NPK E200, E201, E202, E203, E204, E205, E207 E-Sereis Hydraulic Hammer Service Manual Download

CONTENTS
SAFETY ....................................................................................................... 1
INTRODUCTION .......................................................................................... 5
BASIC OPERATING INSTRUCTIONS ......................................................... 5
PRECAUTIONS FOR USING THE NPK HYDRAULIC HAMMER ............... 6
CARRIER MACHINE COMPATIBILITY ....................................................... 7
HAMMER SPECIFICATIONS ...................................................................... 8
STRUCTURE ............................................................................................... 9
HAMMER SERIAL NUMBER LOCATION .................................................... 11
PRINCIPLE OF OPERATION ...................................................................... 12
HYDRAULIC INSTALLATION ...................................................................... 13
MOUNTING INSTALLATION ....................................................................... 16
ROUTINE INSPECTION AND MAINTENANCE ........................................... 17
TWENTY HOUR INSPECTION .................................................................... 18
CHANGING THE TOOL ............................................................................... 19
TROUBLESHOOTING ................................................................................. 21
CHECKING THE HYDRAULIC PRESSURES ............................................. 22
CHECKING THE HYDRAULIC FLOW ......................................................... 23
OIL LEAKAGE .............................................................................................. 25
GAS LEAKAGE ............................................................................................ 26
EXCESS OIL IN THE GAS HEAD INSPECTION PROCEDURE ................. 27
PREVENTION OF CONTAMINATION IN THE HYDRAULIC SYSTEM ....... 28
NITROGEN GAS PRESSURE ..................................................................... 29
GAS CHARGING KIT ................................................................................... 29
CHECKING THE GAS PRESSURE ............................................................. 30
GAS CHARGING THE HAMMER ................................................................ 32
REMOVAL AND MOUNTING OF HYDRAULIC HAMMER .......................... 34
TOOLS REQUIRED FOR DISASSEMBLY .................................................. 35
NPK START-UP KIT .................................................................................... 36
NPK ASSEMBLY LUBRICANT .................................................................... 37
DISASSEMBLY PROCEDURE .................................................................... 38
DISCHARGING GAS PRESSURE ............................................................... 39
DISASSEMBLING THE MAIN BODY ........................................................... 40
DISASSEMBLY OF MAIN VALVE ............................................................... 46
INSPECTION AND REPAIR AFTER DISASSEMBLY .................................. 48
REPLACING THE SEALS ............................................................................ 49
REASSEMBLY OF THE HAMMER .............................................................. 51
REPAIR SECTION INTRODUCTION ........................................................... 66
REPAIR TOOLS AND EQUIPMENT ............................................................ 66
HAMMER SLEEVE AND PISTON RECONDITIONING TOOLS .................. 67
MAIN BODY BORE REPAIR ........................................................................ 69
PISTON ACTIVE SEAL AREA REPAIR ....................................................... 79
PISTON TO SLEEVE RUNNING CLEARANCES ........................................ 80
REPAIR THE STRIKING END OF PISTON ................................................. 81
MAIN BODY SLEEVES ................................................................................ 81
STANDARD TOOLS .................................................................................... 82
ACCESSORY TOOLS .................................................................................. 82
MAXIMUM TOOL TO TOOL BUSHING CLEARANCE ................................ 83
NPK HYDRAULIC HAMMER IMPACT BUSHINGS ..................................... 85
TOOL INSPECTION ..................................................................................... 86
CHISEL TOOL RESHARPENING ................................................................ 87
STANDARD LENGTH FOR NPK TOOLS .................................................... 88
RETAINING PIN ........................................................................................... 89
LUBRICATION ............................................................................................. 90
AUTOLUBE/UNDERWATER PORT IDENTIFICATION ............................... 93
TOOL BUSHING REPLACEMENT .............................................................. 94
TOOL HOLDER BUSHING BORE REPAIR ................................................. 97
TOOL HOLDER ........................................................................................... 100
REPLACEMENT OF TIE RODS .................................................................. 101
MAXIMUM ELONGATION OF TIE RODS .................................................... 102
TIE ROD THREAD INSERTS ...................................................................... 103
TORQUE CHART......................................................................................... 104
TIE ROD TOP NUTS .................................................................................... 104
TORQUE VALUES FOR HAMMER FASTENERS ....................................... 105
MOUNTING PLATE ..................................................................................... 106
STORAGE OF HYDRAULIC HAMMER ....................................................... 107
DECIMAL CONVERSION CHART ............................................................... 108
REBUILD SPECIFICATIONS CHECK SHEETS .......................................... 109
NOTES ......................................................................................................... 116
SERVICE RECORD ..................................................................................... 116

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