NPK NPH-3500, Instruction Manual

Page 1: ...NPH 3500 NPH 4500L Use Genuine NPK Parts Copyright 2020 NPK Construction Equipment Inc www npkce com H000 9620 NPH3500 NPH4500L Pneumatic Hammer Instr Manual 8 20 7550 Independence Drive Walton Hills OH 44146 5541 Phone 440 232 7900 Fax 440 232 6294 ...

Page 2: ...IPLE OF OPERATION 10 INSTALLATION 15 OPERATION 16 LUBRICATION 16 CLEANING THE AIR HOSE 16 OPERATING PROCEDURE 17 AUTOMATIC SHUT OFF 19 LUBRICATION 20 NPK HAMMER GREASE 20 LUBRICANT TERMS AND DEFINITIONS 21 INSPECTION AND MAINTENANCE 23 STORAGE OF PNEUMATIC HAMMER 24 DISASSEMBLY PROCEDURE 26 INSPECTION PROCEDURE 29 INSPECTION 29 REASSEMBLY PROCEDURE 30 TROUBLESHOOTING 32 WARRANTY REGISTRATION FOR N...

Page 3: ...n the cab visible to the operator while operating the hammer STAY CLEAR and TOOL SHARPENING decals are installed on all NPK hammer models Keep them clean and visible NPK will provide decals free of charge as needed 1 Operator and Service personnel must read and understand the NPK INSTRUCTION MANUAL to prevent serious or fatal injury 2 FLYING DEBRIS CAN CAUSE SERIOUS OR FATAL INJURY Keep personnel ...

Page 4: ... the HAMMER without authorization from NPK Engineering 11 Use only genuine NPK replacement parts NPK specifically disclaims any responsibility for any damage or injury that results from the use of any tool or parts not sold or approved by NPK 12 All air line components must be rated 150 greater than maximum system pressure 13 Never attempt to do any maintenance work on the compressor while it is r...

Page 5: ...lures 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 Important It is imperative that grease is maintained in the tool bushing contact area at all times This may require hourly greasing depending on job conditions Important The hammer must be in a vertical positio...

Page 6: ...mer continuously in the same position for more than 30 seconds Do not use the hammer to move material pry material or as a pick on material Do not use the hammer underwater Operate the hammer carefully Do not hit the boom of the carrier with the hammer Operate the hammer in a safe manner ...

Page 7: ...achine Verify carrier stability with hammer before transport or operation Mounting a PNEUMATIC HAMMER that is too small for the carrier machine can damage the PNEUMATIC HAMMER cause tool breakage and void Warranties Please consult NPK Engineering for specific detailed information CARRIER WEIGHT lbs kg HAMMER MOUNTING RECOMMENDED RANGE MODEL STYLE lbs kg NPH 3500 EXCAVATOR 12 000 18 000 5 500 8 200...

Page 8: ...16 7 87 200 55 25 47 3 1202 NPH 4500L 500 5 1 130 9 65 245 66 30 54 8 1392 HAMMER NET WEIGHT MAX AIR AIR HOSE MODEL WITH TOOL CONSUMPTION PRESSURE DIAMETER lbs kg cfm m3 min psi bar in mm NPH 3500 537 260 177 5 9 1 1 25 NPH 4500L 1070 485 254 7 9 1 2 38 Specifications subject to change without notice Working weights may vary with bracket configuration ...

Page 9: ...ER CF FITTING ELBOW D RETAINING PIN F UPPER BUSHING HH TOOL J IMPACT RING N PISTON PB60 FILTER ELEMENT ph11 INLET BUSHING ph3 VALVE ph4 VALVE CAP UPPER ph5 VALVE CAP LOWER ph6 COTTER PIN ph7 HEAD Q TIE ROD R NUT TOP S LOCK PLATE TT RUBBER PLUG U WASHER U1 ASSISTANT COLLAR V NUT BOTTOM ...

Page 10: ... 9 HAMMER SERIAL NUMBER LOCATION SERIAL NUMBER LOCATION sn1 ...

Page 11: ...CIPLE OF OPERATION 1 PISTON UP The compressed air from the inlet port flows through the head chamber 2 through port 1 It reaches the lower chamber 9 through ports 3 4 5 6 7 and 8 which makes the piston N go up ...

Page 12: ...PRINCIPLE OF OPERATION 2 PISTON UP VALVE UP After the piston N opens up port 10 the compressed air of the lower chamber 9 goes into valve s lower chamber 13 through ports 11 and 12 so the valve ph3 goes up ...

Page 13: ... 12 PRINCIPLE OF OPERATION 3 PISTON UP VALVE UP The piston N and valve ph3 go up when the piston opens lower chamber to exhaust port 14 Compressed air exhausts to the outside through port 14 ...

Page 14: ...RINCIPLE OF OPERATION 4 PISTON DOWN The compressed air of the lower chamber exhaust and compressed air is supplied to the upper chamber of the piston N through ports 3 4 5 and 15 so that the piston goes down ...

Page 15: ...er the piston goes down it opens the upper chamber to port 17 Compressed air of the upper chamber is supplied to the valve upper chamber 21 through ports 18 19 and 20 so the valve goes down Before the valve goes down completely the piston N hits the tool HH ...

Page 16: ... 15 INSTALLATION bs10 CONTROL VALVE ds60 LINE UNIT g14 PINS HH TOOL KK HAMMER LL BRACKET ph10 AIR HOSE ph12 COMPRESSOR ph9 EXHAUST PORT ...

Page 17: ...the body of the unit Oil will not flow if the numbers are not properly aligned with the arrow When refilling the line unit the oil valve must be set to position 0 Stop Failure to do so will allow compressed air to blow out the fill port When the oil level drops to the red mark arrow indicates red line in drawing refill oil immediately Use the recommended oil SAE 5W ISO 22 Grade or equivalent oil i...

Page 18: ...e tool on the material and apply down force to the hammer b Operate the hammer with tool in solid contact with the material c Shut off hammer immediately after breaking material DOWN FORCE OPERATE STOP DO NOT USE THE HAMMER TOOL AS A PRY BAR ...

Page 19: ... 18 OPERATION OPERATING PROCEDURE DO NOT USE THE HAMMER AS A HOIST ...

Page 20: ... a unique internal cushioning arrangement which absorbs energy released when blank hammering occurs The exhaust port allows air to exit the main body which ensures the hammer from any damage caused by blank hammering AH6 AIR CUSHION AH7 EXHAUST HH TOOL ...

Page 21: ...um complex soap base with 12 graphite and copper additives for extreme operating conditions UNIVERSAL PLUS 350 deg NPK PART NUMBER 14 oz 397 kg CARTRIDGE G000 1010 120 lb 54 kg KEG G000 1020 35 lb 16 kg PAIL G000 1030 400 lb 181 kg DRUM G000 1040 SUPER DUTY 500 deg NPK PART NUMBER 14 oz 397 kg CARTRIDGE G000 1011 120 lb 54 kg KEG G000 1021 35 lb 16 kg PAIL G000 1031 400 lb 181 kg DRUM G000 1041 CH...

Page 22: ...molecules to cling together It is the ability of those molecules to resist separation under pressure between two metals and to hold these metal surfaces apart FRICTION The resistance to fluid flow in a hydraulic system An energy loss in terms of power output GALLING Surface damage on mating moving metal parts due to friction A severe form of adhesive wear LUBRICATION Use of a substance grease oil ...

Page 23: ...eeping a supply of working fluid in a hydraulic system VIBRATION A quivering or trembling motion VISCOSITY Is the actual SAE weight of the product Example motor oils come in 10 20 30 40 50 and 15 40 SAE weight The viscosity designation of a lubricant indicates its internal resistance to flow ...

Page 24: ...tb3 Corner loading due to excessive wear of the tool bushings tb4 Bending overload from excessive prying or slant hammering tb5 Deformation from overheating by hammering in the same position for over 30 seconds tb6 Chipped due to wrong application or overheating by hammering in the same position for over 30 seconds 4 HOSES Inspect the air hose for wear damage and or hose abrasion 5 LUBRICATION Dur...

Page 25: ...ly greased Cover with a waterproof tarp 2 If the hammer is not to be used for a long period of time lubricate with the recommended oil to the nipple bushing and then work the hammer for about 1 2 seconds 3 When removing the hammer from the machine cover the swivel nipple and the air exhaust port with a waterproof tarp to avoid contamination ...

Page 26: ...he disassembly and assembly of an NPK PNEUMATIC HAMMER HOIST The minimum hoist capacity should be determined by the hammer model Refer to HAMMER SPECIFICATIONS HAMMER HOOK P N H010 7501 For removing and installing tool holder SLEDGE HAMMER AND SLUG WRENCH Size according to hammer model SMALL HAMMER AND BRASS PUNCH For removing the cotter pins SMALL ADJUSTABLE WRENCH ...

Page 27: ... stable 2 Remove the bracket bolts nuts and washers 3 Lift the hammer KK from the bracket LL Using a hoist attach a chain or strap t27 to the hammer and lift it out of the bracket LL 4 Using a hammer t29 and a punch ph13 remove the spring pins CT washer U and slide out the retaining pin D to remove the tool HH ...

Page 28: ...D AIR HAMMER AT COLLAR ph6 COTTER PIN R TOP NUT s8 PLATE U WASHER U1 WASHER 6 With two flathead screwdrivers t22 carefully remove the valve assembly ph14 then remove the valve ph3 dowel pin K valve body ph8 and valve bottom ph5 from the main body A Remove the five rubber aluminum plugs GM A MAIN BODY GM PLUGS K DOWEL PIN ph3 VALVE ph4 VALVE TOP ph5 VALVE BOTTOM ph8 VALVE BODY ph14 VALVE ASSEMBLY t...

Page 29: ...ods Q by using an adjustable wrench while supporting the tool holder C with the lifting hook t86 8 Once the tie rods Q are removed use a hoist to remove the tool holder C and cylinder spacer J 9 Carefully remove the piston N from the main body A ...

Page 30: ...DY NEW 5 12 130 11013489 MIN 5 1094 130 11013745 MIN 5 1251 130 MAXIMUM USEABLE LIMIT BETWEEN PISTON AND MAIN BODY IS 0157 in 0 4mm HAMMER NAME DIAMETER MODEL PART NO in mm NPH 3500 TOOL P TOOL E TOOL FX NEW 3 86 11014271 11014289 11014298 MIN 3 83 NPH 4500L TOOL P TOOL E TOOL FX NEW 4 106 11013604 11013612 11013605 MIN 4 103 USEABLE CLEARANCE BETWEEN THE TOOL AND THE TOOL HOLDER IS 3149 in 8mm IM...

Page 31: ...ting hook t86 4 Install the four 4 tie rods Q into the main body A and secure the bottom nuts V use an anti seize for the bottom nuts Bottom out the tie rods Q and proceed to back them off a 1 2 to 3 4 turn Now apply anti seize to the top area of the tie rods Q 5 Insert the valve ph3 into the valve body ph8 Install the top ph4 and bottom cap ph5 Install the dowel pin K onto the valve body ph3 to c...

Page 32: ...the 4 washers U Apply anti seize on top nuts Install and torque the top nuts R Torque hammer model specific HAMMER MODEL TOP NUTS ft lbs Nm NPH 3500 400 550 NPH 4500L 700 950 9 Install the 2 plates s8 Note Top nuts R must have the proper orientation for the 2 plates to fit properly Always tighten after torque when aligning DO NOT loosen 10 Continue to install the 4 collars AT 4 washers U1 and 4 co...

Page 33: ...ace with oversized Usable limit is 4mm piston Wearing on the main body Main body Replace the Piston Clearance between the Bushing Replace the Bushing Chisel and Bushing Valve Malfunction Oil Clean out Valve and use Recommended oil Drainage Lubricate swivel nipple Dust in Hammer Valve Complete Remove Dust NO HAMMERING Main body Remove Dust Using proper viscosity oil Oil Replace with Recommended oil...

Page 34: ...sing your username 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 NOT ...

Page 35: ...Custom or special application tools which are excluded from warranty NPK RESPONSIBILITY NPK will at its option replace with a new or reconditioned tool any warranted tool that fails by reason of defective material or workmanship free of charge delivered at a place of business of an NPK Dealer Tool breakage is specifically covered ONLY for straight across breakage as shown at locations A Note The t...

Page 36: ...for over 30 seconds THESE WARRANTIES DO NOT COVER FAILURES RESULTING FROM Installation alteration operation maintenance repair or storage which NPK judges improper Inadequate lubrication Exceeding the tool and or tool bushing wear limit Unreasonable delay in making a repair after being notified of a potential product problem THESE WARRANTIES SPECIFICALLY EXCLUDE Any tool which is altered welded ha...

Page 37: ... 36 WARRANTY STATEMENTS ...

Page 38: ... 37 WARRANTY STATEMENTS ...

Page 39: ... 38 WARRANTY STATEMENTS ...

Page 40: ...______________ SERIAL NUMBER _______________ NPK INSTALLATION KIT NUMBER __________________________ CARRIER MANUFACTURER MODEL NUMBER SERIES SERIAL NUMBER DATE OF INSTALLATION _________________ DATE OF 20 HOUR INSPECTION __________ WARRANTY REGISTRATION SENT ...

Page 41: ... Copyright 2020 NPK Construction Equipment Inc www npkce com H000 9620 NPH3500 NPH4500L Pneumatic Hammer Instr Manual 8 20 ...