NPK E Series User manual

HYDRAULIC HAMMER
OPERATORS MANUAL
E SERIES HAMMERS
E200
E204
E201
E205
E202
E207
E203
“Use Genuine NPK Parts”
© Copyright 2020 NPK Construction Equipment, Inc. www.npkce.com H033-9600F E200 - E207 SM E
Hyd Ham Operators Manual 11-20
7550 Independence Drive
Walton Hills, OH 44146-5541
Phone [phone]
Fax [phone]

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CONTENTS
SAFETY.......................................................................................................................... 3
INTRODUCTION.............................................................................................................5
CARRIER MACHINE COMPATIBILITY ..........................................................................6
HAMMER SPECIFICATIONS .........................................................................................7
STRUCTURE..................................................................................................................8
STRUCTURAL DRAWING.......................................................................................... 8
MODELS E200 –E203............................................................................................8
MODELS E204 –E205............................................................................................9
MODELS E207.......................................................................................................10
HAMMER SERIAL NUMBER LOCATION.....................................................................11
SERIAL NUMBER LOCATION (sn1)........................................................................11
HYDRAULIC INSTALLATION.......................................................................................12
BACKHOE/EXCAVATOR HAMMER LINES.............................................................12
SKID STEER HAMMER LINES ................................................................................12
HAMMER CONTROL VALVE...................................................................................12
SKID STEER HAMMER FLOW CONTROL VALVE (OPTIONAL)............................13
PREVENTION OF CONTAMINATION......................................................................14
HYDRAULIC QUICK DISCONNECTS......................................................................15
MOUNTING INSTALLATION........................................................................................17
BACKHOES and EXCAVATORS.............................................................................. 17
SKID STEERS.......................................................................................................... 17
REMOVAL FROM THE CARRIER................................................................................ 17
BACKHOES and EXCAVATORS.............................................................................. 17
REMOVAL FROM THE SKID STEER ......................................................................18
MOUNTING TO THE CARRIER...............................................................................18
BACKHOES and EXCAVATORS...........................................................................18
MOUNTING TO THE SKID STEER.......................................................................... 18
LUBRICATION.............................................................................................................. 19
GREASING PROCEDURE....................................................................................... 19
CORRECT FUNCTION OF GREASING AND GREASE INTERVALS...................... 20
CORRECT GREASE FOR HYDRAULIC HAMMERS............................................... 20
NPK HAMMER GREASE.......................................................................................21
AUTO LUBE SYSTEMS............................................................................................22
AUTO LUBE GREASE LINE PRE-FILLING.............................................................. 23
HAMMER MOUNTED AUTO LUBE GREASE LINE PRE-FILLING.......................... 26
PRIMING THE GREASE LINE...............................................................................26
LUBRICANT TERMS AND DEFINITIONS................................................................ 28
AUTO LUBE / UNDERWATER PORT IDENTIFICATION.............................................30
HIGH HEAT APPLICATION..........................................................................................31
START-UP OPERATION.............................................................................................. 32
HAMMERS THAT ARE NEW, REBUILT, OR HAVE BEEN INACTIVE....................32
BEFORE STARTING THE HAMMER....................................................................... 33
DAILY START-UP PROCEDURE............................................................................. 33
OPERATION.................................................................................................................34
SAFE OPERATING INSTRUCTIONS.......................................................................34
OPERATING TECHNIQUES & PRECAUTIONS...................................................... 35
TAMPER PAD OPERATION.....................................................................................40
IMPACT ENERGY TRANSMISSION THROUGH TOOLS............................................ 41

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IMPACT STRESS WAVES AT THE END OF THE TOOL........................................ 42
TOOL BREAKAGE........................................................................................................ 43
TOOL BREAKAGE DUE TO EXCESSIVE BENDING MOMENT..............................43
CHARACTERISTICS OF THE BROKEN SECTION................................................. 43
TOOL BREAKAGE DUE TO EXCESSIVE WEAR OF THE TOOL HOLDER
BUSHINGS...............................................................................................................44
CHIPPING IN RETAINING PIN SLOT......................................................................46
DEFORMATION OF THE RETAINING PIN SLOT SIDES........................................46
DEFORMATION OF THE TOOL TIP........................................................................ 47
CHIPPING OF A MOIL POINT TOOL TIP ................................................................ 48
CHIPPING OF A CHISEL TOOL TIP........................................................................48
TEMPERATURE RELATED TOOL PROBLEMS......................................................49
TOOL BREAKAGE DUE TO CORROSION.............................................................. 50
TOOL BREAKAGE DUE TO DEFECTIVE MATERIAL.............................................50
ROUTINE INSPECTION AND MAINTENANCE............................................................51
WEEKLY INSPECTION ................................................................................................52
TYPES AND APPLICATIONS OF TOOL...................................................................... 53
STANDARD TOOLS................................................................................................. 53
ACCESSORY TOOLS ..............................................................................................53
TOOL IDENTIFICATION...............................................................................................54
TOOLS..........................................................................................................................55
CHANGING THE TOOL............................................................................................55
MAXIMUM TOOL TO TOOL BUSHING CLEARANCE.............................................56
TOOL INSPECTION ................................................................................................. 58
CHISEL TOOL SHARPENING.................................................................................. 59
STANDARD LENGTH FOR NPK TOOLS................................................................. 60
TOOL RETAINING PIN INSPECTION...................................................................... 61
TORQUE VALUES FOR HAMMER FASTENERS........................................................62
GAS CHARGE ..............................................................................................................63
NITROGEN GAS PRESSURE.................................................................................. 63
GAS CHARGING KIT ............................................................................................... 63
CHECKING THE GAS PRESSURE.......................................................................... 64
CHARGING THE HAMMER...................................................................................... 66
DISCHARGING THE GAS PRESSURE ................................................................... 67
STORAGE OF HYDRAULIC HAMMER........................................................................ 68
WARRANTY REGISTRATION FOR NEW UNITS ........................................................ 69
TOOL WARRANTY....................................................................................................... 70
WARRANTY STATEMENTS......................................................................................... 72
NOTES AND RECORDS .............................................................................................. 76

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SAFETY
Safety notices in NPK Instruction Manuals follow ISO and ANSI standards for
safety warnings:
DANGER (red) notices indicate an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING (orange) notices indicate a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION (yellow) 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.
WARNING and BASIC OPERATING INSTRUCTIONS decals are included with each
NPK hammer and installation kit. Decals must be installed in the cab, visible to 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 personnel and bystanders clear of hammer while in operation.
•Do not operate HAMMER without an impact resistant guard between HAMMER
and operator. NPK recommends LEXANor equivalent material, or steel mesh.
Some carrier manufacturers offer demolition guards for their machine. Check with
the carrier manufacturer for availability. If not
available, please call NPK.
3. Do not hardface or sharpen the tool point with a cutting
torch. Excessive heat from torching or welding can
cause embrittlement, breakage, and flying pieces.
Resharpen by milling or grinding only, using sufficient
coolant.

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SAFETY
4. Fully extend the tool while charging the HAMMER with nitrogen gas. Be sure that
the retaining pin is installed. STAY CLEAR OF TOOL POINT WHILE CHARGING.
5. Do not disassemble a HAMMER before discharging the hammer gas pre-charge.
6. USE NITROGEN GAS ONLY! Store and handle nitrogen tanks per OSHA
regulations.
7. Avoid high pressure fluids. Escaping fluid under pressure can penetrate the skin
causing serious injury. Relieve pressure before disconnecting hydraulic or other
lines.
8. Operate HAMMER from operator’s seat only.
9. Match HAMMER size to carrier according to NPK recommendations. The carrier
must be stable during hammer operation and during transport.
See CARRIER MACHINE COMPATIBILITY section of the NPK instruction manual.
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 and safety glasses when operating the hammer. Consult
OSHA/MSHA regulations when applicable.
13. Beware of flying metal pieces when driving Boom Pins.
14. If modifications are to be made, do not alter the HAMMER without authorization
from NPK Engineering!
15. 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.
For further safety information, consult the AEM Hydraulic Mounted Breakers Safety
Manual, AEM form MB-140 (NPK P/N H050-9600), which is furnished with every NPK
hammer. To request an additional copy, please contact NPK at 440-232-7900 or
Internet at www.npkce.com.

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INTRODUCTION
NPK is a leading manufacturer of HYDRAULIC HAMMERS and has the most complete
product line available anywhere. The success of NPK is due to our commitment to
quality, dependability and long life. The HYDRAULIC HAMMER has many unique
designed features and it is a company philosophy that the NPK HYDRAULIC HAMMER
can be brought to "like new” condition long after competitive products are scrapped.
You can feel confident that you have purchased the best value available.
This comprehensive operator’s manual contains instructions for operating and
maintaining NPK HYDRAULIC HAMMERS. This manual includes helpful information
for obtaining the full potential and efficiency from NPK HYDRAULIC HAMMERS.
Please read this manual thoroughly to understand the NPK HAMMER and its operating
principles before using it.
For additional information or help with any problem encountered, please contact your
NPK authorized dealer.
Whenever repair or replacement of component parts is required, only NPK parts should
be used. NPK is not responsible for failures resulting from substitution of parts not sold
or approved by NPK.
This manual will also assist NPK Dealers and Customers to obtain the longest possible
life from the NPK Demolition Tools.
Customers can use this manual to take corrective action when tool breakage occurs.
Dealers can use this manual to determine if tool breakage can be claimed under
warranty.
Refer to the NPK Demolition Tool Warranty Statement found later in this manual for the
specifics of the warranty coverage.

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CARRIER MACHINE COMPATIBILITY
These carrier weight ranges are intended as a guideline only. Other factors, such as
stick length, counterweights, undercarriage, etc., must be taken into consideration.
Mounting a HAMMER that is too heavy for the carrier machine
can be dangerous and damage the machine. Verify carrier
stability with hammer before transport or operation.
Mounting a HAMMER that is too small for the carrier machine can damage the
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
lb
(kg)
E200
Excavator
2,200 - 4,400
(1,000 - 2,000)
Skid Steer
2,400 - 3,500
(1,100 - 1,600)
E201
Excavator
2,800 - 5,500
(1,300 - 2,500)
Skid Steer
3,000 - 5,500
(1,350 - 2,500)
E202
Excavator
5,400 - 9,000
(2,450 - 4,100)
Skid Steer
5,000 - 7,500
(2,300 - 3,400)
E203
Excavator
6,600 - 12,000
(3,000 - 5,500)
Skid Steer
6,000 - 9,000
(2,700 - 4,100)
E204
Excavator
8,800 - 15,000
(4,000 - 7,000)
Skid Steer
8,000 - 14,000
(3,600 - 6,400)
Backhoe
9,000 - 15,000
(4,100 - 7,000)
E205
Excavator
13,000 - 22,000
(6,000 - 10,000)
Backhoe
13,000 - 20,000
(6,000 - 9,000)
E207
Excavator
22,000 - 31,000
(10,000 - 14,000)
Backhoe
20,000 - 25,000
(9,000 - 11,500)
*Specifications are subject to change without notice.

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HAMMER SPECIFICATIONS
HAMMER
IMPACT
FREQUENCY
MOUNTING
WORKING
TOOL
MODEL
ENERGY
STYLE
WEIGHT
DIA.
WORKING
CLASS
LENGTH
ft. lb.
bpm
lbs.
(kg)
in.
(mm)
in.
(mm)
E200
150
480 - 1,200
Excavator
500
(225)
1.65
(42)
12.2
(311)
Skid Steer
235
(107)
E201
200
500 - 1,200
Excavator
270
(125)
1.85
(47)
13.1
(333)
Skid Steer
550
(250)
E202
350
600 - 1,200
Excavator
425
(195)
2.24
(57)
13.6
(346)
Skid Steer
725
(330)
E203
750
560 - 1,200
Excavator
525
(240)
2.60
(66)
14.4
(367)
Skid Steer
800
(365)
E204
1300
530 - 1,200
Excavator
800
(365)
2.99
(76)
16.1
(408)
Skid Steer
1,075
(490)
Backhoe
800
(365)
E205
1,300
430 - 1,050
Excavator
1,200
(545)
3.39
(86)
18.0
(458)
Backhoe
1,150
(520)
E207
2,000
500 - 840
Excavator
2,100
(955)
4.17
(106)
19.6
(500)
Backhoe
1,850
(840)
HAMMER
OIL FLOW
HYDRAULIC OPERATING
MINIMUM CIRCUIT
MODEL
PRESSURE1
RELIEF2
gpm
(lpm)
psi
(bar)
psi
(bar)
E200
2.5 - 7
(10 - 25)
1,650
(115)
2,150
(150)
E201
4 - 9
(15 - 35)
1,500
(105)
2,000
(140)
E202
7 - 13
(25 - 50)
1,750
(120)
2,250
(155)
E203
8 - 17
(30 - 65)
1,900
(130)
2,400
(165)
E204
12 - 26
(45 - 100)
1,900
(130)
2,400
(165)
E205
13 - 32
(50 - 120)
2,400
(165)
2,900
(200)
E207
24 - 40
(90 - 150)
2,400
(165)
2,900
(200)
NITROGEN GAS PRE-CHARGE
HAMMER
AT AMBIENT TEMPERATURE
(cold before operating)
AT OPERATING TEMPERATURE (hot,
after 1 to 2 hrs. operation)
MODEL
psi
(bar)
psi
(bar)
E200
350
(24)
405
(28)
E201
350
(24)
405
(28)
E202
350
(24)
405
(28)
E203
350
(24)
405
(28)
E204
350
(24)
405
(28)
E205
375
(26)
435
(30)
E207
390
(27)
450
(31)
* Specifications subject to change without notice.
NOTES:
1. Hydraulic operating pressure maximum is inlet pressure at the hammer with the oil at operating
temperature and with the gas charge set at the hot operating pressure. See “CHECKING THE
HYDRAULIC PRESSURES”section in this manual.
2. Circuit relief pressure is at least 500 psi (35 bar) above hammer operating pressure.
3. Cold gas charge is the initial set with the hammer at ambient temperature.
4. Hot gas charge is checked after 1 to 2 hours of running and with a system oil temperature of 140
to 180F (60  to 80  C). This is the preferred check.
5. Gas pressures listed are the maximum allowed. Use tolerance of plus 0, minus 25 psi (2 bar).

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STRUCTURE
STRUCTURAL DRAWING
MODELS E200 –E203
5
OUT PORT
6
IN PORT
30
GREASE FITTING
A
MAIN BODY
AA
PLUNGER BUSHING
B
DRAIN PLUG
BB
PLUNGER
C
TOOL HOLDER
D
RETAINING PIN
E
RETAINING RING
F
UPPER TOOL BUSHING
G
LOWER TOOL BUSHING
HH
TOOL
J
IMPACT RING (SPACER SECTION)
L
GAS HEAD
M
CHARGE VALVE
N
PISTON
O
MAIN BODY SLEEVE (A)
P
MAIN BODY SLEEVE (B)
Q
TIE ROD
R
TOP NUT
U
WASHER
W
VALVE BODY
Y
VALVE BOTTOM CAP
Z
VALVE SPOOL

- 9 -
STRUCTURE
STRUCTURAL DRAWING
MODELS E204 –E205
30
GREASE FITTING
A
MAIN BODY
AA
PLUNGER BUSHING
B
DRAIN PLUG
BB
PLUNGER
C
TOOL HOLDER
D
RETAINING PIN
DD
SWIVEL ELBOW
E
RETAINING RING
F
UPPER TOOL BUSHING
G
LOWER TOOL BUSHING
HH
TOOL
J
IMPACT RING (SPACER SECTION)
L
GAS HEAD
M
CHARGE VALVE
N
PISTON
O
MAIN BODY SLEEVE (A)
P
MAIN BODY SLEEVE (B)
Q
TIE ROD
R
TOP NUT
U
WASHER
W
VALVE BODY
Y
VALVE BOTTOM CAP
Z
VALVE SPOOL