NPK GH Series Service Manual Download

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103

REPLACEMENT OF TIE RODS

After the hammer tie rods have been torqued, install grease fittings (

) as shown.

Grease until no more grease is accepted. Remove the grease fittings (

) and install

plugs (TT).

Summary of Contents for GH Series

Page 1: ...S GH06 GH3 GH07 GH4 GH1 GH6 GH2 GHS2 7550 Independence Drive Walton Hills OH 44146 5541 Phone 440 232 7900 Toll free 800 225 4379 Fax 440 232 6294 Copyright 2009 NPK Construction Equipment Inc www npkce com H055 9640A doc 03 09 Use Genuine NPK Parts ...

Page 2: ...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 pe...

Page 3: ...uring 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 NP...

Page 4: ...OCEDURE 28 NITROGEN GAS PRESSURE 29 GAS CHARGING KIT 29 CHECKING THE GAS PRESSURE 30 GAS CHARGING THE HAMMER 32 REMOVAL AND MOUNTING OF HYDRAULIC HAMMER 33 TOOLS REQUIRED FOR DISASSEMBLY 34 NPK START UP KIT 35 NPK ASSEMBLY LUBRICANT 36 DISASSEMBLY PROCEDURE 37 DISCHARGING GAS PRESSURE 38 DISASSEMBLING THE MAIN BODY 40 DISASSEMBLY OF MAIN VALVE 46 INSPECTION AND REPAIR AFTER DISASSEMBLY 48 REPAIR S...

Page 5: ...RT IDENTIFICATION 94 TOOL BUSHING REPLACEMENT 95 TOOL HOLDER BUSHING BORE REPAIR 98 TOOL HOLDER 101 REPLACEMENT OF TIE RODS 102 MAXIMUM ELONGATION OF TIE RODS 104 TORQUE CHART 105 TORQUE VALUES FOR HAMMER FASTENERS 106 MOUNTING PLATE 107 WARRANTY REGISTRATION FOR NEW UNITS 108 WARRANTY STATEMENT 109 STORAGE OF HYDRAULIC HAMMER 110 DECIMAL CONVERSION CHART 111 REBUILD SPECIFICATIONS CHECK SHEETS 11...

Page 6: ...mponent 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 th...

Page 7: ...tion 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 manor Read the NPK Hydraulic Hammer Operators Manual If additional safe...

Page 8: ...e and void Warranties Please consult NPK Engineering for specific detailed information CARRIER WEIGHT lbs kg HAMMER MOUNTING RECOMMENDED RANGE MODEL STYLE lb kg GH06 Excavator 2 200 4 400 1 000 2 000 Skid Steer 2 400 3 500 1 100 1 600 GH07 Excavator 2 800 5 500 1 300 2 500 Skid Steer 3 000 5 500 1 350 2 500 GH1 Excavator 5 400 9 000 2 450 4 100 Skid Steer 5 000 7 500 2 300 3 400 GH2 GHS2 Excavator...

Page 9: ...5 1650 115 2150 150 350 24 405 28 GH07 4 9 15 35 1500 105 2000 140 350 24 405 28 GH1 7 13 25 50 1750 120 2250 155 350 24 405 28 GH2 GHS2 7 17 25 65 2250 160 2750 190 350 24 405 28 GH3 12 26 45 100 1900 130 2400 165 350 24 405 28 GH4 13 32 50 120 2200 150 2700 185 375 26 435 30 GH6 24 40 90 150 2400 165 2900 200 390 27 450 31 Specifications are subject to change without notice NOTES 1 Hydraulic ope...

Page 10: ...NG PIN E RETAINING RING F UPPER TOOL BUSHING GH3 ONLY G LOWER TOOL BUSHING J 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 AA PLUNGER BUSHING BB PLUNGER DD SWIVEL ELBOW HH TOOL 30 GREASE FITTING ...

Page 11: ...NING RING F IMPACT BUSHING w UPPER TOOL BUSHING G LOWER TOOL BUSHING J SPACER SECTION 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 AA PLUNGER BUSHING BB PLUNGER DD SWIVEL ELBOW HH TOOL 30 GREASE FITTING ...

Page 12: ... 11 HAMMER SERIAL NUMBER LOCATION SERIAL NUMBER LOCATION sn1 ...

Page 13: ...n 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 up...

Page 14: ...lter HAMMER CONTROL VALVE NPK uses two general types of control systems depending upon 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 furnished in the NPK HYDRAULIC INSTALLATION KIT Special hydrau...

Page 15: ...m 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 hig...

Page 16: ...d 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 back pressure sensitive but restrictions cause unnecessary heating of the oil Also the pressure required to operate the hammer plus the restriction in the disconnects may push an older low pressure carrier machine to the limit of its hydraulic system This...

Page 17: ...e 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 32 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 s...

Page 18: ...p Pressure Hose m4 Whip Return Hose m7 Top Bracket m8 Hammer Bolt Package m9 Klik Pin TORQUES OF ALL BOLTS SHOWN ARE WITH THREADS BEING LUBRICATED WITH ANTI SEIZE COMPOUND HAMMER BRACKET ADAPTER BRACKET MODEL BOLT DIA TORQUE ft lb Nm BOLT DIA TORQUE ft lb Nm GH06 1 500 678 5 8 165 225 GH07 1 500 678 5 8 165 225 GH1 1 500 678 5 8 165 225 GH2 GHS2 1 500 678 5 8 165 225 GH3 1 1 4 1000 1356 5 8 165 22...

Page 19: ...g 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 Molybdenu...

Page 20: ...r 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 see page 90 The retaining pin must rotate freely 4 DEMOLITION TOOL Remove the demolition tool and inspect for peening caused by excessive blank...

Page 21: ...Figures 1 and 2 It will easily come out if pulled at an angle as shown in Figure 2 2 Screw an M12 bolt AF or cap screw into the retaining pin D as shown in Figure 3 1 Pull out retaining pin D If the retaining pin D is jammed use a hammer and drift from the opposite side Figure 1 Figure 2 Figure 3 ...

Page 22: ... 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 screwdriver press the rest of the ring into the groove see Figure 5 Figure 4 Figure 5 ...

Page 23: ... HYD Pressure Adjust or replace Hyd temperature too high over 180 F Oil Temperature Reduce throttle clean or add oil cooler Hydraulic pump volume too low Oil Flow Increase circuit flow Oil level of carrier too low Oil Level Add hydraulic oil Erratic running or stops running Defective pump or control valve HYD Pressure Repair or replace Shut off valve closed HYD Pressure Open valve Hoses reversed H...

Page 24: ...e Turn the pressure line shut off valve k4 to the off position Energize the hammer control circuit and note the relief valve setting The relief valve is only used for ultimate safety when the hammer is removed or the shut off valve is closed not to set the hammer operating pressure Therefore to prevent overheating loss of flow and reduced hammer frequency the relief pressure should be set a minimu...

Page 25: ...ow meter between the hammer pressure line and return as shown below Generally the pressure line is on the left and the return is on the right 2 Determine Return Line Pressure 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 ...

Page 26: ...oading 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 Pressu...

Page 27: ...eeve A Disassemble hammer and replace seals pr2 Leakage between tool and bushing Small leakage is normal here Seal in main body sleeve B Disassemble hammer and replace seals pr3 Leakage between main body and valve O ring between valve and body Loose bolts Replace Use thread adhesive tighten pr4 Leakage between valve body and valve top cap O ring under valve cap Loose bolts Replace Tighten pr5 Leak...

Page 28: ...MEDY pr1 Leakage through vent plug Seal in main body sleeve A Disassemble hammer and replace seals pr9 Leakage from top of charge valve O ring in check valve Damaged check valve in charge valve Replace Replace pr10 Leakage between charge valve and head O ring in charge valve Loose charge valve Replace Use thread adhesive tighten pr11 Leakage between head and main body O ring in head Disassemble ha...

Page 29: ...e 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 MODEL PRE CHARGE AT LOAD PRE CHARGE AT LOAD Cold Cold Cold Cold Hot Hot Hot Hot psi bar psi bar psi bar psi bar GH06 350 24 385 26 5 405 28 450 31 GH07 350 24 385 26 5 405 28 450 31 GH1 350 24 400 27 5 405 28 465 32 GH2 GHS2 350 24 400...

Page 30: ...xceeding 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 MODEL AT AMBIENT TEMPERATURE cold before operating psi bar plus 0 minus 25 AT OPERATING TEMPERATURE psi bar plus 0 minus 25 GH06 350 24 405 28 GH07 350 24 405 28 GH1 350 24 405 28 GH2 GHS2 3...

Page 31: ...ammer with the tool fully extended THE HAMMER MUST NOT BE RESTING ON THE POINT 2 Remove the charge valve cap M1 3 Turn the NPK charging adapter T handle g2 full counterclockwise 4 MODELS GH06 GH07 GH1 GH2 GHS2 Remove plug g12 Install adapter g13 part no 30604100 into the female port on the gas head Install NPK charging adapter g1 4 MODELS GH3 GH4 and GH6 Only Install the NPK charging adapter g1 on...

Page 32: ...gauge pressure with the NITROGEN GAS PRESSURE CHART see page 29 If the gas pressure is 25 psi 2 bar or more below specification proceed to NITROGEN GAS CHARGING PROCEDURE If the pressure is correct go to the next step 8 Turn the T handle g2 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 ...

Page 33: ...adapter g1 clockwise 6 Turn the handle g7 on the tank regulator counterclockwise to fully close 7 Open the valve g10 on the nitrogen tank by turning the T handle counterclockwise 8 Slowly adjust the regulator on the nitrogen tank to the correct pressure by turning clockwise See NITROGEN GAS PRESSURE CHART or decal g11 on hammer 9 Charge nitrogen gas until the pressure gauge g8 on the charge adapte...

Page 34: ...ck pin m1 and link pin m2 The hydraulic lines must be handled carefully and sealed to prevent contamination from entering the hammer or the carrier hydraulic system 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 1 Place the hammer horizontal on wood blocks t20 as shown 2 Align the boom pin ...

Page 35: ...EX KEY SOCKETS When repairing NPK 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 disassembly Use with a hex key wrench t25 modified into a straight key by cutting 40 off the short end of the wrench as shown HEX SOCKET SIZE NPK PART NO 14mm 35004590 17mm 35004600 19mm 35004610 HOIST The minimum hoist capacit...

Page 36: ... 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 Plugs and Caps Manuals and Warranty Information ...

Page 37: ...mally 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...

Page 38: ...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 ...

Page 39: ...in the gas head that is different from all other NPK hydraulic hammers After removing the existing plug g12 the adapter g13 part no 30604100 is threaded onto the existing GH06 GH07 GH1 and GH2 GHS2 gas charge fitting This adapter is included in the gas charge kit that is provided with the hammer and allows use of the standard NPK gas charge valve g1 part no 30604040 4 Install the NPK charging adap...

Page 40: ...e is encountered By turning the T handle g2 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 Loosen the charge adapter cap g6 VERY SLOWLY The gas pressure will gradually decrease to zero then REMOVE THE CAP 8 Remove the charge adapter g1 from the hammer 9 Remove NPK adapter part no 30604100 10...

Page 41: ... that the nitrogen gas has been completely discharged 1 Remove the top nuts Loosen the pair A and D or B and C first Then loosen the remaining pair uniformly until the spacer spring tension is relieved 2 Remove the nuts 3 Remove the lockwashers U ...

Page 42: ... levers Care should be exercised so as not to apply undue force Remove the gas head from the tie rods When the gas head is removed hydraulic oil will flow out of the body bore Therefore have oil pans ready b Remove the spring washers AG 5 Sling t27 or hook t28 the tool holder C The tool holder must be kept level and square to the main body ...

Page 43: ...f the tie rods Q are still tight re position the tool holder to remove the bind on the tie rods Q Loosen all four of the tie rods Q before removing any of them 6 Pull out the tie rods Q 7 Hoist the tool holder by a crane to remove it from the main body 8 Remove the spacer section J Hoist the spacer section J by a sling t27 to remove it from the main body ...

Page 44: ...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 sleeves move Direct the port of the swivel adapter downward b To prevent damage to the body bore support A sleeve O with a sling t27 as it comes out c Do not use a steel bar to drive out sleeves Use a nylon strap t27 to support the piston and sleeves as they are removed from the body...

Page 45: ...g chain through tie rod holes and wrap around back of portable power unit NPK part no T000 1031 e Push piston and sleeves from the tool end of body and out gas end 2 MODELS GH06 GH3 HAVE NO A SLEEVE 1 GH06 through GH3 Tap the B sleeve P and the piston N out of the hammer body A towards the tool end 1 using a nylon bar or a dead blow hammer handle t2 as shown ...

Page 46: ...30 on a table t31 Do not use steel bar to drive apart sleeves h Separate A sleeve O from the piston N by tapping the sleeve with a dead blow hammer t2 When removing the sleeves and piston as a unit the point of balance will be on the B sleeve P near where the A sleeve O joins it 11 Remove the piston N from the B sleeve P Separate the piston N from the B sleeve P by rapping the striking end of the ...

Page 47: ...crewdriver t22 or pry bar to remove cap Y Do not force the bottom cap Y when removing it otherwise the valve body W will be damaged causing oil leaks 2 Remove the plunger bushing AA a Remove cap screws from the plunger bushing AA with a hex wrench 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 the valve spool Z out of the case with a hamm...

Page 48: ... cap screws OO from the swivel flanges EE and then remove the swivel flanges EE f Remove the main valve body It is rarely necessary to remove the valve body from the main body If disassembly is needed for any reason proceed as follows Attach a 6 ft 2 meter long extension pipe to the hex wrench and with it loosen each bolt There is thread adhesive on each bolt Use heat on the head of any bolt that ...

Page 49: ... replace if necessary b A and B sleeves Check the inner surface for damage and repair or replace if necessary Complete hammer check sheets and fax to NPK for advice on reuse of main components 3 Tool and Tool Bushing Wear See pages 84 and 85 of this manual Maximum Tool to Tool Bushing Clearance 4 General a Check for damage breakage deformation wear and rust and repair or replace if necessary b Che...

Page 50: ...R 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 prob...

Page 51: ... 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 t7 25026050 POLISHING WHEEL used for cleaning seal grooves in sleeves Green t8 25026030 POLISHING WHEEL used for final polishing of piston sleeves and main body bore Gray t9 25026020 GRINDING WHEEL used to grind weld Red t10 T050 7500 ...

Page 52: ...NG OF PISTON MAIN BODY AND GLAND RING AREA OF NPK A AND B SLEEVES t9 25026020 GRINDING STONE RED USE THIS STONE FOR GRINDING WELD IN HAMMER MAIN BODY t10 T050 7500 CUT OFF WHEEL USE CUT OFF WHEEL TO CLEAN AND REPAIR 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 DE...

Page 53: ...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 us...

Page 54: ...ed 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 clea...

Page 55: ...aken 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...

Page 56: ... EDGES OF THE ENTIRE LENGTH OF THE SCRATCH t8 POLISHING WHEEL GRAY POLISH SCRATCHES IN THE O RING AREAS 9 TO A SMOOTH SURFACE BLEND THIS AREA TO THE SURROUNDING SURFACE DO NOT OVER POLISH CHECK BORE DIMENSION WITH A BORE GAUGE t11 COMPARE WITH SPECIFICATIONS SHOWN IN CHART ON PAGE 61 ...

Page 57: ...g 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 ...

Page 58: ...loration 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...

Page 59: ...l 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 BAL...

Page 60: ...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 ...

Page 61: ...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 61 If dimensions ar...

Page 62: ...3 555 90 30 18 12 460 3 4 T050 7600 3 543 90 00 18 11 460 0 GH2 GHS2 3 939 100 04 3 949 100 30 18 52 470 3 4 T050 7600 3 937 100 00 18 50 470 0 GH3 4 529 115 04 4 539 115 30 20 49 520 5 4 1 2 T050 7605 4 528 115 00 20 47 520 0 GH4 4 923 125 04 4 933 125 30 24 82 630 5 6 T050 7610 4 921 125 00 24 80 630 0 GH6 5 907 150 04 5 917 150 30 27 58 700 5 6 T050 7610 5 905 150 00 27 56 700 0 NOTE Body bore ...

Page 63: ... 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 MODEL d8 in mm d9 in mm d10 in mm d11 in mm GH06 1 14 29 1 18 30 4 17 106 4 17 106 GH07 1 18 30 1 22 31 4 17 106 4 17...

Page 64: ...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 800 225 4379 for recommendations on parts rep...

Page 65: ...H2 GHS2 16 406 15 70 398 GH3 17 90 454 17 50 444 GH4 21 40 544 21 00 534 GH6 23 50 598 23 10 588 MAIN BODY SLEEVES 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 rep...

Page 66: ...RR O RING SS BACKUP RING 1 TOOL END 2 GAS END NOTE GHS2 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 DEFECTIVE SEALS ALL DEFECTIVE SEALS SHOULD BE REPLACED WITH NEW ONES 41 O RINGS DEFORMED WORN WARPED DAMAGED OR DETERIORATED 42 BACKUP RINGS WORN OR DEFORMED 43 U CUP SEALS W...

Page 67: ...e 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 back up rings as shown below and install c ...

Page 68: ... other The sleeve should move smoothly without binding 3 Install B sleeve a Apply hydraulic oil on the seals and install them in B sleeve P b Apply hydraulic oil or NPK assembly lube to the bore of the main body c Push B sleeve P into the main body A bore from the gas head end with pressure port 6 and tank port 5 facing upward Insert the sleeve using a sling t27 until the seals reach the body bore...

Page 69: ...l pins K Apply a small amount of grease on the two dowel pins and install them in B sleeve P The grease holds the pins in place 6 Install A sleeve O a Install the seals in A sleeve O b Apply hydraulic oil on the inner surface of the sleeve c Align the dowel pin holes with the dowel pins in B sleeve P and insert A sleeve O d Push A sleeve O over the piston until it contacts B sleeve P and traps the...

Page 70: ...t4 to diagonally opposite tie rod holes 44 in main body A at tool end 1 String chain t4 through tie rod holes and wrap around back of portable power RAM cylinder t5 Support the end of the B sleeve P with a sling t27 and insert into the gas end of the main body A Bump with a dead blow hammer t2 Align ports with main body A Push B sleeve into body from gas end of body 1 with portable power unit t33 ...

Page 71: ...P from going any further at this point 4 Install the piston N 5 Install A sleeve O Carefully insert the piston N into B sleeve from the gas end of the main body Apply lubricating oil or NPK assembly lube to inside and outside diameters of A sleeve O Align dowel pin holes and install A sleeve O onto piston N flush with B sleeve P a MODELS GH06 GH3 Tap the B sleeve P and the piston N into the hammer...

Page 72: ...he dimensions in the chart on page 72 to locate final position Take care to watch o rings and back up rings on the sleeves as they enter the bore 7 Make sure B sleeve is in proper position See chart below for installation dimensions of correctly installed sleeves A MAIN BODY O MAIN BODY A SLEEVE P MAIN BODY B SLEEVE 5 OUT PORT 6 IN PORT ...

Page 73: ...eves must be bumped back out of the bore until A sleeve O comes clear The problem can then be identified and corrected MODELS GH06 GH3 A MAIN BODY P MAIN BODY B SLEEVE d1 DIMENSION END GAP BOTTOM 1 TOOL END 2 GAS END 5 OUT PORT TANK 6 IN PORT PRESSURE MODELS GH4 GH6 A MAIN BODY O MAIN BODY A SLEEVE P MAIN BODY B SLEEVE d1 DIMENSION END GAP BOTTOM d2 DIMENSION END GAP TOP 1 TOOL END 2 GAS END 5 OUT...

Page 74: ...RTV Silicone 10 Install the spacer section J Align the dowel pins on the B sleeve with dowel pin holes in the spacer section J Make sure grease passages are aligned 11 Make sure the spacer section J is snug to the body If the spacer section J is not square to the body it is because the sleeves are slightly rotated out of position Take a dead blow hammer t2 and rap sharply on the high corner of the...

Page 75: ...ist the tool holder by a crane t34 using slings or a hammer hook t28 and install it onto the spacer section with the retaining pin plug I facing upward as shown d Install tie rods Q into the body from gas head end using a hand wrench t6 The tool holder must be level and square to the main body Do not use an air wrench to thread the tie rods into the bottom nuts ATTENTION ...

Page 76: ...older C 13 Install the spring washers AG Apply a thin coat of grease 28 on the spring washers and install them with the gap at edge as shown below a Pour specified amount of synthetic oil in past A sleeve Any viscosity synthetic motor oil is acceptable OIL CAPACITY MODEL CAPACITY OUNCE cc GH06 1 5 40 GH07 1 5 40 GH1 1 75 50 GH2 GHS2 3 5 100 GH3 3 5 100 GH4 3 5 100 GH6 5 150 NOTE SPRING WASHERS ARE...

Page 77: ... of the o ring before installing it on the gas head Be careful pushing the gas head into position so as not to disturb the spring washers 14 Install the gas head L and lock washers U a Install the lock washers U onto tie rods Q b Apply anti seize compound on the lock washer faces and tie rod threads ATTENTION ...

Page 78: ...ghtened fully by hand the setting may be regarded as normal If the gap d3 is larger than the mentioned dimension this suggests that the spring washers have fallen out of position 16 Tighten all TOP NUTS with a TORQUE WRENCH to recommended torque specification shown in CHART 1 see page 105 It may take several passes at each top nut to achieve this Check that no gap d3 is noted between the sections ...

Page 79: ...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 17 3 Install the valve body W a Install the valve body W on the main body b De grease the bolts and tapped holes in the main body c Apply adhesive on the bolts and tighten them to the specified torque see page 106 17 4 Install the bottom cap Y a Apply a thin coat of greas...

Page 80: ... Apply hydraulic oil or NPK assembly lube to the surface of the valve spool Z Then insert the valve spool Z from the top side into valve body W Make sure that the valve spool Z moves smoothly 17 6 Install the plunger BB and the plunger bushing AA a Apply a thin coat of grease on the o rings RR and back up rings SS and install them on the plunger bushing AA Curl the back up ring SS to form a small ...

Page 81: ... into the plunger bore of the plunger bushing AA Then insert the plunger BB into the plunger bushing AA c Insert the plunger bushing in the valve body with the plunger operation pilot hole upward 8 d Tap carefully with dead blow hammer e Tighten the bolts to the specified torque see page 106 ...

Page 82: ...he valve body b Tighten the bolts to the specified torque see page 106 c Apply grease to the o rings and the back up rings Install them in the swivel elbow DD Install the seal rings AI the swivel elbow DD and stop ring AH on the swivel flange d Using snap ring pliers install the snap ring AJ on the swivel flange EE The JIC fitting on the swivel adapter is off set to clear the swivel flange bolts ...

Page 83: ... gas pressure See Gas Charging the Hammer pages 29 through 32 b Check for gas leaks See Gas Leakage page 27 20 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 Remove the grease fittings and install the existing plugs TT 21 Install the hammer into the hammer bracket ...

Page 84: ... for GH6 Concrete breaking Highway construction General demolition ACCESSORY TOOLS SPECIALTY TOOL SHAPE APPLICATIONS FROST CUTTER Cross cut SX In Line SY for GH07 thru GH4 Edge of trenching Frost cutting ADAPTER TOOL for GH07 thru GH4 For attachments listed below TAMPER PLATE use with adapter tool 9 1 2 x 9 1 2 for GH07 12 x 12 for GH1 thru GH2 GHS2 16 x 16 for GH3 thru GH4 Soil compaction Driving...

Page 85: ...eps MODEL MAXIMUM CLEARANCE INCH mm GH06 1 4 6 5 GH07 1 4 6 5 GH1 1 4 6 5 GH2 GHS2 1 4 6 5 GH3 1 4 6 5 GH4 1 4 6 5 GH6 3 8 10 Step 2 Remove the tool from the tool holder Measure the diameter d16 of the bearing surface of the tool which is located on each side of the retaining pin groove The minimum tool diameter is compared to a new tool bushing only If the tool is at or below the charted value th...

Page 86: ... DIAMETER INCH mm MAXIMUM BUSHING INSIDE DIAMETER INCH mm GH06 1 67 42 4 1 87 47 4 GH07 1 87 47 4 2 07 52 6 GH1 2 26 57 4 2 46 62 6 GH2 GHS2 2 61 66 4 2 82 71 6 GH3 3 01 76 4 3 21 81 6 GH4 3 40 86 4 3 61 91 6 GH6 4 19 106 4 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 v...

Page 87: ... operate to its designed specifications Do not weld repair the impact bushing IMPACT RING INSIDE DIA NEW PISTON END d77 IMPACT RING INSIDE DIA MAX PISTON END d78 IMPACT RING INDENT NEW d79 IMPACT RING INDENT MAX d80 IMPACT RING INSIDE DIA NEW TOOL END d81 IMPACT RING INSIDE DIA MAX TOOL END d82 HAMMER MODEL in mm in mm in mm in mm in mm in mm GH06 1 26 32 1 46 37 0 0 0 2 5 1 65 42 1 85 47 GH07 1 4...

Page 88: ...to remove from the tool holder Dress with a grinder 2 Excessive blank hammering will cause chipping 16 in the retaining pin contact area 15 If neglected the chipping may reduce the life of the tool Dress with a grinder 3 If chipping 16 is found at the top of the tool replace the tool If neglected the piston impact surface will be damaged AM is normal AL needs to be replaced ...

Page 89: ...w DO NOT hardface or sharpen the tool point with a cutting torch Resharpen only with a lathe or milling machine using sufficient coolant MODEL d21 INCH MM d16 REF INCH MM GH06 25 6 4 1 57 40 GH07 25 6 4 1 77 45 GH1 38 9 7 2 17 55 GH2 GHS2 38 9 7 2 52 64 GH3 38 9 7 2 91 74 GH4 50 12 7 3 31 84 GH6 50 12 7 4 09 104 ...

Page 90: ... d16 NEW TOOL LENGTH d23 NEW WORKING LENGTH d22 MODEL INCH MM INCH MM INCH MM GH06 1 63 41 4 19 3 490 12 2 311 GH07 1 83 46 6 20 7 527 13 1 333 GH1 2 23 56 6 23 6 599 13 6 346 GH2 GHS2 2 58 65 6 25 5 648 14 4 367 GH3 2 98 75 6 28 5 725 16 1 408 GH4 3 37 85 6 33 0 838 18 458 GH6 4 16 105 6 38 0 966 19 7 500 NOTE Minimum tool length is determined by the depth of material penetration that is required...

Page 91: ...ation 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 HAMMER MODELS GH06 GH07 GH1 GH2 GHS2 GH3 GH4 GH6 ...

Page 92: ...ou 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 operato...

Page 93: ... M EP 2 Dryden Oil Company Moly EP 2 Exxon Ronex Extra Duty Moly NLGI 2 Fiske Brothers Refining Co Lubriplate MO LITH No 2 John Deere TY6333 TY6341 Moly High Temp Kendall L 424 Mobil Moly 372 Muscle Products Corporation MPC PL 10 Powerlift Grease LP 10 Lithium EP Plus NPK Universal Plus Lithium EP Grease Super Duty EP Grease water resistant Chisel Paste Pennzoil Adhezolith EP 2 Grease Phillips 66 ...

Page 94: ... G000 1010 120 LB KEG G000 1020 35 LB PAIL G000 1030 400 LB DRUM G000 1040 SUPER DUTY 500 deg NPK PART NO 14 OZ CARTRIDGE G000 1011 120 LB KEG G000 1021 35 LB PAIL G000 1031 400 LB DRUM G000 1041 CHISEL PASTE 2000 deg NPK PART NO 14 OZ CARTRIDGE G000 1050 AUTOLUBE SYSTEMS An automatic greasing system is recommended to reduce hammer tool and tool bushing wear The NPK AUTOLUBE System is designed to ...

Page 95: ...acer section J below the main valve for use in adapting for AUTOLUBE and underwater use The air port 17 on the left will allow the connection of an airline that will allow the hammer to be used underwater The grease port 18 located inline with the air port on the right will allow for AUTOLUBE connection ...

Page 96: ...er and lower tool bushings can be cut out with carbon arc t12 or oxygen and acetylene t13 Start cutting in areas 1 and 2 away from the bushing retaining pin bore 19 first and then go to areas 3 and 4 Care should be given not to damage the bushing retaining pin bore 19 Use either carbon arc t12 or cutting torch t13 to cut bushing G Exercise care when cutting to avoid damaging the tool holder If the...

Page 97: ...USHING REPLACEMENT HYDRAULIC PRESS METHOD All tool bushings may be removed with a hydraulic press Weld a steel plate UU to the bushing and press out as shown HYDRAULIC PRESS REQUIREMENT 100 ton minimum All Models ...

Page 98: ...rt HYDRAULIC PRESS REQUIREMENT 100 ton minimum All Models LIQUID NITROGEN METHOD Clean the bore of the tool holder The surface must have no sharp edges or high spots Grind smooth if necessary Wear protective clothing a safety face shield and heavy gloves Fill an adequately sized steel or heavy plastic bucket with liquid nitrogen Attach two pair of vise grip type pliers to the tool bushing Fully su...

Page 99: ...e to Dimension d24 DIMENSION d24 MODEL INCH MM GH06 2 73 69 4 GH07 2 94 74 7 GH1 3 84 97 5 GH2 GHS2 4 06 103 0 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 MODEL DIMENSION d26 INCH MM GH06 2 36 60 GH07 2 56 65 GH1 3 43 87 GH2 GHS2 3 70 94 Cronatron Cronalloy 7940 Eutectic 30...

Page 100: ...03 3 819 97 00 GH3 4 214 107 03 4 213 107 00 GH4 4 607 117 03 4 606 117 00 GH6 5 710 145 04 5 709 145 00 4 Dimension d27 is the diameter of the 25 6 mm undercut at the bottom of the bushing bore MODEL DIMENSION d27 INCH MM GH06 2 65 67 2 2 64 67 0 GH07 2 84 72 2 2 84 72 0 GH1 3 59 91 2 3 58 91 0 GH2 GHS2 3 98 101 1 3 97 100 9 GH3 4 38 111 2 4 37 111 0 GH4 4 77 121 2 4 76 121 0 GH6 5 87 149 2 5 87 ...

Page 101: ...ension 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 MODEL DIMENSION d28 INCH MM GH06 95 24 1 94 23 9 GH07 1 11 28 1 1 10 27 9 GH1 1 19 30 1 1 18 29 9 GH2 GHS2 1 19 30 1 1 18 29 9 GH3 1 19 30 1 1 18 29 9 GH4 1 19 30 1 1 18 29 9 GH6 1 66 42 1 1 65 41 9 ...

Page 102: ...er 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 Pre heat the tool holder weld area to 350 F and maintain this temperature du...

Page 103: ... 2 Remove the tie rod to be replaced 3 Discharge the gas pressure Refer to the DISCHARGING THE GAS PRESSURE section of the manual 4 Loosen the three remaining tie rod top nuts until they are just hand tight Do not loosen the top nuts R too far as oil maybe lost from the gas head 5 Apply Anti Seize compound on the bottom threads of the new tie rod Assemble into the hammer and thread into the bottom...

Page 104: ... 103 REPLACEMENT OF TIE RODS After the hammer tie rods have been torqued install grease fittings 30 as shown Grease until no more grease is accepted Remove the grease fittings 30 and install plugs TT ...

Page 105: ...h 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 NEW LENGTH d29 MAXIMUM LENGTH d30 MODEL INCH MM INCH MM GH06 22 72 577 23 03 585 GH07 22 72 577 23 03 585 GH1 25 71 653 26 02 661 GH2 GHS2 27 95 710 28 27 718 GH3 30 12 765 30 43 773 GH4 36 81 935 37 13 943 GH6 43 90 1115 44 21 1123 ...

Page 106: ...hieve this Check that no gap is noted between the sections Chart 1 Socket Size MODEL Torque Ft lbs Nm in mm GH06 150 200 1 1 16 27 GH07 150 200 1 1 16 27 GH1 185 250 1 1 4 32 GH2 GHS2 295 400 1 7 16 36 GH3 370 500 1 5 8 41 GH4 480 650 1 13 16 46 GH6 850 1150 2 1 2 63 Sweeney 503 Anti seize recommended If you have any questions call the NPK Service Department at 800 225 4379 ...

Page 107: ...0 150 M10 65 85 N A N A GH1 M12 110 150 M10 65 85 N A N A GH2 GHS2 M12 110 150 M12 110 150 N A N A GH3 M16 270 365 M16 270 365 M8 30 40 GH4 M18 370 500 M16 270 365 M8 30 40 GH6 M20 525 710 M18 370 500 M12 110 150 NOTE TORQUES OF ALL BOLTS SHOWN ARE WITH THREADS BEING LUBRICATED HEX SOCKET SIZE BOLT DIAMETER SOCKET HEAD CAP SCREW M10 8mm M12 10mm M14 12mm M16 14mm M18 14mm HAMMER BRACKET ADAPTER BR...

Page 108: ... 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 s...

Page 109: ...Using your user name and password log into the system At the left of the next page click on REGISTRATION Complete the fields with an orange diamond next to them At the bottom of this area click the START REGISTRATION box and continue If the registration is completed online there is no need to mail or fax the warranty registration End users non NPK dealers In the tool bar click on DEALERS You do NO...

Page 110: ... 109 WARRANTY STATEMENT ...

Page 111: ... 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 nitrogen gas be discharged through the gas charge valve M The tool HH should be removed and the piston not shown pushed all the way in Be sure the hydraulic hoses AO are plugged and grease the exposed end of the piston N Cover with a waterproof tarp t21 not sho...

Page 112: ...2 625 9 14 141 41 64 641 5 16 156 21 66 656 11 17 172 43 67 672 3 16 19 188 11 16 69 688 13 20 203 45 70 703 7 22 219 23 72 719 15 23 234 47 73 734 1 4 25 250 3 4 75 750 17 27 266 49 77 766 9 28 281 25 78 781 19 30 297 51 80 797 5 16 31 312 13 16 81 812 21 33 328 53 83 828 11 34 344 27 84 844 23 36 359 55 86 859 3 8 38 375 7 8 88 875 25 39 391 57 89 891 13 41 406 29 91 906 27 42 422 59 92 922 7 16...

Page 113: ...ASURE 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 ...

Page 114: ...__________ NPK HAMMER MODEL______________ SERIAL NO ______________________ MAIN BODY GH06 GH3 GH4 GH6 REFERENCE 1 TOOL END 2 GAS END DIAMETER LENGTH d5a d5b d5c d7 Dimensions to 0 000 inch 0 00 mm COMMENTS ______________________________________________________________________ ______________________________________________________________________ ____________________________________________________...

Page 115: ...ns to 0 00 inch 0 0 mm COMMENTS ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ...

Page 116: ...___ I D d41 Dimensions to 0 00 inch 0 0 mm COMMENTS ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ 50 STAMPING ___________________ ___________________ ____________...

Page 117: ... d10 d13 Dimensions to 0 000 inch 0 00 mm COMMENTS ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ...

Page 118: ... GH3 d42 GH4 GH6 Dimensions to 0 000 inch 0 00 mm COMMENTS ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ...

Page 119: ...inch 0 00 mm COMMENTS ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ FAX ALL SHEETS TO THE NPK SERVICE DEPARTMENT 440 232 6294 ...

Page 120: ...__ SERIAL NUMBER_______________________ NPK INSTALLATION KIT NUMBER ________________________________ CARRIER MANUFACTURER MODEL NUMBER SERIES SERIAL NUMBER DATE OF INSTALLATION _________________ DATE OF 20 HOUR INSPECTION ______________ WARRANTY REGISTRATION SENT SERVICE RECORD ...

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NPK GH Series, Service Manual

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