,MOUNTING THE HAMMER IN THE ENVIRO BRACKET (See Structure of the Enviro Bracket, pages 10, 11, 12, 13, 14) Always apply grease to bolts and/or nuts before assembly, 1. Make sure the Bottom Bracket(10) is lying on wooden blocks with the open side above. Position the hammer with a lifting cord to the open (top) side of the bracket. Slide the hammer horizontal into the bracket far enough to remount swivels. Remount the Swivels to the hammer with Torque according to chart on page 50. Attach a lifting cord to the Swivels and position the hammer in its place. WRT eR Make sure that te spacers are not being displaced and make sure that the grooves for the cushion rubbers in the hammer body are in position. 6. For GH-9: Remount the Cushion Rubbers(3) with Bolts(15) and Washers(21), hand-tight. For GH-10, GH-12, GH-15, GH-18: Remount the Cushion Rubbers(3) with Bolts(14), Bolts(15) and Washers(21), handetight, 7. Position the Supporter(6) together with Spacer(11) and Spacer Plug(4) with the lifting cord at its place and replace the Frontbolts(5). 8. For GH-9, GH-10: Remount Nuts(D) to the Frontbolts(5) and tighten according to Torque Chart on Page Page 49, For GH-12, GH-13, GH-18: Remount Nuts(G) and (H) to the Frontbolts(5) and tighten according to Torque Chart on Page 49. 9, Tighten Cushion Rubbers according to Torque Chart on Page 49. GH-9: Bolts(15), GH-10, GH-12, GH-15 tnd GH-18: Bolts(14) and Bolts(15). 10. Remount Cover(30) with Bolis(32), Bushings(31) and Washers(33) according to Torque Chart on Page 49. 1, Replace Top Bracket (together with Stopper Guide(7) and Stopper(8)) with Bolts(17), Washers(22) and ‘Nuts(20) hand-tight. 12, For GH-9, GH-10, GH-12: Replace Top Supporter(25) with 3x Bolts(18), 3x Nuts(20), 6x Washers(22) +hand-tight For Glf-15, GHI8: Replace Top Supporter(25) with 2x Bolts(18), 2x Nuts(20), 4x Washers(22), 2x. Bolts(19), and 2x Washers(22), hand-tight, 13. For GH-9, GH-10, GH-12: Tighten Nuts(20) for Top Supporter according to Torque Chart on Page 49. For GH-15, GH-18: Tighten Nuts(20) and Bolts(19) for Top Supporter according to Torque Chart on Page 49. 14. Tighten Nuts(20) and Bolts(17) for Top Bracket according to Torque Chart on Page 49. 15, Reinstall the Chisel see page 28: REINSTALLATION.STRUCTURE OF THE HAMMER Top nut Lock washer Side bolt Cylinder bushing(a) —_| Cylinder Piston Cylinder bushing(B) Bottom nut Chisel holder? | Holder bushing Chisel Adapter Drain plug Plunger Plunger bushing, ‘Swivel flange NO Stopper ring ‘Swivel adapter Main valve Bottom plate Grease nipple Cylinder spacer Round bushing Retainer pin Donut ring,PRINCIPLE OF OPERATION zo 48 @ Main valve Piston—| PD rchisel a) Q) G) @ (1) UPSTROKE OF PISTON Hydraulic oil supplied by the carrier hydraulic system enters the NPK HAMMER “IN” port and is directed ‘through port (5) to the top of the plunger, forcing the main valve spool! to the down position Ol flows through the main valve spool to the lower chamber of the position (C2). Oil pressure acts on the piston, raising it up and compressing the nitrogen gas. Oil in the upper chamber of the piston (Cl) is forced out the return line, through port (4). (2) VALVE SHIFT {As the piston rises, the lower chamber (C2) is opened to passage (3) and oil flows into chamber (C3) of the main valve spool. Since the area acting on the main valve spool in chamber (C3) is greater than the area of the plunger, the main valve spool shifts upward. The return line is closed with the main valve spool in the up position. (3) POWER STROKE With the main valve spool in the up position, chamber (C2) is closed off from the “IN” port and opened to chamber (C1). The piston is driven downwards by the compressed nitrogen gas as the oil in lower chamber (C2) circulates to upper chamber (C1). When the piston opens passage (3) to the upper chamber (C1), the oil in main valve spool chamber (C3) is switched to low pressure and the main valve’s spool shifts downward. After the piston opens passage (3) to upper chamber (Cl), the main valve spool opens chamber (C1) to the return fine. (4) IMPACT ‘The piston impacts the chisel and the main valve spool shifts to the full down position. High pressure oil is directed to the lower chamber of the piston for the start of another cycle. AUTOMATIC ENERGY RECYCLING: On extremely hard material, the piston will rebound before the valve shifts and the frequency (blow per minute) automatically increases while maintaining the full, impact energyOPERATION BEFORE STARTING THE HAMMER 1. CHECK THE NITROGEN GAS PRESSURE (NEW HAMMERS) ‘The nitrogen gas recharge is factory checked before shipment. However, it is recommended the pressure be checked before using the NPK HYDRAULIC HAMMER for the first ime. For the inspection procedure, see CHECKING THE GAS PRESSURE, page 36. Return line 1 A stop valve Ion 2. STOP VALVE, ‘A ‘\ The NPK HYDRAULIC INSTALLATION uses two stop valves located on the arm of the cartier. Orr ‘ew When using the NPK HYDRAULIC HAMMER be GD) Hammer sure these valves are turned to the “ON” position. JON} end Pressure line U | UJ. stop valve 3. PRE-OPERATION INSPECTION AND WARM UP. Before operating the NPK HYDRAULIC HAMMER, be sure to perform the specified DAILY INSPECTION. See page 30. ‘Warm up the NPK HYDRAULIC HAMMER, by running half RPM, so the blow per minute of the hammer is reduced (low), and the backhoe or excavator in accordance with the base machine instruction manual. Thi especially important during cold weather operation. START-UP OPERATION Operate the NPK HYDRAULIC HAMMER in the upright position, at half engine throttle setting, for about one hour. During this start-up period, inspect the NPK HYDRAULIC HAMMER and INSTALLATION KIT for leaking or loose connections. Do not operate on a slanted surface during the startup Hammerin asa surface i Vertical perateen hammering 20UNDERWATER TYPE / AUTOMATIC LUBRICATION Wrong connection for Air Supply Port and Automatic Lubricating Port causes damage. Connect Air Supply at AIR mark on Cylinder and Automatic lubrication at GRS mark. ‘Automatic Lubricating Port ‘Air Supply Port aiOPERATING TECHNIQUES AND PRECAUTIONS Press the tip of the chisel vertically against the object tobe broken. Be sure the object is stable before activating the NPK HYDRAULIC HAMMER. Raise the front of the machine slightly and apply down force on the foot pedal to start the NPK HYDRAULIC HAMMER. 4A CAUTION Applying excessive force to the HAMMER wi raise the carrier too high and jolt the operator when the material breaks. Let the NPK HYDRAULIC HAMMER do the work. ‘As soon as the material is broken, release the control lever or pedal to prevent unnecessary blank hammering. Stop rele) hammering Blank hammering is continued HAMMER operation after the at ‘material is broken. This will overheat the hydraulic system chet and cause undue wear. broken, »> 2F: The direction of force from the boom (the direction tangent to the arc of the boom) P: Penetration direction of the chisel A: Fulerum For the most efficient demolition, align the direction of force (F) from the boom with penetration direction (P) of the chisel. Failure to do this decreases the transfer of energy from the piston to the rock and increases the bending forces atthe fulcrum of the chisel. This unnecessary added stress leads to the following problems: 1) Premature bushing wear and/or chisel breakage 2) Breakage of side bolts 3) Breakage of bracket front bolts ‘The sound of the HAMMER changes when the chisel binds or the working angle is incorrect, Tangential direction ARC of hammer Keep the boom direction of force in the same Girection the chisel is penetrating. Use the boom cylinder to pre-load the HAMMER (apply down pressure), and use the bucket and arm cylinder for alignment. Keep the chisel tangent to the are of the boom. 23DO NOT USE THE CHISEL AS A PRY BAR Excessive prying can cause premature bushing wear and chisel or side bolt breakage. DO NOT HAMMER CONTINUOUSLY IN THE SAME POSITION FOR MORE THAN 30 SECONDS. If the chisel can not break or penetrate into the material after hammering in the same position for 30 seconds, change the working location. Hammering in the same position for a long time will reduce the working efficiency, will increase the hydraulic oil temperature, and accelerate chisel wear. ALWAYS WORK BY BREAKING TO A FREE FACE The material must have some where to break. Start at an edge. DO NOT ALLOW THE CHISEL TO HIT THE BOOM Use caution when tucking the HAMMER in tight to the boom for transportation hammering location ithe object does not pr, break ater iting for 30 secondsDO NOT DROP THE HAMMER RAPIDLY ON AN OBJECT Remember the hydraulic HAMMER is heavier than an ‘empty bucket and will move faster than expected. DO NOT USE THE HAMMER OR BRACKET TO MOVE LARGE OBJECTS Do not use the HAMMER bracket for purposes other than for what itis intended for. AVOID OPERATING THE HAMMER WITH CYLINDERS AT THE END OF STROKE Continuous operation with the boom cylinder fully closed or extended may damage the hydraulic cylinder. 25Fey Neh) BEWARE OF FLYING PROJECTILES FROM THE HAMMER POINT Do not use the HAMMER in such a way as to cause rock, etc., to be thrown towards the cab. A DANGER DO NOT OPERATE THE HAMMER WITHOUT THE CAB WINDOW OR SHIELD IN PLACE Cab window or shield must be in place to protect the operator from rock thrown out from the point, PN AGTINE) DO NOT USE THE HAMMER AS A HOIST The HAMMER is not intended to lift an object. To do so can be dangerous. A WARNING DO NOT OPERATE HAMMER UNDERWATER Do not allow parts, other than the chisel, to be submerged in water. Underwater operation will damage he HAMMER seals and allow water to enter the hydraulic system, The HAMMER can be modified for underwater operation, = contact the NPK dealer for more information. 26 N Do not use the hammer under water.INSTRUCTIONS FOR USE OF NPK CHISELS Make certain that the chisel you are going to use is a genuine NPK product stamped “NPK”. If the breaker fails to operate normally due to the use of a chisel other than our genuine products, we do not take any responsibility for the result, © Since chisels are used under severe working conditions, they might be broken or chipped if used ina ‘wrong way. When using them, follow the handling precautions given below. Handling precautions (1) As deseribed in page 23, operate the breaker it applied into the direction of driving, If the pressing direction does not align with the driving direction, undue flexure load is applied to the 1, thus causing the chisel to bend or causing breakage as shown in Fig. i ars mea ee Fig. 1 such a way that the pressing force of the breaker is always (2) Apply grease sufficiently. If the chisel is used without being properly greased, the sliding surface between the bushing and chisel seizes to cause breakage. (3) Do not cool the chisel rapidly by using water or the like during working, Ifthe chisel is cooled quickly, its condition of hardening changes to cause breakage or chipping, obo ive te tise at he same pain forma 30 secon the chs den comin thse pi forme han 3 seo therempomreatteegeafbecislitewserant te frinscepsto “7S ‘cause deformation or premature wear as shown in Fig.2. Fig.2 (5) Avoid blank hammering: breakage or chipping occurs in the part that is engaged with the retainer pin as shown in Fi (©) Replace the round bushing and holder bushing with new ones when they reach their useful i be used, chipping or breakage will occur on the head of the chisel 's. Ia worn bushing conti as shown in Fig3. Fig.3 (7) Do not harden again or weld for repair. ‘The condition of hardening changes to cause breakage or chipping, 2CHANGING THE CHISEL 1, REMOVAL 1) Remove Cap Serews(28) and Cover Plate(27), see Structure of Bracket on pages 10, 11, 12, 13, 14. 2) Remove the donut ring by using plier. See Fig.1 and Fig.2. Ttwill easily come out if pulled at an angle of 30 degrees with the centre as shown in Fig.2. 3) Screw a M12 bolt or cap screw into the retainer pin. 4) Pall out retainer pin, Ifthe retainer pin holds so tight that it cannot be ‘out at its back. pulled out, hammer Bona ng | | Fig2 Fig.l 2, REINSTALLATION 1) Clean the retainer pin housing hole and donut ring groove. 2) Coat the surface of the chisel with heat resistant grease, then install chisel 3) Apply grease to the donut ring housing groove, 4) Coat the retainer pin with heat resistant grease, then install it, 5) _ Install the donut ring in the following procedure. , While deforming the donut ring as shown in Fig.3, partially force it into the groove b. Using the handle ofthe plier, press the rest ofthe ring into the groove litte by little. See Fig.4. oT Fig.3 Fig. 6) Install the Cover Plate(27) see pages 10, 11, 12, 13, 14, structure of the Enviro bracket with Cap Serevs(28) see Torque Chart on page 49. 28INSPECTION AND MAINTENANCE TWENTY HOURS INSPECTION (A)SIDE BOLT AND BOLTS Inspect all bolts - retighten as necessary. See "Torque Charts", page 49 and page 50. (B) WELDS ‘Check for cracks - repair if necessary. (C)CHISEL Remove the chisel, see removal of the chisel on page 28, and inspect for peening caused by excessive blank hammering, Ifnecessary, grind edges smooth. (D) CHISEL RETAINER PIN Remove the retainer pin, se removal of the chisel on page 28, and inspect for pening caused by excessive blank hammering, If necessary, grind edges smooth. E) FRONT BOLTS (See Structure of Enviro Bracket on pages 10, 11, 12, 13, 14) ‘The two front bolts ensure the position of the supporter. With the hammer disconnected from the excavator ‘and lying on wooden blocks, the front bolts can be taken out, for inspection and replaced if necessary ‘To remove the front bolts, first remove the Nuts, one by one. Replace the front bolt when it shows. excessive wear, Tighten the Nuts with torque according Torque Chart on page 49. BRACKET SPACERS ‘The Spacers guide the motion of the HAMMER in the Bottom Bracket, Replace the spacer if worn below 15mm thickness (over Smm wear). Oper cushion rubber failure, Some Spacers are mounted with rubber Spacer Plugs(4). See Structure of Enviro Bracket on pages 10, 11, 12, 13, 14 the HAMMER with wear exceeding this limit can result in 29ROUTINE INSPECTION AND MAINTENANCE DAILY INSPECTION: 1, VISUAL INSPECTION Visually inspect the HAMMER daily. Detect trouble as early as possible! 2. CHISEL LUBRICATION Grease the chisel at least twice per shift, more often if the sliding surfaces 8 are dry or conditi 3. CHISEL and HOLDER BUSHING WEAR are extremely dusty or abrasive. Check the chisel and holder bushing for damage, wear or deformation. Replace the chisel and/or bushing when wear exceeds the maximum clearance limit. See MAXIMUM CLEARANCE BETWEEN CHISEL AND BUSHING on page 33, Do not hard-face or sharpen a chisel with a cutting torch. Excessive heat VIMPYANC ACW from cutting or welding causes brittlement, breakage, and fying pieces. Reshape only with a lathe or milling machine using sufficient cooling. 4, BOLTS Inspect al bolts ~retighten when necessary. See Torque Charts on page 49 and page $0. 5. CUSHION RUBBER - inspect for damage 6. FRONT BOLTS Inspect and retighten when necessary. See TORQUE CHART on page 49. WELDS Check for cracks - repair as necessary. 8. HOSE AND TUBING Check for oil leaks, loose clamps and hose abrasion, 9, CHISEL RETAINER PIN Inspect for damage. 10. HYDRAULIC OIL ‘The maximum operating temperature is 80°C. Inspect the oil in the hydraulic oil tank for level, contamination and deterioration, Add oil or change oil ifnecessary. If neglected, the HAMMER will break down or the hydraulic components of the excavator will be damaged. ‘See CONTAMINATION CONTROL OF HYDRAULIC OIL on page 32. Change filter element and hydraulic oil at the following intervals according to the procedures described in the operation Filter element: every 100 hrs, Hydraulic oil: every 600 hrs. ‘manual of the excavator. 30REPAIRING A CRACK IN THE BRACKET Ifthe HAMMER has been over-stressed due to improper operation or installed on too large carrier, the ‘mounting bracket may develop a fatigue crack. IMPORTANT: welding should only be done by certified personal. 1. Remove the hammer from the cartier and take the hammer out of the bracket. If welding is nearby any rubber part (Spacer plugs, cushion rubbers, spacers, tc.): remove, 2. Drill a Smm hole through the bracket at the end of the erack to prevent further crack propagation. 3. Grind out the erack and weld as shown. Use welding rod AWS E7016 or equivalent welding rod (JIS 23211 D4316.DINSIS 43(R)10) 4, For plate size over 20mm thick use weld joint according Fig. 1, for plate size up to 20 mm thick use weld joint according Fig. 2: 6mm min 3mm min 30° ase ~ Fig.1 Fig2 5. Grind weld flush as shown: DIRECTION OF GRINDING —_— Ley DIRECTION OF PRINCIPLE STRESS 31CONTAMINATION CONTROL OF HYDRAULIC OIL 1. A hydraulic HAMMER is harder on oil than a bucket, so the oil is apt to deteriorate and will be Contaminated sooner. Neglect of contaminated oil can not only damage the hydraulic HAMMER but also cause problems in the excavator. This could result in damaged components, Due care should be taken to ccheck for contamination of the oil and to change it if tis found contaminated. * When the hydraulic oil shows low viscosity and bubbles, this indicates thatthe oil is deteriorated, Ifthe oil is dark brown and gives off offensive odour, itis severely deteriorated. Change the oil immediately. * When the oil is clouded, or the oil filter often becomes clogged, it indicates that the oil is contaminated. Change the oil % To change the contaminated hydraulic oil, drain the hydraulic system completely and clean components. Do not mix new oil with the old. 2. Do not allow any foreign matter to mix with the oil. Take special care in preventing foreign material from centering the hydraulic system through the hose or pipe connection when changing the hydraulic HAMMER with the bucket, For example: sand in the hydraulic system will cause fatal damage to the components. ‘The oil filter should be replaced if necessary. 3. Low oil level will cause heat b to mixing with air, leading to a damaged hydraulic HAMMER and carrier components, up, resulting in deterioration of the oil. Also it may cause cavitation due Keep a proper oil level at all times. 4. Do not use the hydraulic HAMMER at an operating temperature higher than 80°C, The proper operating oil temperature range is between 50°C and 80°C. Since contaminated cooler fins cause reduced efficiency of the cooler, keep the cooler fins clean at al times. 5. Water in the hydraulic oil will lead to damage of the hydraulic HAMMER. When out of service, the hydraulic HAMMER should be stored indoors. Drain off water and foreign matter from the hydraulic tank at specified intervals. CHANGING OF THE FILTER ELEMENT AND HYDRAULIC OIL Change the filter element and hydraulic oil at the following intervals and according to the procedures described in the operation manual of the excavator: Filter element: every 100 brs, Hydraulic oil: every 600hrs. 32MAXIMUM CLEARANCE BETWEEN CHISEL AN BUSHING Replace the chisel holder bushing when the clearance reaches the maximum limit listed below. Replace the chisel when the outside diameter is wom to the limit for the minimum chisel diameter listed below. MAXIMUM | LIMIT OF MIN. MODEL |CLEARANCE| — CHISEL LimiT__|_DIAMETER GH 10 123 GHAO 10 133 GH-I2 15 143 GH-AS 15 153 GHAI 15 162 (mm) OPERATING THE HAMMER WITH CLEARANCES EXCEEDING WINAVNSINUIN(CRM THE LIMIT MAY DAMAGE THE INNER PARTS OF THE HAMMER AND VOID THE HAMMER WARRANTY. 33GAS CHARGING KIT AIL NPK HYDRAULIC HAMMERS are furnished with the following gas charging kit, In addition, a nitrogen tank and pressure regulator valve (not furnished with the HAMMER) are required. They can be obtained from your local welding supply house. q-°< 1. Hose 2. Plug 3. Charging valve 4, Tool box REGULATOR VALVE 34NITROGEN GAS PRESSURE ‘The nitrogen gas pressure must be measured with no pre-load on the chisel. Remove the chisel or position the HAMMER with the chisel fully extended against the retainer pin, The HAMMER must not be resting vertical on the chisel. The gas pressure in the HAMMER will vary according to the gas temperature. PREFERRED METHOD: ‘The preferred method to measure or charge the nitrogen gas pressure is with the hydraulic system temperature stabilised at maximum operating temperature. ALTERNATE METHOD: The nitrogen gas pressure can be measured or charged at ambient temperature (cold), before operating the HAMMER, 1 is recommended the pressure be verified at operating temperature. Exceeding the gas pre-charge specifications ean result in damaging HAMMER components. The NPK WARRANTY does not cover failures resulting from exceeding the specified nitrogen gas pressure. ‘Charging Gas Pressure Range at ambient | _ Charged Gas Pressure 1 ating for Deliv fapan eee temperature(before operating) for Delivery at NPK Jap MPa (kgf/cm?) MPa(kgficm?) GH 1.6 -25 (16-25) 2.222) GHA0 GHz 16-24 (16-24) 2.0(20) GS Gres 35CHECKING THE GAS PRESSURE Check the nitrogen gas pressure every two weeks. PROCEDURE 1, The gas pre-charge is measured with no pre-load on the chisel. Remove the chisel or position the HAMMER with the chisel fully extended. THE HAMMER MUST NOT BE RESTING ON THE POINT. Equipped with the ENVIRO BRACKET the Adapter Cap can be reached by folding the Cover(30) open after removing the top bolts of Cover(30), see pages 10, 11, 12, 13, 14 Adapter cap T-handle 2. Remove the adapter 3. Tum the NPK charging 4, Install the NPK charging A DANGER valve T-handle anti- valve on the hammer clockwise until it stops adapter, Remove the adapter cap only Not the adapter assembly! 6, Tum the T-handle clockwise Pressure As the T-handle is screwed in, a resistance is encountered. By tuming the T-handle further, the nitrogen gas pressure will be indicated on the pressure gauge Stop turning the T-handle when the gauge reads pressure, Do not 5. Tighten the charging valve over tighten. cap. gauge 7. Compare the gauge pressure with the NITROGEN GAS PRESSURE. See page 35. If the gas pressure is below specification, proceed to the NITROGEN GAS CHARGING PROCEDURE. 8. Tum the T-handle anti-clockwise until it stops asin step 3. 9. Slowly loosen the charging valve cap to relieve the nitrogen gas pressure trapped in the charging valve. 10. Remove the charging valve from the HAMMER adapter. 11, Replace the adapter cap on the adapter. 12, Replace Cover(30) and fasten according Torque Chart on page 49. 36DISCHARGING THE GAS PRESSURE With the ENVIRO BRACKET the Adapter Cap can be reached by folding the Cover(30) open after removing, the top bolts of Cover(30), see pages 10, 11, 12, 13, 14 PROCEDURE Adapter cap T-handle 1. Remove the NGE R Remove the adapter cap only Not the adapter assembly! 2. Turn the NPK charging valve T-handle —anti- clockwise until it stops. 3. Install the NPK charging valve on the hammer adapter. Label showing gs pressure to be charged 4, Tighten the charging valve cap. 5. Turn the T-handle clockwise. As the T-handle is screwed in, a resistance is encountered. By turing the T-handle further, the nitrogen gas pressure will be indicated om the pressure gauge. Stop turning the T-tandle when the gauge reads pressure. Do not over tighten, 37 6. Loosen the charging valve cap VERY SLOWLY. The ‘gas pressure will gradually decrease to zero; then REMOVE THE CAP. 7, Remove the charging valve from the hammer and reinstall the adapter cap, 8. Install Cover(30) according ‘Torque Chart on page 49,GAS CHARGING THE HAMMER ‘Do not stand near the chisel when A DANGER charging with nitrogen gas «STAY CLEAR OF THE CHISEL WHILE CHARGING Lx ‘THE HAMMER WITH GAS. The chisel may be impacted by the piston and forced out abruptly. ‘¢ Make sure the retainer pin is mounted when the chisel is in Nitrogen tank the hammer. * USE NITROGEN GAS ONLY PROCEDURE 1. Camry out steps 1 through 4 of CHECKING THE GAS PRESSURE. See page 36. 2. Remove the cap from the charging valve, Pec Remove the adapter cap only, not the adapter assembly! Pressure gauge | | Nitrogen tank 3. Install a pressure 4 Connect a hose from the 6. Tum the handle on the regulator on a tank of pressure regulator on the tank regulator anti- nitrogen gas. nitrogen tank to the clockwise to full closed. charging valve 7. Open the valve on the 5. Turn the T-handle on the nitrogen tank by turning charging valve clockwise. the handle anti-clockwise. 8. Slowly adjust the regulator on the nitrogen tank to the correct pressure by turning clockwise. ‘See NITROGEN GAS PRESSURE, page 35. 9. Charge nitrogen gas until the pressure gauge on the charging valve is at the correct setting, then turn the T-handle anti-clockwise all the way out. 10, Close the nitrogen tank valve and then remove the hose from the charging valve. FIZ NEINIIN (CIM Some nitrogen gus may be trapped in the hose. Loosen fittings slowly to release pressure. IL. Remove the charging valve from the HAMMER adapter. 12, Replace the adapter cap. 13, Replace Cover(30) (according Torque Chart on page 49) 38TROUBLESHOOTING UNDERSTAND THE BASICS: 1, The NPK HYDRAULIC HAMMER hy/draulic operating pressure is determined by the nitrogen gas pre charge pressure in the HAMMER, not the relief valve setting of the cartier. 2. The NPK HYDRAULIC HAMMER energy per blow is determined by the nitrogen gas pre-charge pressure, not by the pump volume. Energy is proportional to gas pressure. 3. The NPK HYDRAULIC HAMMER frequency (blow per minute) is determined by oil flow to the HAMMER. Frequency is proportional to oil flow. TROUBLESHOOTING CHART PROBLEM CAUSE CHECK REMEDY Loss of impact power, | Low gas pressure. Gas Pressure | Recharge gas. Gas pressure too high, Gas Pressure | Reduce gas pressure ‘Stop valve partially closed. | Valve position | Open valve. Relief valve set too low (must Loss of frequency, | Be 20-3.5MPa (0-35kgfiem! | Hyd. Pressure | Adjust or replace over HAMMER pressure) (HAMMER stows pea Hydr. Temperature too high. | Gi remperanue | Reduce throttle, clean or (over 80°C) Ps add oil cooler. Byeatle pump votieie 6 Of ring Increase circuit flow. Oil level of carrier too low. | Oil Level ‘Add hydraulic oil. Defective pump orcontrol | raydr. Pressure _| Repair or replace. Stop valve closed. Tiydr, Pressure | Open valve. Pressure is on left. Hoses reversed. Hydr. Pressure | Pressure ison Return Tine blocked. Hydr. Pressure | Eliminate obstruction. Erratic running or [Oil level of carrier too Tow. | Oil Level “Add hydraulic oil stops running. ‘Gas pressure too high. Gas Pressure | Reduce gas pressure, Zero gas pressure Gas Pressure _| Cheek for leak and . repair. Charge gas. HAMMER main valve TaaNabe Disassemble and inspect malfunctioning valve components Disassemble HAMMER Piston not eyeling Hydr, HAMMER | onset piston DETERMINE THE CAUSE OF THE PROBLEM ‘Technical problems are caused by either [1] the hydraulic HAMMER or (2] the hydraulic system (carrier Iydraulics or installation kit.). Checking the hydraulic pressure and flow, and the HAMMER gas pressure, will if the problem is the HAMMER or the carrier. If the pressures and flow available to the HAMMER are correct, the problem is in the HAMMER. deter 39)CHECKING THE HYDRAULIC PRESSURE AND FLOW 1 Installation of a Flow Meter Equipped with Pressure Loading Valve. Install the flow meter between the HAMMER pressure line and return as shown below. Soop valve Generally, the pressure line is on the left and the return is on the right, 2. Determine Return Line Pressure (Pressure Drop) Open both stop valves and press the HAMMER foot switch. ‘Measure the pressure with the load valve of the pressure / flow meter in full open condition. The return line pressure should not exceed 2MPa (20kefem?). 3. Determine Relief Valve Pressure and Oil Flow NOTE: The pressure-flow curve varies according to the exeav: “Measure flow and pressure with the flow meter. the excavator model Adjust the load valve to zero restriction. Wamupiehyaic men otowescnane |_|! ou to normal operating temperature. Set engine ao Load valve throttle to maximum. Press HAMMER foot | GUL switch. Tum in the loading valve knob and _ oo record the pressure and flow at regular intervals Teripoaeeniinntet | mip ror= flow on the other. Increase pressure until relief ut usable area shown in Fig.1 on page 41. select switch Flow display ‘Typical flow meter equipped with pressure loading valve. 404, Check the HAMMER Operating Condition (Example of pressure-flow) ‘The working pressure of the NPK HYDRAULIC HAMMER is self-regulating, determined by the gas pressure Draw the HAMMER working range on the measured pressure-flow graph, Use the maximum pressure and flow values from the specification chart in this manual. ‘The HAMMER working pressure range should be within the line A-B-C-D. PRESSURE-FLOW CURVE Hammer working ressure range Flow(Limin) Pressure (kgtiem?) " 3.0.35 MPR allowance Fig.l For example, the condition shown in Fig.l is acceptable. The condition shown in Fig.2 or Fig.3 is not. If condition shown in Fig.2 or Fig.3 occurs, check for relief valve failure, wom pump, or excessive HAMMER gas pressure, NOTE: The relief pressure should be set a minimum, of 3.0 to 3.5 MPa (30 to 35 kgficm!) above the HAMMER working pressure. ‘The NPK HYDRAULIC HAMMER frequency (blows per minute) is determined by the hydraulic flow delivered to the HAMMER. The higher the oil flow, the higher the frequency. Do not exceed the ‘maximum of oil flow specifications. PRESSURE-FLOW CURVE. Hammer working pressure range Flow(Limin) 0 Pressure (kgfem?) Fig2 Relief pressure 4 PRESSURE-FLOW CURVE Hammer working pressure range Flow(L/min) 0. Pressure (kgfem’) Fig3 Relief preureOIL LEAKAGE Exceeding 80°C hydraulic operating temperature reduces sea life. A small amount of oil leakage between the chisel and holder bushing at location (B) is considered as normal. {foil leak is significant, locate the point of origin. Oil running down the chisel may be coming from a loose hose. It is normal for a new seal to leak slightly until the seal seats with usage. Points to cheek for oil leakage. Small leakage is normal + DF GE \ Aa/ B 5 “YT oO = a thf Ac PROBLEM CAUSE REMEDY [Disassemble HAMMER and replace A) Leakage through drain hole. [Seal in cylinder bushing(A). seals. ) Leakage between chisel and [Disassemble HAMMER and replace (eases 34° | seal in eylinder bushing(B). ae holder bushing sals. ving berwan valve cae and | (©) Leakage bereen cylinder and |e Replace. valve ease, Loose bots [Loctite thread, tighten. (0) Leakage between valve case [O-ring under top plate Replace and plunger bushing. Loose bolts. ‘Tighten |(E) Leakage between valve case [O-ring under bottom plate, [Replace and bottom plate. [Loose bolts. (Tighten. |(F) Leakage between valve case O-ring under swivel flange. _|Replace. and swivel flange. - eee my |(G) Leakage between hose fitting [Loose or damaged hose [Tighten or replace. and swivel adapter. fitting. bs 7 42GAS LEAKAGE (if the gas pressure drops over 1MPa(10kgf/em”) per day) Exceeding 80°C hydraulic operating temperature reduces seal life. Soapy water a To locate gas leak, apply soapy water at the points indicated PROBLEM CAUSE. REMEDY [O-ring in check valve. Replace. () Leakage from top of adapter. [Damaged check valve in, Replace. ladapter. (K) Leakage between adapter [O-ring in adapter Replace. and head eap. Loose charge valve, Loctite thread, tighten, (L) Leakage between head [Disassemble HAMMER and replace (L) Leakage between head eaP | in ead cap. isasse rep and cylinder. seals ; [Disassemble HAMMER and replace (M) Leakage through drain plug. {Seal in eylinder bushing(A). | seals. 43REPLACEMENT OF SIDE BOLTS Loose side bolts are susceptible to stretching or breakage. Because the mating surfaces become seated during initial operation, the result may be lost tension and loosening of the side bolts, even though the top nut has not tumed. REASSEMBLING PROCEDURE Lc er = the Make sure all Nitrogen gas is out! 2. Using a peening spanner, loosen the diagonally paired top nuts, either A and D or B and C. See Fig.1 and Fig.2. 3. Loosen the remaining two top nuts. A B " 4 trogen gas, see page 37. Fig.t Fig2 4, Remove the lock washers. See Fig.3. 5. Remove the head cap in the manner as shown in Fig.4 and Fig,5. > Fig Figs 446. Remove the Belleville spring, See Fig.6 Hang the chisel holder in a level position. See Fig.7. Belleville spring Fig Fig? Fig Using a spanner that fits the width across flats of the bolts, turn each bolt anti-clockwise. See Fig.8. Pull out the bolts, and then put in new bolts. In case the bolts are not being replaced: I. Remove the chisel holder. 2. Remove the cylinder spacer and then remove the bolts from the cylinder. 45ASSEMBLING PROCEDURE 10. Clean and remove oil or grease on the thread of the side bolts. Apply molybdenum disulphide filled SideBolt grease to the thread of bottom nuts and the thread of the new side bolts 1. Using the spanner on the flats of the bolts, turn the bolts clockwise and screw the bolts into each bottom nut. See Fig.9. i Fig9 12. Apply vaseline to the Belleville spring, and then install it. See Fig.10. The Belleville spring installing. position is shown in Fig.11 Vaseline Vaseline © Chisel side Fig.10 Fig.11 13. Pour clean hydraulic fluid (shown in Table) into the interior of the cylinder bush(A). MopeL | QUANTITY GH 300 ce GH-10 300 ce. GH-12 400 ce GH-15 300 ce GHA 700 ce 4614, 17. Install the head cap. After making sure the end face of the bolt gets into contact with the face of the bottom nut, be sure to loosen the bolt by turning it 90 to 180 degrees anti-clockwise. See Fig.13 Put one of the lock washers in position, and then by turning the bolts, put the lock washer in secure engagement with the bolt and the head cap. See Fig. 14. | Set another lock washer in the opposite-corner position in the same manner, Apply molybdenum disulphide to the treaded area of the each bolt Install two top nuts in diagonal position, and then evenly tighten them hand tight. (Fig. 15) a Fig. S19, 20. ai. 2. 2. 24. 26. Install the lock washer on each of the remaining bolts See Fig.16. Hand-tighten the other top nuts on the diagonally positioned bolts ‘Make sure the gap is 7 to 8 mm between the cylinder and head cap. See Fig.17. If the gap is found larger than specified, check to see if the Belleville spring or the 7-8mm spacer is out of position. Gl Fig.17 Using a peening spanner, tighten the top nuts tll the head cap is in contact with the cylinder and the cylinder spacer with the chisel Holder. Loosen top nuts A and D and retighten A and D with the pre-torque according to the table on page 49. Loosen top nuts B and C and retighten B and C with the same pre-torque as A and D. Put marks on each top nut, lock washer and head cap. See fig. 18. Ss 4x Fig 18 Use the following (next page) nut-turning manner for tightening them, 48.TORQUE CHART SIDE BOUT TORQUE TURN-OF -NUT METHOD: Model | Thread | Pre | Socket | Start Torque | Size | Position | First | Second | Third | Fourth | TOTAL Nm turn turn turn turn | ANGLE (kgf-m) mm we y | cus |rsume| oe | m | O| OO S conleoe| » | » || Ol | a) oe z BY) one haw] aw | |B] OIC] @ on eA )\ cuslme| oo | oo | BIAS ©) fo | cnn) aow | aw | os | O| D/O | OKO] « LIS ‘Torque Chart BRACKET* [Moder Front boit(5) Cushion Rubber(3) ‘Nut Plate(12/13) — eR = aware en ee fc ef awesome |GH-10 | 1%(D) | 900 (80) : : M20 550 (55) ‘M20 850 (55) M10, 60/6) |GH-12 | 1%4°(G) | 1,000 (100)} 1%"(H) | 900 (90) M20, 550 (55) ‘M20 550 (55) M10, 60(6) |GH-18 } 14°(G) |1,000 (100) 1%47(H) | 900 (90) M20, ‘850 (55) ‘M20 550 (55) M10 60(6) [Model ‘Top Bracket Top Supporter(25) ‘Cover (27) Cover (30) ‘Stopper Guide(7) ae ee oa | ek | eek | ee, | eee neat a | fcr ac oem fs ae ioe oe ee ae Pees i] i] St |= cn rs [Hn fee |e | ae [aero [wor [rencon| oman [nm ses [en a ‘HGH, GH-10, GHi-12: Top supporter is atlached together with Top Bracket with Nut(20) * See Structure of Enviro Bracket on pages 10, 11, 12, 13, 14 49DSNAINIINEH escesive ighcning at se bate may ease reakage ona ult in injury. TIGHTING OF THE OTHER BOLTS The threads must be clean and dry Torque Chart BARE HAMMER [Mecer Bol (Valve Case) Bok (Tp Plate/Botiom Plate) Bolt (Swivel Adapter) Nm (kgm) No (kgm) Nm (kgm) cH 2a 95096) 22, 750(75) m2. 130(13) HAO 2a $50(95) M2. 750(75) iz 130113) GH? Moa 950(95) M22, 75075) mz 130(13) CHS Mor 4,400(140) M24 950,95) Mia 200420) Gite M27. 4,400(140) 2a 950(95) wig 200(20 Torque Chart HYDRAULIC HOSE Torque Chart PIPING Hydraulic Spanner | Tightening Spanner | Tightening Hose dia | Hose ting | obeused | tore Boteda, | #bE wed] tre in mm | (kgm mm | (gem) | 3/16 7/16-20UN 16 20 (2) MIO 17 60 (6) va PF Wa | 25@5) MI2 | oan 38 PF 3/8 2 50(3) W2 3/4-16UN, 27 80 (8) 3/4 1-1/16-12UN_ 36 180 (18) 1 [rsnerun| 41 | 20020) Lobvs | iesis-2un 50 250 (25)NOTICES ON HYDRAULIC HOSES ‘The hydraulic hoses are recommended to be changed within two years at longest, Be sure to make close check of the hoses every day. (1) APPLICATION OF HOSES © The hoses should be used within the following range of temperature. Service temperature of the fluid -40°C - +100°C Atmospheric temperature = 40°C = 470°C © Donot make any mending, repairing and alterations to the hoses, (2) INSTALLATION OF HOSES © Don't twist nor extend the hoses. It is dangerous that the twisted hoses should cause burst near the fitings when the hoses are under pressure, © Prevent damage to the outside hose. A damaged outside hose can cause early dangerous burst atthe bent portion of the hose. © Fasten properly following to the specified fastening torque. If not, it can not be sealed well, and cause to oil leakage and breakage of the fittings, (3) MAINTENANCE AND CHECK © Besure there is no damage or exposure of reinforced layer. © Besure there is no oil leakage from fittings. (4) STORE © Keep the hoses in a clean and dry atmosphere, where there is no hazardous gas, away from the sunshine, and within the range of temperature, - 10°C - +40°C. Tightening Torque for Hydraulic Hoses Hydraulic Hoses Width Across Flat | Tightening Torque inch mm Nm (kgf-m) 3/16 716-20UN 16 202) 14 PRU 19 252.5) 3/8 PESIS, 22 50 (5) 12 3/4-16UN 21 80(8) 34 1-1/16-12UN 36 180 (18) 1 1-5/16-12UN, 41 20020) 14 1-5/8-12UN. 50 25025) slSTORAGE OF HYDRAULIC HAMMER For short-term storage between jobs, place the HAMMER horizontal on wood blocks. Be sure the chisel is liberally greased and the hydraulic hoses are capped. Cover with a waterproof tarpaulin, Hydraulic Apply grease oe Plug the hose ends Wood block Ifthe NPK HYDRAULIC HAMMER is not tobe used for a long period of time (months) itis recommended the gas pressure be discharged, see page 37. The chisel should be removed, and the piston pushed all the way in with a nylon bar, while the charging valve is mounted and open. Do not clean the impact chamber inside the hammer with a steam cleaner or high pressure cleaner. Grease the exposed end of the piston. Be sure the hydraulic hoses are plugged. Cover with a waterproof tarpaulin. 32NOTES NPK HYDRAULIC HAMMER EXCAVATOR DATE OF INSTALLATION DATE OF 20 HOUR INSPECTION SERVICE RECORD: MODEL NUMBER SERIAL NUMBER MANUFACTURER MODEL NUMBER... SERIAL NUMBER... 33NPK NIPPON PNEUMATIC MFG. CO., LTD. 11-5, 4-CHOME, KAMUJI, HIGASHINARI-KU, OSAKA, JAPAN NPK EUROPE TRADING BV WORLD TRADE CENTER, PO BOX 30157, 3001DD ROTTERDAM THE NETHERLANDS Copyright © 2001 Nippon Pneumatic Mfg. Co., Ltd. & NPK Europe Trading BV All rights reserved,GH-12 CODE NO.105702 RAMS PREFACE MRE COMI, Met ws HS MAES OAS - Rhesmseran, When you order these parts, nform of their models, product code number, part numbers, part names and required quantities. FH MEMORANDUM HAOTR, BREXBICAATE, Please utilize under-table for pacts-order and maintenance of your machine, ete. Bho es PRODUCT CODE NUMBER he SERIAL NUMBER WASAB DATE DELIVERED ako535 a co. Ro & WO ae PART WO. 11015476 11015591 11015906 11024551 11024569 11030954 11035516 11036365 11037264 11038346 11038353 11040367 11046380 11049202 11049350 11050549 11050564 11050721 11050978 11055381 11055399 11056314 11056728 11058736 11063229 11063674 11063682 11063690 11063708 11063716 11064953 11063732 11063740 11063757 11063765 11063773 11063799 11063807 11086404 16019895 11065075 11065224, 11065083 11065091. 22002010 22003010 22004010 22004030 25201110 105 PARTS az PART WAME AD y™ PEP? Rey? FeoDD HI Bn= 7°59" yyy PR7°% Basa a-seey Bryy7? 997 RAN APRO IES Abe? yy7™ RAN KIG SpA 500» 599 RT 9RAT? Yh PHI YT 9D, B998 RAY AT™ 23> B27 9994 27? 79 pnb LEY" RRA AT RID" DAT ha BARRA y3 DYVRr RAH e WYENT 993.4) YYYR IT 793 (B) Ft ARS eoaby agk R497? BT oBAI ob RAB T 992 SOUR 99a DE-Fery by7° toh Rhyne eey 7°39 Ft74(P) seta (B) FETA (RX) FEA (PC) 7299" 7299" 7299 7299" FP 4ADaTe yyy At -v9ab Gu-i2 7ry-9 GHST2 HANMER Re PART NAHE SPRING ADAPTOR CAP CHECK VALVE RUBBER PLUG SEAL RING ADAPTOR DONUT RING ROLLER PIN DRAIN PLUG SYIVEL ADAPTOR STOPPER RING SWIVEL FLANGE SEAL RING PLUNGER PLUNGER BOTTOM PLATE PLUNGER BUSHING YASHER WAIN VALVE COLLAR LOCK YASHER TOP PLATE EXHAUST VALVE SPRING VALVE CASE SIDE BOLT CYLINDER CYLINDER SPACER CYLINDER BUSHING (a) CYLINDER BUSHING (B) CHISEL HOLDER PISTON HEAD CaP BOTTOH WUT HOLDER BUSHING ROUND BUSHING RETAINER PIW TOP NUT STOPPER PIN PLUG CHISEL (P) CHISEL (B) CHISEL (FX) CHISEL (PC) PLUG PLUG PLUG PLUG DISC SPRINGk0535 AS -9URb PARTS LIST WRB 105702 GH-12 97y-4 CODE NO. GH-12 HAMMER HF RRS ft ITEM PART NAHE ary 10 25302030 GREASE NIPPLE 5 107 25307070 ata 72499" SNAP RING 2 108 = 25307430 ad 7°99" SNAP RING 1 109 25401030 Oy 7* 0 RING 1 110 25401300 © ovy7~ 0 RING 4 111 25501010 t4nye™~% NYLON BALL. 1 112 2992120077792 BUSHING 2 11329999810 © -23.4RT ya SLIDE RING 3 114 35100828) m-5e%y ROLLER PIW 4 115 35372040 Nt a7 97? yy BACK UP RING 4 116 61100120 ov y7~ 0 RING 1 117 61100160 © Oya 0 RING 2 118 61100240 oyy97 0 RING i 119 61100280 ouy9> 0 RING 3 120 61100300 oyya* 0 RING i 121 61100650 OU y~ 0 RING 2 122 62100400 od 0 RING 2 123. 62100450 Oy ya~ 0 RING 1 124 62100600 Ov y9> 0 RING 4 128 62100850 ov y>~ 0 RING 3 126 = 62101850 Oy y9~ 0 RING it 127 62101950 v»9* 0 RING 1 128 © 62401600 uy” 0 RING il 129 64121400 IDI At oy IDI PACKING 5 130 64651400 DDI n° vy DDI PACKING i 131 67450160 A" 99727? yy9™ BACK UP RING A 132 67450300 ata 97 772 9D" BACK UP RING i 133° 67450650 N79 7¥ 972 yy7~ BACK UP RING 2 134 68251850 ata 97979 D9" BACK UP RING 10 135 68280400 ava ¥F 97° D7~ BACK UP RING 2) 136 © 68260850 ava 97772 yY9> BACK UP RING 3 137 68350450 AT a¥r 972 y Dye BACK UP RING 1 138 68351600 nt 297979 ID9™ BACK UP RING 1 139 74012025 497227439 CAP SCREW 12 140 74022050 © $4979 29929 CaP SCREV 3 141 74024060 $4972 A729 CAP SCREW 3 1 14225414080 23979 9-8 STEP SEAL0535 as ITEH ae PART NO. 11024569 11046380 25401030 25401300 25414080 29999810 35372040 61100120 61100160 61100240 61100260 61100300 61100650 62100400 62100450 62100600 82100850 62101850 62101950 62401600 64121400 64651400 87450160 67450300 67450650 68251850 68260400 68260850 68350450 68351600 PARTS. 1108311 & PART NAME HD Aya OyDy* Oye AFIT 9b ASAb YI D2IPATE IIe yyy? Oya oyyy™ Oya Oya oyyye aya yyy? anya Oya ouyy> ayy ayy IDI Ae 94y DIN? yey R997 7TVYI™ NADI ITED NIVITEMYDI® ADIT 97 YYI™ ADIPITEYDA™ DIIIIIT EY DT™ D79IPITVYII™ DPMPAT YI AT -YYRb LIST 2-999" SEALING ORT P ce SEAL RING SEAL RING NG 0 RING STEP SEAL SLIDE RING BACK UP RING RI RI RI RI RI RI RI RI RI RI RI NG N NG NG NG HG NG NG RING NG NG No RING IDI PACKING DDI PACKING BACK BACK BACK BACK BACK BACK Back BACK uP uP uP uP uP uP uP uP RING RING ok asi ai) onaCODE No. s870068 ITEM PARTSNO 2 50020107 2 50020208 3 50010452, 4 50010901 5 s0011409, 6 98701029 7 98700996 8 98700974 3 50016017 20 98701000 an 50026033 12 98700993 13 98701033 14 71020060 as 71920050 16 72020045 a 71930110 ae 71030150 is 71030070 20 76110130 2a 76330120 22 76330130 23 76430320 24 25113370 25 98701018 26 soo160aa 27 98700972 28 74016030 29 98701032 30 98701030 31 98701031 32 71016030 33 9aso0226 PARISLIST BRACKET CP GH-12 ENVIRO PARTSNAME, Nor (6) NUT (#) CUSHION RUBBER SPACER PLUG FRONT BOLT (1) SUPPORTER STOPPER GUIDE STOPPER SPACER BOTTOM BRACKET SPACER NUT PLATE NUT PLATE BOLT BOLT BOLT BOLT BO) BOLT NOT WASHER WASHER SPRING WASHER SCREW TOP SUPPORTER SPACER COVER CAP SCREW BOTTOM RUBBER COVER COVER BOLT LOCK WASHER ory