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.

- 10 -
GENERAL DESCRIPTION
The G025 hydraulically actuated grease pump is used to lubricate the 2,500 to 15,000
ft. lb. class NPK hydraulic hammers. Due to its compact design, it can be mounted
directly to the hammer upper support block.
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.

- 11 -
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.
To protect the Auto Lube system, the pump includes a relief valve (a3) which opens at
4060 psi (280 bars). The discharge opening (157) of the pressure relief valve is placed
opposite of the cartridge holder.
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 be
able to check the lubricant level when the cartridge is almost empty, the pump main
housing (G025 only) is equipped with an inspection window (155) as shown on the next
page.

- 12 -
GENERAL DESCRIPTION
To make sure the pump unit is functioning, the unit has a visible eccentric shaft (a56)
which rotates during operation.
In the case of wear of the pumping element (grease pump cartridge),the grease comes
out of the lateral relief hole (156).
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.

- 13 -
FUNCTIONAL DESCRIPTION
G015
The pressure line (6) to the hammer is connected to the pressure port POIL (126) of the
NPK Auto Lube pump via a tap in connection on the hammer top bracket. The oil is
then routed through a filter (a60) with an orifice (a61) to the hydraulic motor (a58), which
ensures continuous drive. The hydraulic oil is returned to the hydraulic circuit via the
return port ROIL (127) then to a tap in connection on the hammer return line (5) at the
hammer top bracket.
The hydraulic motor drives a worm shaft, which transmits the revolutions of the motor to
the eccentric shaft. As the eccentric shaft revolves, it strokes the delivery plunger which
is part of the pumping element (a11). The stroking of the delivery plunger creates
suction and delivery of the lubricant. An integrated check valve (k3) prevents the
lubricant from being fed back into the grease pump cartridge. Through the grease port
(18), the lubricant is sent to the hammer (KK). Grease cartridges (a54) are used as a
storage reservoir for the lubricant. A discharge opening (157) in the main housing for
the lubricant, is opposite the cartridge holder.
5 HAMMER OUT
6 HAMMER IN
18 GREASE OUTLET PORT
126 INLET (HYDRAULIC) PORT
127 RETURN (HYDRAULIC) PORT
157 GREASE OUTLET
a5 THROTTLE
a11 GREASE PUMP CARTRIDGE
a54 GREASE CARTRIDGE
a58 HYDRAULIC MOTOR
a60 FILTER
a61 ORIFICE
k3 CHECK VALVE
KK HAMMER

- 14 -
FUNCTIONAL DESCRIPTION
G025
The pressure line (6) to the hammer is connected to the pressure port POIL (126) of the
NPK Auto Lube pump via a tap in connection on the hammer top bracket. The oil is
then routed through a filter (a60) with an orifice (a61) to the hydraulic motor (a58), which
ensures continuous drive. The hydraulic oil is returned to the hydraulic circuit via the
return port ROIL (127) then to a tap in connection on the hammer return line (5) at the
hammer top bracket.
The hydraulic motor drives a worm shaft, which transmits the revolutions of the motor to
the eccentric shaft. As the eccentric shaft revolves, it strokes the delivery plunger which
is part of the pumping element (a11). The stroking of the delivery plunger creates
suction and delivery of the lubricant. An integrated check valve (k3) prevents the
lubricant from being fed back into the grease pump cartridge. Through the grease port
(18), the lubricant is sent to the hammer (KK). Grease cartridges (a54) are used as a
storage reservoir for the lubricant. The relief valve (a3) for the lubricant is preset to
4060 psi (280 bars). A discharge opening (157) in the main housing for the lubricant, is
opposite the cartridge holder.
5 HAMMER OUT
6 HAMMER IN
18 GREASE OUTLET PORT
126 INLET (HYDRAULIC) PORT
127 RETURN (HYDRAULIC) PORT
157 GREASE RELIEF VALVE OUTLET
a3 RELIEF VALVE
a5 THROTTLE
a11 GREASE PUMP CARTRIDGE
a54 GREASE CARTRIDGE
a58 HYDRAULIC MOTOR
a60 FILTER
a61 ORIFICE
k3 CHECK VALVE
KK HAMMER

- 15 -
PREPARATION
BEFORE STARTING
CHECK AND MAKE SURE YOU HAVE THE CORRECT NPK INSTALLATION KIT
FOR YOUR ATTACHMENT. Check the hammer model against the NPK Hammer
Mounted Grease Pump Assembly description. All NPK Hammer Mounted Grease
Pump Assemblies are designed for a specific NPK Hammer. IF THERE ARE ANY
DISCREPANCIES, IMMEDIATELY CONTACT NPK OR YOUR DEALER.
OPEN BOX AND TAKE INVENTORY OF PARTS RECEIVED AGAINST NPK
PARTS LIST AND DRAWINGS BEFORE YOU BEGIN. This will ensure there are
no missing or damaged parts, which may affect installation time. NPK takes every
precaution to ensure every Hammer Mounted Grease Pump Assembly is shipped
complete, but sometimes errors can occur.
Remove one part at a time from the box and check off on the NPK parts list. All
parts are marked with an NPK part number and balloon item number for ease of
identification. Place checked parts in a clean area to prevent damage or
contamination. Do not remove protective packaging from parts until ready for
use.
The Hammer Mounted Grease Pump Assembly can be installed by one
mechanic. Follow safe working practices.
No special tools should be required for this installation. Basic hand tools and a
welding unit may be required.
Review the installation drawings for general understanding of installation.
Position the hammer on a flat surface for ease of installation.
All work during the installation should be performed in a protected area. The
Hammer Mounted Grease Pump Assembly parts must not be exposed to rain,
dirt, grinding dust, steam cleaning or other contaminates which can be introduced
into the carrier hydraulic system during installation.
PREPARATION FOR WELDING
Properly ground the negative welder wire as near to the weld area as possible for
good penetration.
Prepare all weld areas by removing dirt, oil, and paint.
Welding may cause a possible fire. Make sure all areas are
free from flammable debris!

- 16 -
INSTALLATION PROCEDURES
ORING FACE SEAL FITTING (ORFS) INSTALLATION TIPS
Check oring, face of fitting, and tube or
hose end for damage and replace if
necessary. (RR1) shows a GOOD oring,
(RR2) shows a NICKED oring, (RR3)
shows a BENT oring, (RR4) shows a CUT
oring.
Damage (11) to a hose end (OR2) and a
fitting end (OR1) are shown above.
Apply a small amount of grease to
the oring (RR) and oring groove
(BA) to hold the oring in place
before assembly.
Make sure the fitting face and the tube or hose
face are parallel as displayed above in example.
158 – PARALLEL
159 – NON-PARALLEL
Torque fittings as tight as possible
by hand with standard wrenches.
The face seal will not deform with
high torque.
Use two wrenches (t6) to hold the hoses (AO) in
place while tightening. Start the carrier and heat
oil to operating temperature [140° - 180°F (60° -
80°C)]. Retighten all fittings.
ORFS SIZE MINIMUM ASSEMBLY
TORQUE
NPK
ORING
PART
NUMBER
Dash Threads Ft./Lb. Nm
-6 11/16-16 25-29 34-40 L019-6010

- 17 -
INSTALLATION PROCEDURES
HOSE INSTALLATION TIPS
Connect the larger diameter hoses first. Larger hoses are more difficult to bend and
maneuver, while the smaller lines are usually more flexible and easier to install.
Do not twist (102) the hoses during
installation. Pressure applied to a twisted
hose can result in premature hose failure
or loose connections. Attach both ends of
hose to its connection point. Let the hose
find its natural position (103), then tighten
both ends of the hose. Use a back-up
wrench.
Elbows and adapters furnished in the
NPK Installation Kit provide easier
accessibility to carrier components for
maintenance and inspection.
Make sure the hose is routed with the
proper bend radius to prevent kinking,
flow restrictions or failures at the hose
coupling.

- 18 -
INSTALLATION INSTRUCTIONS
G015
For NPK 500 to 1300 ft. lb. class hammers (with fixed hammer port connections).
1. The grease pump should be mounted
with the grease cartridge (a54) in the
vertical position (facing up), with the
hammer assembly (DR) in a
horizontal position (as shown). It
must be ensured that neither dirt nor
any other type of contamination may
fall into the intake area below the
cartridge when the cartridge is being
re-filled.
2. Remove the existing adapter fittings
from the grease pump assembly.
Install one ORFS adapter fitting (g19),
NPK part number L1213-6600, into
the port labeled “P OIL ” (126) and one
check valve (k3b), NPK part number
G025-6300 into port “R OIL ” (127).
Install one check valve (k3a), NPK
part number G100-6300, into the port
labeled “P GREASE ” (18).
3. Remove the hammer (KK) from its
bracket (LL).

- 19 -
INSTALLATION INSTRUCTIONS
G015
For NPK 500 to 1300 ft. lb. class hammers (with fixed hammer port connections).
4. Weld the mounting plate (a28) and
drill the access hole in the hammer
bracket according to the “Bracket
Modification” instructions supplied by
NPK. Drill and tap hole in the bracket
support block per instructions. For
additional information, contact the
NPK Service Department at 1-800-
225-4379. Re-install the hammer into
the bracket. Bolt the grease pump
(FZ) to its mounting plate using the
two hex head cap screws (AF1), NPK
part number G025-4530 and washers
(U), NPK part number G025-4700.
Using high strength thread adhesive,
torque the hex head cap screws to 80
ft. lbs. (110Nm).
NOTE: Washers (G025-4700) must
be installed per fig. 1.
(Ref “a” and “b” angles)
5. Install adapter fittings (g19) into the
swivel tees (a62). Install swivel tees
onto the existing port fittings in the
hammer inlet (6) and outlet (5) ports.
Orient the pressure side tee so that
the SAE port faces towards the
hammer’s gas head. Orient the return
tee so that the SAE port faces the
right hand side plate of the hammer
bracket.