NPK G015 User manual

INSTRUCTION MANUAL
AUTO LUBE SYSTEM
Hammer Mounted
Hydraulically Actuated
7550 Independence Drive
Walton Hills, OH 44146-5541
Phone [phone]
Toll-free [phone]
Fax [phone]
© Copyright 2019 NPK Construction Equipment, Inc. www.npkce.com G025-9600g Hammer
Mounted Auto Lube System 11-19
“Use Genuine NPK Parts”

CONTENTS
- 1 -
INTRODUCTION...........................................................................................................................................3
RECOMMENDED UNITS FOR NPK HAMMERS.........................................................................................3
IMPORTANT SAFETY INFORMATION........................................................................................................4
GREASE PUMP ASSEMBLY .......................................................................................................................5
G015 SPECIFICATIONS ..........................................................................................................................5
G025 SPECIFICATIONS ..........................................................................................................................5
TECHNICAL DATA...................................................................................................................................6
HYDRAULIC MOTOR ..........................................................................................................................6
PUMPING ELEMENT...........................................................................................................................6
GENERAL ............................................................................................................................................6
G015 MOUNTING SPECIFICATIONS......................................................................................................7
G025 MOUNTING SPECIFICATIONS......................................................................................................7
GENERAL DESCRIPTION ...........................................................................................................................8
FUNCTIONAL DESCRIPTION....................................................................................................................13
G015........................................................................................................................................................13
G025........................................................................................................................................................14
PREPARATION ..........................................................................................................................................15
BEFORE STARTING..............................................................................................................................15
PREPARATION FOR WELDING............................................................................................................15
INSTALLATION PROCEDURES................................................................................................................16
ORING FACE SEAL FITTING (ORFS) INSTALLATION TIPS...............................................................16
HOSE INSTALLATION TIPS ..................................................................................................................17
INSTALLATION INSTRUCTIONS ..............................................................................................................18
G015........................................................................................................................................................18
For NPK 500 to 1300 ft. lb. class hammers (with fixed hammer port connections)...........................18
For NPK 500 to 1300 ft. lb. class hammers (with swivel hammer port connections).........................22
For NPK 2000 ft. lb. class hammers (with top brackets that include joint fittings).............................25
G025........................................................................................................................................................32
For NPK 2,500 to 15,000 ft. lb. class hammers .................................................................................32
BEFORE START-UP ..................................................................................................................................38
AUTO LUBE GREASE LINE PRE-FILLING ...........................................................................................38
PRIMING THE GREASE LINE................................................................................................................38
UNDERWATER USE..................................................................................................................................40
AUTO LUBE TROUBLESHOOTING ..........................................................................................................40
GREASE CARTRIDGES.............................................................................................................................41
CARTRIDGE ADAPTER (G025 ONLY)..................................................................................................41
CHANGING THE CARTRIDGE ADAPTER (G025 ONLY).....................................................................42
CHANGING THE FLAT SEAL (G015)....................................................................................................43
CHANGING THE FLAT SEAL (G025)....................................................................................................43

CONTENTS
- 2 -
CHANGING THE GREASE CARTRIDGE (G015)..................................................................................44
CHANGING THE GREASE CARTRIDGE (G025)..................................................................................45
GREASE CARTRIDGE REFILLING.......................................................................................................46
REPLACEMENT OF THE FILTER AND DIAPHRAGM..............................................................................47
REPLACEMENT OF THE (LUBRICANT) RELIEF VALVE.........................................................................48
PUMP CARTRIDGE TEST PROCEDURE.................................................................................................49
REPLACEMENT OF THE PUMP CARTRIDGE.........................................................................................50
THROTTLE ADJUSTMENT........................................................................................................................51
ADJUSTMENT OF FLOW TO THE HYDRAULIC MOTOR....................................................................51
KEYWORDS FOR COMMON G015 AUTO LUBE COMPONENTS ..........................................................53
KEYWORDS FOR COMMON G025 AUTO LUBE COMPONENTS ..........................................................54
KEYWORDS FOR COMMON HAMMER MOUNTED AUTO LUBE HYDRAULIC MOTOR COMPONENTS
....................................................................................................................................................................55
WARRANTY STATEMENTS ......................................................................................................................56

- 3 -
INTRODUCTION
The NPK AUTO LUBE System is designed to automatically provide a supply of grease
to the hammer tool bushing - increasing tool bushing life by reducing tool bushing wear.
Due to its compact design, it can be mounted directly to the hammer.
The AUTO LUBE system utilizes a hydraulic motor-driven high pressure pump capable
of pushing low viscosity EP2 grease in cold weather. The pump is activated via by-pass
hose lines from the hammers pressure and return lines, to run whenever the hammer is
operated.
The NPK AUTO LUBE system is comprised of the grease pump assembly, adapter
fittings and hoses at the pump, hammer and hammer top bracket. The grease line
length varies according to the NPK hammer size. Use 1/4” maximum I.D. line, 5000 psi
minimum working pressure with 6 JIC hose ends for the grease line from the pump to
the hammer.
For help with any installation problem, or for additional information, call the NPK Service
Department at 1-800-225-4379.
RECOMMENDED UNITS FOR NPK HAMMERS
AUTO LUBE
MODEL PUMP CARTRIDGE RESERVOIR CAPACITY HAMMER MODELS
G015
SINGLE
CARTRIDGE
14 oz.
(400 g)
PH3, PH4
GH4, GH6
E205, E207
G025 SINGLE
CARTRIDGE 14 oz.
(400 g) GH7, GH9, GH10,
GH12, GH15, GH18
GH23, GH30
E208, E210A, E213,
E216, E220, E225

- 4 -
IMPORTANT SAFETY INFORMATION
READ AND UNDERSTAND ALL SAFETY INFORMATION AND INSTRUCTIONS FOR
THE CARRIER AND THE NPK PRODUCT.
SAFE NPK PRODUCT OPERATION
Read and understand the Operator Manuals. Safety notices in NPK
Instruction Manuals follow ISO and ANSI standards for safety warnings:
DANGER (red) safety notices indicate an imminently hazardous
situation which, if not avoided, will result in death or serious
injury.
WARNING (orange) safety notices indicate a potentially hazardous
situation which, if not avoided, could result in death or serious
injury.
CAUTION (yellow) safety notices indicate a potentially hazardous
situation, which, if not avoided, may result in minor or moderate
injury.
ATTENTION (blue) notices in NPK Instruction Manuals are an NPK
standard to alert the reader to situations which, if not avoided,
could result in equipment damage.
Keep all decals clean and visible. NPK will provide replacement NPK decals free
of charge, as needed.
Keep personnel and bystanders clear of NPK product while in operation. FLYING
DEBRIS CAN CAUSE SERIOUS OR FATAL INJURY.
Do not operate NPK product without a suitable shield between the NPK product and
operator. FLYING DEBRIS CAN CAUSE SERIOUS OR FATAL INJURY.
Operate the NPK product from the operator’s seat only.
Match the correct NPK model to the carrier according
to NPK recommendations.
Escaping fluid under pressure can penetrate the skin,
causing serious injury. Protect hands and body from
fluids under pressure. Avoid the hazard by relieving
pressure before disconnecting any lines. Search for
leaks with a piece of cardboard or other object. If an
accident occurs, see a doctor immediately!
Hydraulic fluid injected into the skin must be surgically
removed within a few hours or gangrene may result.

- 5 -
GREASE PUMP ASSEMBLY
G015 SPECIFICATIONS
G025 SPECIFICATIONS
18 GREASE OUTLET PORT
30 GREASE FITTING
126 INLET (HYDRAULIC) PORT
127 RETURN (HYDRAULIC) PORT
a5 THROTTLE
a9 MOUNTING HOLE
a11 GREASE PUMP CARTRIDGE
a54 GREASE CARTRIDGE
a56 ECCENTRIC SHAFT
a57 FILTER/ORIFICE ASSEMBLY
a58 HYDRAULIC MOTOR
a59 MAIN HOUSING
18 GREASE OUTLET PORT
30 GREASE FITTING
126 INLET (HYDRAULIC) PORT
127 RETURN (HYDRAULIC) PORT
155 INSPECTION WINDOW
a3 RELIEF VALVE
a5 THROTTLE
a9 MOUNTING HOLE
a11 GREASE PUMP CARTRIDGE
a53 GREASE CARTRIDGE
ADAPTER
a54 GREASE CARTRIDGE
a56 ECCENTRIC SHAFT
a57 FILTER/ORIFICE ASSEMBLY
a58 HYDRAULIC MOTOR
a59 MAIN HOUSING

- 6 -
GREASE PUMP ASSEMBLY
TECHNICAL DATA
HYDRAULIC MOTOR
G015 G025
HYDRAULIC FLOW (maximum) .53 gpm (2 lpm) .53 gpm (2 lpm)
WORKING PRESSURE 1300 - 3625 psi 1300 - 3625 psi
(90 - 250 bar) (90 - 250 bar)
MAXIMUM RETURN PRESSURE 290 psi (20 bar) 290 psi (20 bar)
*ECCENTRIC SPEED 14 rpm 14 rpm
@ .47 gpm (1.8 lpm)
TEMPERATURE RANGE 32 - 158⁰F 32 - 158⁰F
(0 - 70
⁰
C) (0 - 70
⁰
C)
*Eccentric speed can be adjusted with throttle.
PUMPING ELEMENT
G015 G025
DELIVERY RATE PER STROKE .004 oz. (.12 cmᶟ).004 oz (.12 cmᶟ)
**STROKES AT STANDARD 14 per minute 14 per minute
HYDRAULIC FLOW
WORKING PRESSURE 4060 psi 4060 psi
(280 bar) (280 bar)
**Stroke number can be adjusted with throttle.
GENERAL
G015 G025
WEIGHT 9 lbs. (3.9 kg) 15 lbs. (6.7 kg)
LUBRICANT EP2 grease or EP2 grease or
chisel paste chisel paste
GREASE SUPPLY re-fillable re-fillable
cartridges cartridges

- 7 -
GREASE PUMP ASSEMBLY
G015 MOUNTING SPECIFICATIONS
G025 MOUNTING SPECIFICATIONS

- 8 -
GENERAL DESCRIPTION
The G015 hydraulically actuated grease pump is used to lubricate the 500 to 2000 ft. lb.
class NPK hydraulic hammers. Due to its compact design, it can be mounted directly to
the hammer bracket.
The NPK hammer mounted auto lube system is connected to the hydraulic system of
the carrier unit via the pressure line (6) of the hammer to port P OIL (126) of the lube
pump housing (a59).
The hydraulic oil is routed via a filter/diaphragm (a57) to the hydraulic motor (a58),
which ensures continuous drive. The hydraulic oil is returned to the circuit via the
hammer return line (5), or port R OIL (127) on the lube pump housing.

- 9 -
GENERAL DESCRIPTION
The hydraulic motor (a58) drives a worm shaft (a55), which turns a gear/eccentric unit
(a26). As the gear/eccentric unit revolves, it strokes the delivery plunger (a27), which is
part of the pumping element (a11). The stroking of the delivery plunger creates suction
and delivery of the lubricant.
As the hydraulic motor is rotated, a continuous supply of lubricant is delivered to the
hammer via the pressure channel. An integrated check valve prevents the lubricant
from being fed back into the grease pump cartridge.
Transparent plastic reusable cartridges (a54) serve as a storage reservoir for the
lubricant. The lubricant level is checked visually by the follower piston (a66).
To make sure the pump unit is functioning, the unit has a visible eccentric shaft (a56)
which rotates during operation.
If there is failure of the hydraulic system or the Auto Lube pump, a grease fitting (30) is
integrated into the unit for manual greasing.
NOTE: This grease fitting is not used to fill the grease cartridge.