NPK E Series User manual

HYDRAULIC HAMMER
OPERATORS MANUAL
E SERIES HAMMERS
E200 E204
E201 E205
E202 E207
E203
Copyright © 2012 NPK Construction Equipment, Inc. www.npkce.com H033-9600E E200 - E207 Hyd
Ham Operators Manual 11/12
"Use Genuine NPK Parts
”

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CONTENTS
SAFETY..........................................................................................................................2
INTRODUCTION.............................................................................................................4
CARRIER MACHINE COMPATIBILITY ..........................................................................5
HAMMER SPECIFICATIONS .........................................................................................6
HYDRAULIC INSTALLATION.........................................................................................7
HYDRAULIC QUICK DISCONNECTS........................................................................9
LUBRICATION..............................................................................................................12
GREASING PROCEDURE.......................................................................................12
CORRECT GREASE AND GREASE INTERVALS...................................................13
NPK HAMMER GREASE.......................................................................................15
AUTOLUBE SYSTEMS............................................................................................. 15
AUTOLUBE GREASE LINE PRE-FILLING............................................................... 16
LUBRICANT TERMS AND DEFINITIONS................................................................ 19
START UP OPERATION ..............................................................................................21
HAMMERS THAT ARE NEW, REBUILT, OR HAVE BEEN INACTIVE ....................21
BEFORE STARTING THE HAMMER....................................................................... 22
DAILY START-UP PROCEDURE.............................................................................22
OPERATION.................................................................................................................23
SAFE OPERATING INSTRUCTIONS.......................................................................23
OPERATING TECHNIQUES & PRECAUTIONS ...................................................... 24
ROUTINE INSPECTION AND MAINTENANCE............................................................ 29
TWENTY HOUR INSPECTION.....................................................................................30
TOOLS..........................................................................................................................31
STANDARD TOOLS................................................................................................. 31
ACCESSORY TOOLS .............................................................................................. 31
CHANGING THE TOOL............................................................................................32
MAXIMUM TOOL TO TOOL BUSHING CLEARANCE.............................................33
TOOL RETAINING PIN INSPECTION......................................................................35
TOOL INSPECTION.................................................................................................36
TIE RODS.....................................................................................................................37
TIE ROD TORQUE...................................................................................................37
TORQUE VALUES FOR HAMMER FASTENERS........................................................ 38
GAS CHARGE .............................................................................................................. 39
NITROGEN GAS PRESSURE..................................................................................39
GAS CHARGING KIT ............................................................................................... 40
CHECKING THE GAS PRESSURE..........................................................................41
CHARGING THE HAMMER...................................................................................... 42
DISCHARGING THE GAS PRESSURE ................................................................... 43
WARRANTY STATEMENTS.........................................................................................44
STORAGE OF HYDRAULIC HAMMER........................................................................ 48
NOTES AND RECORDS ..............................................................................................49

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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.
Warning Decal for Cab Installation
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 800-225-4379 or
Internet at www.npkce.com.

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INTRODUCTION
NPK is a leading manufacturer of boom mounted 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.

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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 subject to change without notice.

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HAMMER SPECIFICATIONS
HAMMER
MODEL IMPACT ENERGY
CLASS
FREQUENCY WORKING WEIGHT MOUNTING STYLE TOOL
DIA WORKING
LENGTH
ft lb bpm lbs (Kg) in (mm) in (mm)
E200 150 480 - 1200 500 (225) Skid Steer 1.7 (42) 12 (311)
235 (107) Excavator
E201 200 500 - 1200 550 (250) Skid Steer 1.9 (47) 13 (333)
270 (125) Excavator
E202 350 600 - 1200 725 (330) Skid Steer 2.2 (57) 13.5 (346)
425 (195) Excavator
E203 750 560 - 1200 800 (365) Skid Steer 2.6 (66) 14.5 (367)
525 (240) Excavator
E204 1300 530 - 1200 1075 (490) Skid Steer 3.0 (76) 16 (408)
800 (365) Backhoe
800 (365) Excavator
E205 1300 430 - 1050 1150 (520) Backhoe 3.4 (86) 18 (458)
1200 (545) Excavator
E207 2000 500 - 840 1850 (840) Backhoe 4.2 (106) 20 (500)
2100 (955) Excavator
HAMMER
MODEL OIL FLOW HYDRAULIC OPERATING
PRESSURE 1
CIRCUIT
RELIEF
minimum
GAS CHARGE
PRESSURE
Cold 2Hot
3
gpm (L/min) psi (bar) psi (bar) psi (bar) psi (bar)
E200 2.5 - 7 (10 - 25) 1650 (115) 2150 (150) 350 (24) 405 (28)
E201 4 - 9 (15 - 35) 1500 (105) 2000 (140) 350 (24) 405 (28)
E202 7 - 13 (25 - 50) 1750 (120) 2250 (155) 350 (24) 405 (28)
E203 8 - 17 (30 - 65) 1900 (130) 2400 (165) 350 (24) 405 (28)
E204 12 - 26 (45 - 100) 1900 (130) 2400 (165) 350 (24) 405 (28)
E205 13 - 32 (50 - 120) 2400 (165) 2900 (200) 375 (26) 435 (30)
E207 24 - 40 (90 - 150) 2400 (165) 2900 (200) 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 Service 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.

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HYDRAULIC INSTALLATION
NPK INSTALLATION KITS are available for virtually all compatible backhoe loaders,
excavators, and skid steers. Complete parts and instructions for the hydraulic
installation of the NPK HYDRAULIC HAMMER including valving and/or controls, hoses
and fittings, boom and stick tubing, and clamps are provided.
HAMMER LINES
Typically, the pressure line is arranged on the left side of the boom and the return line
on the right side. Flow to the hammer is controlled from an auxiliary valve on the carrier
or from an NPK supplied valve. Hydraulic oil is routed back to the tank thru the carrier’s
oil cooler and filter.
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 control valve, flow control valves, etc., are
furnished in the NPK HYDRAULIC INSTALLATION KIT. Special hydraulic pressure
control valves are not required. The NPK HYDRAULIC HAMMER operating
pressure is self-regulating.
2. CONTROL SYSTEM USING THE NPK MULTIVALVE.
For carriers not equipped with a suitable auxiliary or spare valve section, the NPK
HYDRAULIC INSTALLATION KIT includes a solenoid operated, priority flow control
valve to operate the NPK HYDRAULIC HAMMER. The NPK MULTIVALVE is
specifically designed for the operation of boom mounted attachments.

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HYDRAULIC INSTALLATION
PREVENTION OF CONTAMINATION
1. A hydraulic hammer is harder on oil than using a bucket, so the oil is apt to
deteriorate and breakdown sooner. Neglect of the oil system can not only damage
the hydraulic hammer but also cause problems in the carrier which could result in
damaged components. Care should be taken to check for contamination of the oil
and to change it if it is found contaminated. Oil sampling at regular intervals is
highly recommended.
When the hydraulic oil shows low viscosity and bubbles, this indicates that the oil
is deteriorated. If the oil is dark brown and gives off an offensive odor, it is
severely deteriorated. Change the oil immediately.
When the oil is clouded, or the oil filter has become clogged, it indicates that the
oil is contaminated. Change the oil immediately!
To change the contaminated hydraulic oil, drain the hydraulic system completely
and clean components. Do not mix new oil with the old.
2. Do not allow any contamination to mix with the oil. Take special care in preventing
contamination from entering the hydraulic system 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 higher than 180°F
(80°C). The proper operating oil temperature range is between 120°F (50°C) and
180°F (80°C). Since contaminated cooler fins causes reduced efficiency of the
cooler, keep the cooler fins clean at all times. Check the hydraulic oil cooling system
to be sure it is working effectively. The use of a heat gun is the best way to evaluate
if the cooler is working properly.
5. Water in the hydraulic oil will lead to damage of the hydraulic hammer and carrier.
Drain off water and foreign matter from the hydraulic tank at specified intervals.
When out of service, the hydraulic hammer should be stored indoors.
CHANGING THE FILTER ELEMENT AND HYDRAULIC OIL
Change the filter element and hydraulic oil at the intervals described in the operation
manual of the Skid Steer when using a hydraulic implement. Another method is to set
up an oil sampling schedule and change accordingly.

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HYDRAULIC INSTALLATION
HYDRAULIC QUICK DISCONNECTS
NPK recommends against the use of non-NPK quick disconnects on
hydraulic circuits operating NPK Products.
1. The hydraulic pulsations caused by hydraulic hammer operating can cause internal
pieces of non-NPK quick disconnect to disintegrate. These pieces would migrate
into the hammer, causing damage.
2. If quick disconnects are used when the hammer is removed from the excavator, the
quick disconnects should be capped to keep them clean. If this is not done,
contamination on the disconnect will be flushed 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 of the disconnects
may push an older, low pressure, carrier machine to the limit of its hydraulic system.
This would interfere with proper hammer operation. However, the NPK approved
quick disconnects are properly sized so that the hammer operation is not
affected.
APPROVED CONNECTION
Hose to Tube Connection NOT RECOMMENDED CONNECTION Non-NPK Quick Disconnects
NPK APPROVED CONNECTION QUICK DISCONNECTS
CONTACT YOUR NPK DEALER FOR ADDITIONAL INFORMATION ABOUT
NPK QUICK DISCONNECTS

- 10 -
HYDRAULIC INSTALLATION
HYDRAULIC QUICK DISCONNECTS
If hydraulic quick disconnects are used with the NPK Hammer, it is recommended that
the following precautions be followed.
1. Periodic inspection of both male
and female ends (A) is
recommended to ensure the
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 before coupling.
3. Be sure that the couplers (B) are
completely seated together.
4. When replacing couplers, be sure
that couplers are replaced as a set,
male and female. Do not use one
new end and one used end.

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MOUNTING INSTALLATION
NPK Mounting Installation Kits include the parts required to adapt the NPK HYDRAULIC
HAMMER to the carrier. NPK mounting kits include the hammer mounting bracket,
flow control valve (if required), and hoses to connect to the carrier hydraulic system.
A – Mounting pins
C – Whip hoses
D – Top Bracket
E – Top Bracket Bolt Package
F – Klik Pin
MOUNTING TO CARRIER
1. Place the hammer (A) horizontal
on wood blocks (B), as shown.
2. Align the boom pin holes. Install
the stick pin (D) before the cylinder
link pin (C).
3. Clean away any dirt found on the
hose connections and connect
hoses (E). Pressure line is on left,
return line on right side of boom.
4. Open shut-off valves (F).
REMOVAL FROM THE CARRIER
1. Close pressure and return line
shut-off valves.
2. Disconnect the hydraulic hoses
3. Cap the pressure and return line
hoses on the carrier and install
plugs in the hammer hoses.
4. Position hammer horizontally on
wood blocks (E) and remove the
boom pins (F).
The hydraulic lines must be handled carefully and
sealed to prevent contamination from entering the
hammer or the carrier h
y
draulic s
y
stem.

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LUBRICATION
GREASING PROCEDURE
Manual greasing for hammers without AUTOLUBE system.
1. Place the hammer in a vertical position, applying enough downforce to push the tool
up into the hammer. This prevents grease from entering piston impact area.
2. Turn the machine off.
3. Grease the hammer until grease begins to come out around the tool and lower
bushing.
APPLY DOWNFORCE TO PUSH TOOL UP INTO HAMMER
NOTE: USE A GOOD QUALITY EP #2 LITHIUM BASED GREASE WITH WEAR
INHIBITING ADDITIVES, SEE PAGES 13, 14, AND 15.

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LUBRICATION
CORRECT GREASE AND GREASE INTERVALS
Proper hammer maintenance requires a sufficient supply of the correct grease to the
tool (chisel). The tool must be pressed against a hard surface until it stops up inside the
hammer. This prevents grease from entering piston impact area and ensures proper
distribution of grease between the tool and tool bushings.
GREASE INTERVALS
If the hammer is not connected to an Autolube system, see page 15, the hammer must
be greased at regular intervals to get the best life from the tool and tool bushings.
There are two ways to determine grease intervals:
First, grease the hammer at the beginning of the job until grease comes out between
the tool and the lower tool bushing. Run the hammer until the shank of the tool starts to
look dry. This determines the time interval for the greasing of this particular hammer on
this particular job. Typically, this is 1 to 4 hours. Also, note the amount of grease
needed to re-grease the tool. This gives you 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
operator grease the hammer once every hour of hammer operation. Again, grease the
hammer until grease comes out between the tool and tool bushing. This is usually more
often than required, but is far cheaper than replacing prematurely worn tools and tool
bushings.
CORRECT GREASE
The type of grease used is very important. NPK recommends a lithium soap base EP
(Extreme Pressure) NLGI #2 Grease, with Moly (Molybdenum Disulfide) or other
surface protecting additives. A high drop point (500° F, 260° C) grease is desirable.
On the following page is a list of commonly available greases, by manufacturer and
brand name that meet NPK’s recommendations. NPK does not endorse any one brand
as being superior to another. If you or your customers use a brand not listed, please
call the NPK Service Department at 800-225-4379.

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LUBRICATION
CORRECT GREASE FOR HYDRAULIC HAMMERS
MANUFACTURER BRAND NAME
Amalie Oil Co. LI-2M
Amoco Rykotac EP Grease
Amolith Grease 94601
Rykon Premium Grease EP (Grade 94108)
Rykon Premium Moly Grease (Grade 94114)
Amoco Molylith Grease 92006
Amsoil, Inc. GHD
BP Oil, Inc. Bearing Gard-2
Caterpillar Multipurpose Molydbenum Grease (MPGM)
Cato Oil and Grease Company Moly Lithflex CX AS
CITGO Citgo Extra Range Grease
Conoco, Inc. Super Lube 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 Company Philube MW
Shell Retinax ® AM Grease 71119
Retinax ® HD Grease
Standard Oil Company Bearing Gard-2
Sun Refining & Marketing Company Prestige Moly 2 EP
Texaco, U.S.A. Molytex EP 2
Union Oil Company Unoba Moly HD #2
Unocal Unoba Moly HD #2

- 15 -
LUBRICATION
CORRECT GREASE FOR HYDRAULIC HAMMERS
NPK HAMMER GREASE
NPK now offers hammer grease specially formulated to meet severe job requirements.
The grease is available in three different temperature ranges - 350°, 500°, and 2000°.
All are compatible with Autolube systems.
Universal Plus and Super Duty are lithium soap based products that resists washout
and contain NPK-10 additive for surface protection in friction affected areas.
Chisel Paste is an aluminum complex soap base with 12% graphite and copper
additives for extreme operating conditions.
UNIVERSAL PLUS
350 deg NPK PART NO.
14 OZ. CARTRIDGE 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
automatically provide a continuous supply of
grease to the hammer tool and tool bushing –
increasing tool and tool bushing life by reducing
wear. The AUTOLUBE pump is capable of
pumping EP2 grease in cold weather. The
pump output is adjustable according to the
requirements of the hammer model and to
compensate for tool bushing wear.
NPK hammer models E203, E204, E205 and E207 have a connection port (A) for an
automatic greasing system (C). Do not use the plugged port in the tool holder
assembly. Use grease fitting (B) for manual greasing.
Refer to the NPK AUTOLUBE Instruction Manual for details.

- 16 -
LUBRICATION
AUTOLUBE GREASE LINE PRE-FILLING
It is mandatory that the supply line from the Autolube main pump to the connection on
the hammer is primed with grease before it is used. Failure to do this will result in no
grease being administered to the hammer tool for two to three hours. This can and will
result in severe galling of the tool and tool bushing.
PRIMING THE GREASE LINE
1. Place the hammer (KK) in a vertical position, applying enough down force to push the
tool up into the hammer.
2. Turn the machine off.
3. Fill the NPK Autolube pump reservoir with a power greaser through the fill fitting on
the side of the pump, or from the top by removing the fill cover. Use a premium
quality grade EP-2, high temperature grease with wear inhibiting additive.
4. Disconnect the grease line (29) from the
Autolube main pump cartridge (a4).
5. Install part number G100-8050 hose fill
adapter (a13) onto the #6 JIC end of the
grease line (29) previously removed.
6. Remove the grease line (29) at the
hammer (KK).
7. Attach a grease gun (t37) or power
greaser to the grease line (29) leading to
the hammer.

- 17 -
LUBRICATION
AUTOLUBE GREASE LINE PRE-FILLING
8. Pump grease through the grease line
(29) until a steady stream of grease (28)
is realized at the opposite (hammer) end.
9. Re-attach the grease line (29) to the
hammer (KK).
10. Pump twenty more shots of grease into
the grease line (29). This will prime the
hammer cavity and pre-lube the tool.
Look for grease coming out around the
tool (HH) at the tool bushing (see
arrow).
11. Remove the hose fill adapter (a13) and
re-connect the grease line (29) to the
Autolube pump (FZ).
NOTE: If the Autolube has run out of grease, the above procedure should be
used to purge all the air out of the line before using the hammer. Failure
to do this will result in an intermittent supply of grease to the hammer.

- 18 -
LUBRICATION
AUTOLUBE GREASE LINE PRE-FILLING
G100-8050 Hose Fill Assembly
30 B160-4010 Grease Fitting – ¼” NPT male
DQ K301-6620 Male x Female Adapter - #6 JIC male x ¼” NPT female

- 19 -
LUBRICATION
LUBRICANT TERMS AND DEFINITIONS
TERM DEFINITION
ADHESIVE The ability of grease, gear lubricant or oil to cling to
metal.
ANTI WEAR AGENTS Used to help combat metal-to-metal contact, thus
reducing wear.
COHESIVE The ability of grease, gear lube or oil to cling to itself,
thus resisting tearing apart.
CONSISTENCY Consistency of grease is its hardness or firmness. It is
determined by the depth in millimeters to which the cone
of a penotrometer sinks into a sample under specified
conditions. Consistency of grease may be influenced by
the type and amount of thickener, viscosity of oil, working
and other factors.
CONTAMINATION Foreign material that could damage a part.
DROPPING POINT The minimum temperature at which the oil in a grease
subjected to heat begins to actually drip and breakdown.
EXTREME PRESSURE
AGENTS Additives that under extreme pressure form an adherent
film on metal surfaces, thus forming a film of protection.
FILM STRENGTH Film strength is defined as the tendency of oil 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, etc.) to reduce friction
between parts or objects that move against each other.
NLGI A rating given to a grease from the National Lubricating
Grease Institute. This rating determines the hardness of
the grease and goes on from a 000 to a 6 rating. Most
greases are NLGI #2 rated.
OILINESS Oiliness is measured of the coefficient of friction of a
lubricant. Oiliness or lubricity depends on the adhering
characteristics of an oil. It is determined by the attraction
between the molecules of the oil and the molecules of
another material. Of two oils having the same viscosity
but different degrees of fluid friction, the one with the
lower friction index has the higher degree of oiliness.
PUMP A device which converts mechanical force into hydraulic
fluid power. Basic design types are gear, vane, and
piston units.