Hydraulic Hammer

HYDRAULIC HAMMER
SERVICE MANUAL
PH SERIES HAMMERS
PH06 PH07
PH1 PH2
PH3 PH4
“Use Genuine NPK Parts”
7550 Independence Drive

Walton Hills, OH 44146-5541
Phone (440) 232-7900
Toll-free (800) 225-4379
Fax (440) 232-6294
© Copyright 2019 NPK Construction Equipment, Inc. www.npkce.com h055-9660H PH06,

PH07, PH1, PH2, PH3, PH4 Hyd Ham Service Manual 3-19
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 the 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.
-2-
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, see page 8.
The carrier must be stable during hammer operation and during transport.
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 if conditions warrant. Consult OSHA regulations.
13. Wear safety glasses at all times. Beware of flying debris.
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.
-3-
CONTENTS
SAFETY .......................................................................................................................................... 2
INTRODUCTION ............................................................................................................................ 6
BASIC OPERATING INSTRUCTIONS ........................................................................................... 6
PRECAUTIONS FOR USING THE NPK HYDRAULIC HAMMER .................................................. 7
CARRIER MACHINE COMPATIBILITY CHART ............................................................................ 8
HAMMER SPECIFICATIONS ......................................................................................................... 9
STRUCTURE .................................................................................................................................. 11
STRUCTURAL DRAWING .................................................................................................. 11
PRINCIPLE OF OPERATION ......................................................................................................... 14
HYDRAULIC INSTALLATION ......................................................................................................... 15
HAMMER CONTROL VALVE ............................................................................................. 15
PREVENTION OF CONTAMINATION ................................................................................ 17
CHANGING THE FILTER ELEMENT AND HYDRAULIC OIL ............................................ 17
HYDRAULIC QUICK DISCONNECTS ................................................................................ 18
MOUNTING INSTALLATION .......................................................................................................... 20
LUBRICATION ................................................................................................................................ 22
GREASING PROCEDURE ................................................................................................. 22
CORRECT FUNCTION OF GREASING AND GREASE INTERVALS ............................... 23
FUNCTION OF GREASING ................................................................................................ 23
GREASE INTERVALS ........................................................................................................ 23
CORRECT GREASE FOR HYDRAULIC HAMMERS ......................................................... 23
NPK HAMMER GREASE .................................................................................................... 24
AUTO LUBE SYSTEMS ...................................................................................................... 25
AUTO LUBE GREASE LINE PRE-FILLING ........................................................................ 26
PRIMING THE GREASE LINE ............................................................................................ 26
HAMMER MOUNTED AUTO LUBE GREASE LINE PRE-FILLING.................................... 28
PRIMING THE GREASE LINE ............................................................................................ 28
AUTO LUBE / UNDERWATER PORT IDENTIFICATION .............................................................. 32
DUST SUPPRESSION ................................................................................................................... 33
PH1, PH2, PH3 and PH4 MODELS .................................................................................... 33
HIGH HEAT APPLICATION ............................................................................................................ 35
ROUTINE INSPECTION AND MAINTENANCE ............................................................................. 36
WEEKLY INSPECTION .................................................................................................................. 37
ANTI-BLANK FIRE FEATURE ........................................................................................................ 38
TROUBLESHOOTING .................................................................................................................... 40
TROUBLESHOOTING CHART ........................................................................................... 40
CHECKING THE HYDRAULIC PRESSURES ................................................................................ 41
CHECKING THE HYDRAULIC FLOW AT RATED PRESSURE .................................................... 43
OIL LEAKAGE ................................................................................................................................ 45
GAS LEAKAGE ............................................................................................................................... 46
EXCESS OIL IN THE GAS HEAD INSPECTION PROCEDURE ................................................... 47
NITROGEN GAS PRESSURE ........................................................................................................ 48
GAS CHARGING KIT ..................................................................................................................... 48
CHECKING THE GAS PRESSURE ............................................................................................... 49
GAS CHARGING THE HAMMER ................................................................................................... 51
TOOLS AND EQUIPMENT REQUIRED FOR HAMMER DISASSEMBLY AND
ASSEMBLY ..................................................................................................................................... 53
NPK START-UP KIT ....................................................................................................................... 55
NPK ASSEMBLY LUBRICANT ....................................................................................................... 56
DISASSEMBLY PROCEDURE ....................................................................................................... 57
MODELS PH06 - PH07 ....................................................................................................... 57
MODELS PH1 THROUGH PH4 .......................................................................................... 58
DISCHARGING THE GAS PRESSURE ......................................................................................... 61
-4-
CONTENTS
INSPECTION AND REPAIR AFTER DISASSEMBLY .................................................................... 65
REPAIR SECTION INTRODUCTION ............................................................................................. 66
REPAIR TOOLS AND EQUIPMENT .............................................................................................. 66
HAMMER SLEEVE AND PISTON RECONDITIONING TOOLS .................................................... 67
MAIN BODY BORE REPAIR .......................................................................................................... 69
INSPECTION AND GENERAL POLISHING OF MAIN BODY ............................................ 69
NPK RECONDITIONING TOOL ......................................................................................... 70
REPAIR OF BODY BORE BY GRINDING AND POLISHING............................................. 71
HONING MAIN BODY ......................................................................................................... 73
MAIN BODY BORE DIMENSIONS ..................................................................................... 74
PISTON ACTIVE SEAL AREA REPAIR ......................................................................................... 75
PISTON REPAIR PROCEDURE ........................................................................................ 75
PISTON TO SLEEVE RUNNING CLEARANCES .......................................................................... 76
REPAIR THE STRIKING END OF PISTON ................................................................................... 77
MAIN BODY SLEEVES .................................................................................................................. 77
REPAIR OF SLEEVE INSIDE DIAMETER ......................................................................... 77
REPLACING THE SEALS .............................................................................................................. 78
REASSEMBLY OF THE HAMMER ................................................................................................ 80
GENERAL ........................................................................................................................... 80
PH06 – PH07 ...................................................................................................................... 87
PH1 – PH2 .......................................................................................................................... 94
PH3 – PH4 .......................................................................................................................... 101
START-UP OPERATION ................................................................................................................ 108
STANDARD TOOLS ....................................................................................................................... 110
ACCESSORY TOOLS .................................................................................................................... 110
TOOLS ............................................................................................................................................ 111
TOOL IDENTIFICATION ..................................................................................................... 111
CHANGING THE TOOL ...................................................................................................... 112
MAXIMUM TOOL TO TOOL BUSHING CLEARANCE ....................................................... 114
TOOL INSPECTION ........................................................................................................... 116
STANDARD LENGTH FOR NPK TOOLS ........................................................................... 117
CHISEL TOOL SHARPENING ............................................................................................ 118
ADAPTER TOOL REPLACEMENT ................................................................................................ 119
TOOL REPLACEMENT ...................................................................................................... 119
TOOL BUSHING REPLACEMENT ................................................................................................. 122
GAS HEAD BOLT TORQUE ........................................................................................................... 125
TORQUE VALUES FOR HAMMER FASTENERS ......................................................................... 126
MOUNTING PLATE ........................................................................................................................ 127
WELDS ........................................................................................................................................... 128
HARDFACING .................................................................................................................... 128
SURFACE PREPARATION ................................................................................................ 128
UNDERLAYMENT .............................................................................................................. 129
HARDFACE ........................................................................................................................ 129
STORAGE OF HYDRAULIC HAMMER .......................................................................................... 130
WARRANTY REGISTRATION FOR NEW UNITS .......................................................................... 131
WARRANTY STATEMENTS .......................................................................................................... 132
DECIMAL CONVERSION CHART ................................................................................................. 136
REBUILD SPECIFICATION CHECK SHEETS ............................................................................... 137
-5-
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 instruction manual contains instructions for repairing 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.
BASIC OPERATING INSTRUCTIONS

 READ OPERATORS MANUAL
Do not pry with tool.
Apply down force perpendicular to work surface.
Avoid blank hammering.
Do not hammer continuously in the same position for more
than 30 seconds.
 Important:
It is imperative that grease is maintained in the tool bushing
contact area at all times. This may require hourly greasing
depending on job conditions.
Important:
The hammer must be in a vertical position with downforce
applied to push the tool all the way in. This prevents grease
from entering piston impact area.
USE A GOOD QUALITY, HIGH TEMPERATURE EP#2
GREASE CONTAINING ANTIWEAR ADDITIVES.
If machine is equipped with an AUTO LUBE System, check grease reservoir daily.
 PERFORM VISUAL INSPECTIONS DAILY
Do not operate hammer if leaks are present or with loose or missing fasteners, etc.
 MAINTAIN A CLEAN HYDRAULIC SYSTEM
Keep hoses clean and capped when dismounting or storing hammer.
Change oil and filters as recommended by carrier manufacturer.
 DO NOT SUBMERGE HAMMER UNDERWATER
Unless modified for underwater operation.
-6-
PRECAUTIONS FOR USING THE NPK
HYDRAULIC HAMMER
 Perform daily inspections.
 Avoid blank hammering.
 Do not hammer continuously in the same position for more than 30 seconds.
 Do not use the hammer to move material, pry material, or as a pick on material.
 Do not use the hammer underwater unless the hammer has been modified for
underwater operation.
 Prevent contamination from entering the hydraulic hoses when mounting or
dismounting the hammer from the carrier.
 Maintain a clean hydraulic system. Replace the filter element with a new one and
change hydraulic oil at specified intervals.
 Operate the hammer carefully. Do not hit the boom of the carrier with the hammer.
 Operate the hammer in a safe manner. Read the NPK Hydraulic Hammer Operators
Manual.
If additional safety information is needed, consult the AEM Hydraulic Mounted Safety
Manual. To request a free copy, please contact NPK at 800-225-4379 or e-mail us at
www.npkce.com.
-7-
CARRIER MACHINE COMPATIBILITY CHART
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)
PH06 Excavator 2,200 - 4,400 (1,000 - 2,000)
Skid Steer 2,400 - 3,500 (1,100 - 1,600)
PH07 Excavator 2,900 - 4,850 (1,300 - 2,200)
Skid Steer 2,900 - 4,850 (1,300 - 2,200)
PH1 Excavator 4,850 - 5,955 (2,200 - 2,700)
Skid Steer 4,850 - 5,955 (2,200 - 2,700)
PH2 Excavator 5,955 - 8,820 (2,700 - 4,000)
Skid Steer 5,955 - 8,820 (2,700 - 4,000)
PH3 Excavator 8,820 - 13,228 (4,000 - 6,000)
Skid Steer 8,820 - 13,228 (4,000 - 6,000)
PH4 Excavator 13,228 - 19,842 (6,000 - 9,000)
Skid Steer 13,228 - 19,842 (6,000 - 9,000)
*Specifications are subject to change without notice.
-8-
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)
PH06 150 480 - 1200 Excavator 220 (100) 1.65 (42) 11.8 (300)
2-pc Skid Steer 525 (238)
PH07 200 450 - 1,300 Excavator 275 (125) 1.85 (47) 12.4 (316)
PH1 350 550 - 1,100 Excavator 500 (227) 2.24 (57) 14.0 (356)
PH2 500 500 - 1,200 Excavator 610 (277) 2.60 (66) 15.1 (384)
PH3 750 500 - 1,150 Excavator 990 (449) 2.99 (76) 16.5 (419)
PH4 1300 400 - 1,000 Excavator 1,235 (560) 3.39 (86) 18.5 (469)
Skid Steer N/A
MINIMUM
HAMMER HYDRAULIC HAMMER HYDRAULIC HYDRAULIC
MODEL OIL OPERATING CIRCUIT RELIEF
FLOW PRESSURE VALVE SETTING
gpm (lpm) psi (bar) psi (bar)
PH06 4-9 (15 - 35) 1,740 - 2,030 (120 - 140) 2,530 (174)
PH07 4-9 (15 - 35) 2,175 - 2,465 (150 - 170) 2,965 (204)
PH1 7 - 15 (25 - 55) 2,175 - 2,465 (150 - 170) 2,965 (204)
PH2 7 - 16 (25 - 60) 2,175 - 2,465 (150 - 170) 2,965 (204)
PH3 12 - 27 (45 - 100) 2,175 - 2,465 (150 - 170) 2,965 (204)
PH4 12 - 27 (50 - 120) 2,175 - 2,465 (150 - 170) 2,965 (204)
-9-
HAMMER SPECIFICATIONS
*NITROGEN GAS PRE-CHARGE

HAMMER AT AMBIENT AT OPERATING
MODEL TEMPERATURE TEMPERATURE
(cold before operating) (hot, after 1 to 2 hrs.
operation)
psi (bar) psi (bar)
PH06 175 (12) 220 (15)
PH07 175 (12) 220 (15)
PH1 175 (12) 220 (15)
PH2 175 (12) 220 (15)
PH3 175 (12) 220 (15)
PH4 175 (12) 220 (15)
*plus 0, minus 25 psi (2 bar)
Specifications are 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. Pressures listed are maximum. Use tolerance of minus 25 psi (2 bar).
- 10 -
STRUCTURE
STRUCTURAL DRAWING
MODEL PH06 - PH07
30 GREASE FITTING
A MAIN BODY
BB PLUNGER
D RETAINING PIN
E RETAINING PIN RING
G TOOL BUSHING
HH TOOL
L GAS HEAD
M GAS CHARGE VALVE
N PISTON
O MAIN BODY SLEEVE (A)
P MAIN BODY SLEEVE (B)
Z VALVE SPOOL
- 11 -
STRUCTURE
STRUCTURAL DRAWING
MODELS PH1 – PH4
30 GREASE FITTING
A MAIN BODY
BB PLUNGER
D RETAINING PIN
E RETAINING PIN RING
G TOOL BUSHING
HH TOOL
L GAS HEAD
M GAS CHARGE VALVE
N PISTON
O MAIN BODY SLEEVE (A)
P MAIN BODY SLEEVE (B)
Z VALVE SPOOL
- 12 -
HAMMER SERIAL NUMBER LOCATION
SERIAL NUMBER LOCATION (sn1)
- 13 -
PRINCIPLE OF OPERATION
OPEN VALVE
(1) UPSTROKE (2) VALVE SHIFT (3) POWER STROKE (4) IMPACT
N PISTON 33 NITROGEN GAS CHAMBER ABOVE PISTON

Z MAIN VALVE SPOOL 34 UPPER CHAMBER OF PISTON
BB PLUNGER 35 LOWER CHAMBER OF PISTON
HH TOOL 36 CHAMBER OF VALVE SPOOL
5 OUT PORT 37 NITROGEN GAS
6 IN PORT
(1) UPSTROKE OF PISTON

Hydraulic oil supplied by the carrier machine hydraulic pump enters the NPK HAMMER
"IN" port (6) and is directed through port (h1) to the top of the valve plunger, forcing the
main valve spool (Z) to the down position. Oil flows through the main valve spool (Z) to
the lower chamber of the piston (35). The oil pressure acts on the piston (N), raising the
piston up, compressing the nitrogen gas (37). Oil in the upper chamber of the piston (34)
is forced out the return line through port (h2).
(2) VALVE SHIFT
As the piston (N) rises, lower chamber (35) is opened to passage (h3) and oil flows into
the chamber (36) of the main valve spool (Z). Since the area acting on the main valve
spool (Z) in chamber (36) is greater than the area of the plunger (BB), the main valve
spool (Z) shifts up.
(3) POWER STROKE
With the main valve spool (Z) in the up position, chamber (35) is closed off from the "IN"
port (6) and opened to chamber (34) and the return line via passages (h4) and (h2). The
piston (N) is driven downwards by the compressed nitrogen gas (37) as the oil in lower
chamber (35) re-circulates to upper chamber (34). When the piston (N) opens passage
(h3) to upper chamber (34), the oil in main valve spool chamber (36) is switched to low
pressure and the main valve spool (Z) shifts down.
(4) IMPACT
The piston (N) impacts the tool (HH) and the main valve spool (Z) shifts to the down
position. High pressure oil is directed to the lower chamber of the piston (35) for the start
of another cycle.
AUTOMATIC ENERGY RECYCLING: Extremely hard material will impart greater rebound
energy to the piston (N) after it strikes the tool (HH). This will assist the incoming oil in raising
the piston (N) against the gas pressure in chamber (33). This reduces upstroke time and
therefore increases hammer frequency (beats per minute). The impact force of the hammer
remains the same on each impact.
- 14 -
HYDRAULIC INSTALLATION
Hydraulic installation kits are available for virtually all compatible backhoe loaders,
excavators and skid steers from the manufacturer.
Complete parts and instructions for NPK designed hydraulic installations including
valves and/or controls, hoses and fittings, boom and stick tubing and clamps can be
provided.
BACKHOE/EXCAVATOR HAMMER LINES

Typically, the pressure line should be arranged on the left side of the
boom and routed to the hammer “IN” port (6) and the return line is
routed from the hammer “OUT” port (5) on the right side. Flow to
the hammer is controlled from the carrier’s auxiliary valve or from an
NPK supplied flow valve. Hydraulic oil is generally routed back to
the tank thru the carrier’s oil cooler and filter.
SKID STEER HAMMER LINES

Flow to the hammer (m3) is directed from an auxiliary valve on the skid steer. NPK
hammer ports are marked “IN” and “OUT”. Return oil (m4) is routed back to tank
through the skid steer return hydraulic circuit.
HAMMER CONTROL VALVE

There are two general types of control systems
depending on 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 actuators,
flow control valves, etc., are supplied by the hydraulic kit supplier. NOTE: Special
pressure control valves are not required. The NPK Hammer hydraulic operating
pressure is self-regulating.
2. CONTROL SYSTEM USING THE NPK FLOW VALVE (MULTIVALVE).

For carriers not equipped with a suitable auxiliary or spare valve section, NPK can
provide a solenoid operated, priority flow control valve to operate the NPK hammer.
The NPK MULTIVALVE is specifically designed for the operation of boom mounted
attachments.
- 15 -
SKID STEER HAMMER FLOW CONTROL VALVE (OPTIONAL)
On skid steers where auxiliary flow is excessive for the NPK hammer model, an NPK
flow control valve (ma3) is recommended.
NOTE: Be sure that the pressure (m3) and return (m4) lines are properly routed.
Inlet pressure connects to port “P” on the NPK flow control valve. Regulated flow from
valve port “H” (m5) connects to the “IN” port on the NPK hammer. The “OUT” port on
the hammer connects to port “T2” (m6) on the flow control valve. Port “T1” connects
to the return line (m4) on the skid steer.
- 16 -
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 often becomes 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 or excavator, when using a hydraulic implement. Another
method is to set up an oil sampling schedule and change accordingly.
- 17 -
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 (32) 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 in 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 in 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.
NOT RECOMMENDED CONNECTION
APPROVED CONNECTION (39) Non-NPK Quick Disconnects (32)
NPK APPROVED CONNECTION QUICK DISCONNECTS

CONTACT YOUR NPK DEALER FOR ADDITIONAL INFORMATION ABOUT
NPK QUICK DISCONNECTS
ROFLEX COUPLING STUCCHI COUPLING
- 18 -
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 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 the male (DXm) coupler and
the female (DXf) before coupling.
3. Be sure that the couplers are

completely seated together (38).
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.
- 19 -
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,
mounting pins (optional), flow control valve (optional), and hoses to connect to the
carrier hydraulic system (optional).
BACKHOES and EXCAVATORS

AF Hex Head Cap Screw (if required)
g20 Male Adapter (if required)
m12 Hex Nut (if required)
DXm Male Quick Disconnect (if required)
DXf Female Quick Disconnect (if
required)
m1 Stick Pin (if required)
m2 Link Pin (if required)
m3 (Whip) Pressure Hose
m4 (Whip) Return Hose
m7 Top Bracket
m8 Hammer Bolt Package
m9 Klik Pin (if required)
SKID STEERS
NPK Mounting Installation Kits for skid

steers include parts required to adapt the
NPK HYDRAULIC HAMMER to the
carrier. NPK mounting kits include the
hammer mounting bracket (m7), and
hoses (m3 and m4) to connect to the
carrier hydraulic system. The flow control
valve (ma3) is optional.
REMOVAL FROM THE CARRIER

1. Close pressure and return line shut-off
valves (k4) if available.
2. Disconnect hydraulic hoses (m3 and
m4) before laying the hammer down.
3. Cap the pressure and return lines on
the carrier and connect the hammer
whip hoses to the hammer bracket.
4. Position the hammer (DR) horizontal
on wood blocks (t20) and remove stick
(m1) and link (m2) pins.
- 20 -
MOUNTING INSTALLATION
REMOVAL FROM THE SKID STEER
1. Position the hammer (DR) horizontally
onto the ground or wood blocks (t20)
as shown.
2. Disconnect both inlet and outlet
hoses.
3. Unlatch the mechanism holding the
hammer bracket to the carrier’s
coupler plate. (Consult the machine
manufacturer’s operator/instruction
manual for this procedure.
The tool end of the hammer should be set lower than the head end to prevent
moisture from entering the hammer through the tool area.
MOUNTING TO THE CARRIER

1. Place the hammer assembly (DR)
horizontally on wood blocks (t20) as
shown.
2. Align the stick pin bore (m26). Install
the stick pin. Then align the link pin
bore (m25).
3. Connect the pressure side hose (m3)
and the return side hose (m4).
4. Open the shut-off valves (k4) if
available.
MOUNTING TO THE SKID STEER

1. Place the hammer (DR) horizontally
onto wood blocks (t20) as shown.
2. Align the carrier’s coupler plate with
the hammer bracket. Couple the two
per the machine manufacturer
recommendations.
3. Connect the hoses.
Consult the skid steer manufacturer’s operators manual to

review the mounting and removal process!
The hydraulic lines must be handled carefully and sealed to
prevent contamination from entering the hammer or the
carrier’s hydraulic system.
- 21 -
LUBRICATION
GREASING PROCEDURE
Manual greasing for hammers without an Auto Lube System.
1. Place the hammer in a vertical position, applying enough down force to push the tool
up into the hammer.
2. Turn the carrier off.
3. Grease the hammer until grease begins to come out around the tool and the lower
end of the tool bushing.
4. Grease the hammer at least once per hour or install an NPK Auto Lube System.
See “CORRECT GREASE AND GREASE INTERVALS” for a more exact greasing
procedure.
APPLY DOWN FORCE TO PUSH TOOL UP INTO HAMMER
NOTE: USE A GOOD QUALITY EP #2 LITHIUM BASED GREASE WITH WEAR

INHIBITING ADDITIVES, SEE NEXT PAGE.
- 22 -
LUBRICATION
CORRECT FUNCTION OF GREASING AND GREASE INTERVALS
Proper hammer maintenance requires a sufficient supply of the correct grease to the
tool (chisel). It is recommended that an NPK AUTO LUBE SYSTEM be used.
FUNCTION OF GREASING
To properly grease, 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 Auto Lube System, the unit
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 FOR HYDRAULIC HAMMERS

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.
There are many manufacturers of grease that meet NPK’s recommendations. NPK
does not endorse any one brand as being superior to another. If you or your customers
question a brand to be used, please call the NPK Service Department at 800-225-4379.
- 23 -
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 two different temperature ranges: 350° and 500°F.
“Universal Plus” and “Super Duty” are lithium soap based products that resist 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 NPK PART

350 deg NUMBER
14 oz. (.397 kg) CARTRIDGE G000-1010
120 lb. (54 kg) KEG G000-1020
35 lb. (16 kg) PAIL G000-1030
400 lb. (181 kg) DRUM G000-1040
SUPER DUTY NPK PART

500 deg NUMBER
14 oz. (.397 kg) CARTRIDGE G000-1011
120 lb. (54 kg) KEG G000-1021
35 lb. (16 kg) PAIL G000-1031
400 lb. (181 kg) DRUM G000-1041
CHISEL PASTE NPK PART

500 deg NUMBER
14 oz. (.397 kg) CARTRIDGE G000-1050
*14 oz. (.397 kg) CARTRIDGE G025-1050
35 lb. (16 kg) PAIL G000-1060
400 lb. (181 kg) DRUM G000-1070
*Hammer Mounted Auto Lube only
- 24 -
LUBRICATION
AUTO LUBE SYSTEMS
An automatic greasing system is recommended to reduce hammer tool and bushing
wear. NPK offers two types of Auto Lube Systems:
“Auto Lube Pump” “Hammer Mounted Auto Lube Pump”
The NPK Auto Lube Systems are 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 Auto Lube pumps are 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 PH Series hammer models have a connection port (26) for an automatic greasing
system. Refer to the NPK Auto Lube Instruction Manuals for details.
If an Auto Lube System is not used, you can grease the unit manually through the
grease fitting (30).
- 25 -
LUBRICATION
AUTO LUBE GREASE LINE PRE-FILLING
It is mandatory that the supply line from the Auto Lube 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 in a vertical position,

applying enough down force to push the
tool up into the hammer.
2. Turn the excavator/backhoe off.
3. Fill the NPK Auto Lube pump reservoir

with a power greaser through the fill
fitting (30) on the side of the pump or
from the top by removing the fill cover
(a1). Use a premium quality grade EP-
2, high temperature grease with wear
inhibiting additive. (See “CORRECT
GREASE”.)
4. Disconnect the grease line (29) from the

Auto Lube main pump cartridge (a4).
5. Install NPK part number G100-8050, hose fill adapter (a13), onto the #6 JIC female
end of the grease line (29) previously removed.
ITEM PART DESCRIPTION

NUMBER
Grease Fitting - 1/4"
30 B160-4010 NPT male
Male x Female
F5 K301-6620 Adapter -
#6 JIC male x 1/4"
NPT female
- 26 -
LUBRICATION
AUTO LUBE GREASE LINE PRE-FILLING
6. Remove the grease line (29) at the

hammer assembly (KK).
7. Attach a grease gun (t37) or power

greaser to the grease line (29) leading
to the hammer.
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

10. Pump twenty more shots of grease,

using a grease gun or power greaser,
into the grease line (29). This will
prime the hammer tool cavity and pre-
lube the tool (HH). Look for grease
coming out around the tool at the tool
bushing (see arrow).
11. Remove the hose fill adapter (a13) and

re-connect the grease line (29) to the
Auto Lube pump (FZ).
NOTE: If the Auto Lube unit has run out of grease, the above procedure should
be used to purge all air out of the grease line before using the hammer.
Failure to do this will result in an intermittent supply of grease to the
hammer.
- 27 -
LUBRICATION
HAMMER MOUNTED AUTO LUBE GREASE LINE PRE-FILLING
It is mandatory that the supply line from the Auto Lube 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.
1. Place the hammer in a vertical

position, applying enough down force
to push the tool up into the hammer.
2. Turn the excavator/backhoe off.

3. Make sure there is a full grease
cartridge (a54) installed in the
Hammer Mounted Auto Lube
assembly. Ensure that the flat seal
(a65) in the lubrication passage (176)
is not damaged. Use a premium
quality grade EP-2, high temperature
grease with wear inhibiting additive.
(See “CORRECT GREASE”.)
4. Disconnect the grease line (29) at the

5. Attach a grease gun (t37) or power

greaser to the grease fitting (30) on
the front side of the Hammer Mounted
Auto Lube pump assembly (FZ).
6. Pump grease through the pump to the

grease line (29) until a steady stream
of grease (28) is realized at the
opposite (hammer) end.
- 28 -
LUBRICATION
HAMMER MOUNTED AUTO LUBE GREASE LINE PRE-FILLING
7. Re-attach the grease line (29) to the

8. Pump twenty more shots of grease, using a grease gun (t37) or power greaser into
the pump assembly (FZ). This will prime the hammer tool cavity and pre-lube the
tool (HH). Look for grease coming out around the tool at the tool bushing (see
arrow).
NOTE: If the Auto Lube unit has run out of grease, the above procedure should
be used to purge all air out of the grease line before using the hammer.
Failure to do this will result in an intermittent supply of grease to the
hammer.
- 29 -
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 Additives that under extreme pressure form an adherent
AGENTS 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.
- 30 -
LUBRICATION
LUBRICANT TERMS AND DEFINITIONS
TERM DEFINITION
RESERVOIR A container for keeping a supply of working fluid in a

hydraulic system.
VIBRATION A quivering or trembling motion.
VISCOSITY Is the actual SAE weight of the product. Example motor
oils come in 10, 20, 30, 40, 50 and 15/40 SAE weight.
The viscosity designation of a lubricant indicates its
internal resistance to flow.
- 31 -
AUTO LUBE / UNDERWATER PORT
IDENTIFICATION
NPK PH Series Hammers are equipped with two ports on the main body (A) used in
adapting for AUTO LUBE and underwater use. The air port (17) will allow the
connection of an airline that will allow the hammer to be used underwater. The grease
port (26), located in line with the air port, will allow for AUTO LUBE connection.
- 32 -
DUST SUPPRESSION
PH1, PH2, PH3 and PH4 MODELS
NPK offers an add-on water ready kit for PH Series hammers with enclosed brackets.
This system reduces dust at the point of impact in concrete, rock or whatever is being
broken.
An integrated water spray nozzle (wn1) located in the bracket of the hammer is aimed at
the point where the hammer’s tool (HH) makes contact with the breaking area. This,
combined with a wide spray angle, provides maximum dust suppression coverage.
NOZZLE LIST
HAMMER NOZZLE FREE PASSAGE MAXIMUM FILTER

MODEL PART NO. DIAMETER DIAMETER
in. (mm) in. (mm)
PH1 PH1-5020 .036 (0.91) .009 (0.23)
PH2 PH2-5020 .044 (1.12) .011 (0.28)
PH3 PH3-5020 .044 (1.12) .011 (0.28)
PH4 PH4-5030 .052 (1.32) .013 (0.33)
- 33 -
DUST SUPPRESSION
PH1, PH2, PH3 and PH4 MODELS
WATER READY KIT
HAMMER WATER HAMMER

MODEL READY BRACKET
KIT ASSY.
PH1 PH1-9200 PH1-8000
PH2 PH2-9200 PH2-8002
PH3 PH3-9200 PH3-8000
PH4 PH4-9200 PH4-8000
ITEM DESCRIPTION
NUMBER
AF hex head cap screw
f1 straight fitting
f2 straight fitting (PH4 only)
f5 male adapter fitting
LL1 enclosed hammer bracket
m29 hose clamp
U washer
wh1 water hose assembly
wn1 water spray nozzle
- 34 -
HIGH HEAT APPLICATION
NPK offers a high heat conversion kit for the PH1 through PH4 hammers.
HAMMER KIT PART

MODEL NUMBER
PH1 PH1-9510
PH2 PH2-9510
PH3 PH3-9510
PH4 PH4-9510
Kit includes:
AF Hex Head Cap Screw

AT Boom Pin Collar
C1 Hex Nut
D Retaining Pin
NOTE: No special seals are required. Standard seals will work with “MINERAL OIL”
based flame retardant oil.
NOTE: Water glycol based fluid may shorten seal life.
NOTE: Special protection for the hydraulic hoses is recommended.
- 35 -
ROUTINE INSPECTION AND MAINTENANCE
1. VISUAL INSPECTION
Detect a potential problem early.
FASTENERS
Inspect all fasteners and retighten as necessary. See pages 125 and 126 for torque
values.
WELDS Check for cracks, repair as necessary, see page 128.
HOSES AND TUBING Check for oil leaks, loose clamps and hose abrasion.
RUBBER MOUNTS Inspect for damage.
HYDRAULIC OIL
MAINTAIN A CLEAN HYDRAULIC SYSTEM
If non-petroleum oil is used, contact the NPK Service
Department for compatibility. Keep hoses clean and capped
when dismounting or storing hammer. Change oil and filters as
recommended by carrier manufacturer. Periodic oil sampling is
recommended.
2. DEMOLITION TOOL LUBRICATION
Important:
It is imperative that grease is maintained in the tool bushing contact
area at all times. This may require hourly greasing depending on
job conditions.
Important:
The hammer must be in a vertical position with downforce applied to push the tool all
the way in. This prevents grease from entering piston impact area. Pump grease into
grease fitting until grease is seen coming out between the tool and bushing.
USE A GOOD QUALITY, HIGH TEMPERATURE EP#2 GREASE CONTAINING ANTI-
WEAR ADDITIVES. 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.
If machine is equipped with an AUTO LUBE System, check grease reservoir daily.
3. TOOL and TOOL BUSHING WEAR
Check the tool and tool bushings for damage, wear or deformation on a regular weekly
basis. Replace the tool and/or bushings when wear exceeds the maximum clearance
limit. See MAXIMUM TOOL TO TOOL BUSHING CLEARANCE, see pages 114 and
115.
Do not hardface or sharpen the tool point with a cutting torch.
Excessive heat from torching or welding causes
embrittlement, breakage, and flying pieces. Resharpen only
with a lathe or milling machine using sufficient cooling.
Please consult your authorized NPK Dealer or NPK Service Department for additional
information.
4. DO NOT SUBMERGE HAMMER UNDERWATER
Unless modified for underwater operation.
- 36 -
WEEKLY INSPECTION
1. FASTENERS
Inspect all fasteners and retighten as necessary, see “TORQUE VALUES FOR
HAMMER FASTENERS”.
2. WELDS
Check for cracks and repair as necessary, see “MOUNTING PLATE”. Consult
your authorized NPK Dealer or NPK Service Department for additional
information.
3. TOOL RETAINING PIN

Remove the retaining pin and inspect for peening caused by excessive blank
hammering. If necessary, grind edges smooth as shown in “TOOL RETAINING PIN
INSPECTION”. The retaining pin must rotate freely.
4. DEMOLITION TOOL
Remove the demolition tool and inspect for peening caused by excessive blank
hammering. If necessary, grind edges smooth as shown in “TOOL INSPECTION”.
5. GAS CHARGE
Check and adjust, if required, see “NITROGEN GAS PRESSURE” and
“CHECKING THE GAS PRESSURE”.
- 37 -
ANTI-BLANK FIRE FEATURE
HOW TO SWITCH: PH06 THROUGH PH07 MODELS
1. Remove the hammer assembly (KK) from

the hammer bracket assembly (LL) and
place in a horizontal position, with the
ports facing upward on a workbench or
other secure place.
2. To use the hammer in anti-blank hammer

mode, you must remove the plug (pta) on
the side of the hammer body. Make sure
the pin (ppn) below the plug is in the
position shown in fig. 1. To remove and
switch the pin, there is a 4mm threaded
hole (49) provided. Re-install the plug
and torque to 30 ft. lbs. (40 Nm).
3. To use the hammer in the blank hammer

mode, you must remove the plug (pta) on
the side of the hammer body. Make sure
the pin (ppn) below the plug is in the
position shown in fig. 2. Re-install the
plug and torque to 30 ft. lbs. (40 Nm).
4. Install the hammer into the bracket assembly.
- 38 -
ANTI-BLANK FIRE FEATURE
HOW TO SWITCH: PH1 THROUGH PH4 MODELS
1. Remove the hammer assembly (KK) from

the hammer bracket assembly (LL) and
place in a horizontal position, with the
ports facing upward on a workbench or
other secure place.
2. Exchange the long plug (ptk), NPK part number 11071818, with the short plug (ptl),
NPK part number 11071826. Both plugs are threaded into the side of the hammer
body. Torque to 30 ft. lbs. (40 Nm).
a. To use the hammer in the anti-blank hammer mode, insert the short plug into
the upper port (abpu) and the long plug into the lower port (abpl).
b. To use the hammer in the blank hammer mode, insert the long plug into the
upper port (abpu) and the short plug into the lower port (abpl).
3. Install the hammer into the bracket assembly.
DO NOT change the anti-blank feature when the hydraulic oil is hot! Serious
injury can occur!
- 39 -
TROUBLESHOOTING
UNDERSTAND THE BASICS:
1. The NPK HYDRAULIC HAMMER hydraulic operating pressure is determined by the
nitrogen gas pre-charge pressure in the hammer, not the relief valve setting of the
carrier. NPK Hydraulic Hammers are self-regulating for hydraulic pressure.
2. The NPK HYDRAULIC HAMMER energy per blow is determined by the nitrogen gas
pre-charge pressure, not the pump volume. Impact energy is proportional to gas
pressure.
3. The NPK HYDRAULIC HAMMER frequency (blows per minute) is determined by oil
flow to the hammer. Frequency is proportional to oil volume (gallons per minute or
liters per minute). The hammer hydraulic circuit must be set to provide the correct
flow to the hammer.
TROUBLESHOOTING CHART
PROBLEM CAUSE CHECK REMEDY
Loss of impact power. Low gas pressure. Gas pressure Recharge gas
Loss of frequency Gas pressure too high. Gas pressure Reduce gas pressure.
(hammer slows down)
Shut-off valve partially Valve position Open valve.
closed.
Carrier relief valve set too Hydraulic pressure Adjust or replace carrier
low. Must be 400 to 500 psi relief valve.
(27 to 34 bar) over hammer
operating pressure.
Hydraulic oil temperature Oil temperature Reduce throttle. Clean or
too high. Should be 180⁰F add an oil cooler.
(83⁰C) or below.
Hydraulic pump volume too Oil flow Increase hydraulic circuit
low. flow.
Oil level of carrier too low. Oil level Add hydraulic oil.
Erratic running or Defective hydraulic pump or Hydraulic pressure Repair or replace
stops running. control valve. Hydraulic pump or control
valve.
Shut-off valve closed. Hydraulic pressure Open shut-off valve.
Hoses reversed. Hydraulic pressure Pressure is on the left and
return is on the right.
Return line blocked. Hydraulic pressure Eliminate obstruction.
Oil level of carrier too low. Oil level Add hydraulic oil.
Gas pressure too high. Gas pressure Reduce gas pressure.
Zero gas pressure. Gas pressure Check for leak and repair.
Hammer main valve Hydraulic pressure Disassemble and inspect
malfunctioning. valve components.
Hammer piston not cycling. Hydraulic pressure Disassemble hammer and
inspect piston.
DETERMINE THE CAUSE OF THE PROBLEM

Technical problems are caused by either (1) the hydraulic hammer or (2) the hydraulic
system (carrier hydraulics or installation kit). Checking the hydraulic pressure and flow,
and the hammer gas pressure, will determine if the problem is in the hammer or the
carrier. If the pressures and flow available to the hammer are correct, the problem is in
the hammer.
- 40 -
CHECKING THE HYDRAULIC PRESSURES
Install glycerin filled gauges in the

hammer pressure and return lines. If you
have an NPK Hydraulic Installation Kit
with shut-off valve (k4), install the gauges
in the gauge ports (k8) provided.
Each NPK shut-off valve has an “ON”

(k5) and an “OFF” (k6) position. Make
sure both shut-off valves are in the “ON”
position before attempting to operate your
attachment.
If there is no gauge port, install a swivel run tee (f3) with a reducer (a86), test hose
(t81) and 0-5000 psi gauge (g8f) in the pressure side or a 0-700 psi gauge (g8) in the
return side, between the hose connection (hf1) and pressure (m3) or return (m4)
hoses.
NOTE: The test hose should be long enough to be clear of the hammer and flying
debris.
1. DETERMINE RETURN LINE PRESSURE
If NPK shut-off valves are present, make sure they are in the “ON” position, and then
operate the hammer. The return line pressure should not exceed 300 psi (21 bar).
- 41 -
CHECKING THE HYDRAULIC PRESSURES
2. DETERMINE THE SYSTEM RELIEF VALVE PRESSURE
If available, turn the NPK pressure line

shut-off valve (k4) to the “OFF” position
(k6).
If not available, remove the pressure side

hose (m3) and cap (AR) the swivel “T”
(f3).
Energize the hammer control circuit and note the relief valve setting on the 0-5000 psi
gauge (g8f).
NOTE: The relief valve is used only for ultimate safety, when the hammer is removed
or the shut-off valve is closed. DO NOT use to set the hammer operating pressure.
Therefore, to prevent overheating, loss of flow and reduced hammer frequency, the
relief pressure should be set at a minimum of 500 psi (35 bar) above the listed hammer
operating pressure. Some carriers may require 1000 psi (70 bar). Call the NPK Service
Department at 1-800-225-4379 for details.
3. DETERMINE THE HAMMER OPERATING PRESSURE
Open both shut-off valves, if present. Operate the hammer and note the operating
pressure. The operating pressure of the NPK Hydraulic Hammer is self-regulating and
is determined by the gas pressure setting. If the operating pressure is low, check the
gas pressure. See “CHECKING THE GAS PRESSURE”.
NOTE: Stay clear of hammer when checking line pressures!
HAMMER HAMMER HYDRAULIC MINIMUM HYDRAULIC

MODEL OPERATING CIRCUIT RELIEF
PRESSURE VALVE SETTING
psi (bar) psi (bar)
PH06 1,740 - 2,030 (120 - 140) 2,530 (174)
PH07 2,175 - 2,465 (150 - 170) 2,965 (204)
PH1 2,175 - 2,465 (150 - 170) 2,965 (204)
PH2 2,175 - 2,465 (150 - 170) 2,965 (204)
PH3 2,175 - 2,465 (150 - 170) 2,965 (204)
PH4 2,175 - 2,465 (150 - 170) 2,965 (204)
- 42 -
CHECKING THE HYDRAULIC FLOW AT RATED
PRESSURE
1. Installation of a Flow Meter Equipped with Pressure Loading Valve.
Install the flow meter (t36) between the hammer pressure line and return as shown
below.
Generally, the pressure line (m3) is on the left and the return (m4) is on the right,
looking from the operator’s seat.
2. Determine Return Line Pressure (Backpressure).

Open both stop valves and press the hammer foot switch. Measure the pressure
with the load valve of the flow meter in full open condition.
- 43 -
CHECKING THE HYDRAULIC FLOW AT RATED
PRESSURE
3. Determine Relief Valve Pressure and Oil Flow.
Measure flow and pressure with the flow meter. Adjust the load valve to zero
restriction. Warm up the hydraulic system of the excavator to normal operating
temperature. Set engine throttle to maximum. Press hammer foot switch. Turn in
the loading valve knob and record the pressure and flow at regular intervals on
graph paper. Record pressure on one axis of the graph and flow on the other.
Increase pressure until relief setting is reached. This is the circuit flow chart. Refer
to hammer specification chart for correct flow at rated pressure for each hammer.
fm1. Load Valve

fm2. Flow/Temperature Display
fm3. Flow/Temperature Switch
fm4. Pressure Gauge
5. Out
6. In
Typical flow meter with pressure loading valve.
FLOW VS. PRESSURE CHART fl FLOW (GPM)

pr PRESSURE (PSI)
TYPICAL EXAMPLE
psi (bar)
- 44 -
OIL LEAKAGE
Exceeding 180F (80C) hydraulic operating temperature reduces seal life.
A small amount of oil leakage between the tool and tool bushing at location (pr2) is
considered normal.
If oil leak is significant, locate the point of origin. Oil running down the tool may be
coming from a loose hose.
It is normal for a new seal to leak slightly until the seal seats with usage.
POINTS TO CHECK FOR OIL LEAKAGE
PROBLEM CAUSE REMEDY

(pr1) Leakage through vent plug. Seal in main body sleeve A. Disassemble hammer and replace seals.
(Small amount is normal)
(pr2) Leakage between tool and Seal in main body sleeve B. Disassemble hammer and replace seals.
bushing. Small leakage is
normal here.
(pr7) Leakage hose and fitting. Loose or damaged hose fitting. Tighten or replace.
(pr11) Leakage between main O-ring between main body and gas Replace.
body and gas head. head.
Loose cap screws. Tighten.
(pr13) Leakage between main O-ring under port fitting. Replace.
valve body and port fitting. Loose fitting. Tighten.
(pr14) Leakage from plug. O-ring under plug. Replace.
Loose plug. Tighten.
- 45 -
GAS LEAKAGE
(If the gas pressure drops over 25 psi (2 bar) per day).
Exceeding 180F (80C) hydraulic operating temperature reduces seal life.
TO LOCATE GAS LEAK, APPLY SOAPY WATER (t23) AT THE POINTS INDICATED.
PROBLEM CAUSE REMEDY

(pr1) Leakage through vent plug. Seal in main body sleeve A. Disassemble hammer and replace
seals.
(pr9) Leakage from top of charge O-ring in check valve. Replace.
valve. Damaged check valve in charge Replace.
valve.
(pr10) Leakage between charge O-ring in charge valve. Replace.
valve and head. Loose charge valve. Use thread adhesive, tighten.
(pr11) Leakage between head O-ring in head. Disassemble hammer and replace
and main body. seals.
- 46 -
EXCESS OIL IN THE GAS HEAD INSPECTION
PROCEDURE
As the low pressure oil piston seal in the “A” Sleeve starts to wear out, the piston may
pull oil into the gas head. The gas volume is then decreased and the hydraulic oil
pressure required to move the piston to its full upstroke position increases.
With the hammer suspended, check and adjust the nitrogen gas pressure to the
ambient or to the hot specification shown in the chart below.
Load the hammer by pressing it against a solid object until the tool stops up inside. The
gauge reading should not be much above the loaded gas pressure shown on the chart
below. If the loaded gas pressure is high, there is excess oil in the gas head and the
hammer must be resealed.
HAMMER GAS CHARGE PRESSURE

MODEL AMBIENT TEMPERATURE OPERATING TEMPERATURE
(cold before operating) (hot, after 1 to 2 hrs. operation)
PRE-CHARGE AT LOAD PRE-CHARGE AT LOAD
psi (bar) psi (bar) psi (bar) psi (bar)
PH06 175 (12) 200 (14) 220 (15) 250 (17)
PH07 175 (12) 200 (14) 220 (15) 250 (17)
PH1 175 (12) 200 (14) 220 (15) 250 (17)
PH2 175 (12) 200 (14) 220 (15) 250 (17)
PH3 175 (12) 200 (14) 220 (15) 250 (17)
PH4 175 (12) 200 (14) 220 (15) 250 (17)
NOTES:
1. Cold gas charge is the initial set with the hammer at ambient temperature.
2. 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.
3. Pressures listed are maximum. Use a tolerance of minus 25 psi (2 bar).
- 47 -
NITROGEN GAS PRESSURE
The nitrogen gas pressure must be measured with no preload on the tool. Remove the
tool or position the hammer with the tool fully extended against the tool retaining pin.
The hammer must not be resting vertical on the tool. The gas pressure in the hammer
will vary according to the gas temperature.
PREFERRED METHOD
The preferred method to measure or charge the nitrogen gas pressure is with the
hydraulic system temperature stabilized after 1 to 2 hours of running and with a system
oil temperature of 140° to 180°F (60° to 80°C).
ALTERNATE METHOD
The nitrogen gas pressure can be measured or charged at ambient temperature (cold),
before operating the hammer. It is recommended the pressure be verified at operating
temperature.
DO NOT OVERCHARGE THE HAMMER!
Exceeding the gas pre-charge specifications can result in damaging
hammer components. The NPK WARRANTY does not cover failures resulting from
exceeding the specified nitrogen gas pressure.
NITROGEN GAS PRE-CHARGE

HAMMER AT AMBIENT TEMPERATURE AT OPERATING TEMPERATURE (hot,
MODEL (cold before operating) after 1 to 2 hrs. operation)
*psi (bar) *psi (bar)
PH06 175 (12) 220 (15)
PH07 175 (12) 220 (15)
PH1 175 (12) 220 (15)
PH2 175 (12) 220 (15)
PH3 175 (12) 220 (15)
PH4 175 (12) 220 (15)
*The gas charge tolerances plus 0, minus 25 psi (2 bar).
GAS CHARGING KIT

PART NO. 7300588
ALL NPK HYDRAULIC HAMMERS are furnished with the following gas charging kit. In
addition, a nitrogen tank and pressure regulator valve (not furnished with the hammer)
is required. These can be obtained from your local welding supply house. An optional
regulator valve is available from NPK.
g1. CHARGE ADAPTER (PART NO. 30604040)

g3. PLUG (PART NO. 30102050)
g4. HOSE (PART NO. 20118010)
g5. CHARGING KIT BOX (PART NO. 35001030)
g7. OPTIONAL REGULATOR VALVE (PART NO.
21101060)
- 48 -
CHECKING THE GAS PRESSURE
Inspect the nitrogen gas pressure every 100 hours.
PROCEDURE
1. The gas pre-charge is measured with

no preload on the tool (HH).
Remove the tool or position the
hammer assembly (DR) with the tool
fully extended.
2. Remove the charge valve cap (M1)

from the hammer charge valve (M).
Do not remove the charge valve
assembly!
3. Turn the NPK charge adapter T-

handle (g2) to a full counterclockwise
position.
4. Install the NPK charging adapter

(g1) on the hammer charge valve
located on hammer gas head (L).
5. Tighten the charge adapter cap (g6).
- 49 -
CHECKING THE GAS PRESSURE
6. Turn the T-handle (g2) clockwise.
As the T-handle is screwed in, a
resistance is encountered. By
turning the T-handle further, the
nitrogen gas pressure will be
indicated on the pressure gauge
(g8). Stop turning the T-handle
when the gauge reads pressure. Do
not overtighten!
7. Compare the gauge pressure with the NITROGEN GAS PRE-CHARGE chart in the
NITROGEN GAS PRESSURE section. If the gas is 25 psi (2 bar) or more below
the specification, proceed to the NITROGEN GAS CHARGING PROCEDURE
section of the manual. If the pressure is correct, go to the next step.
8. Turn the T-handle counterclockwise until it stops, as in step 3.
9. Slowly loosen the charge adapter cap to relieve the nitrogen gas pressure trapped
in the charge valve.
10. Remove the charge adapter from the hammer charge valve.
11. Replace the charge valve cap on the charge valve.
- 50 -
GAS CHARGING THE HAMMER
USE NITROGEN GAS

ONLY.
STAY CLEAR OF THE TOOL WHILE

CHARGING THE HAMMER WITH GAS. The
tool may be impacted by the piston and
forced out abruptly.
PROCEDURE
1. Carry out steps 1 thru 4 of CHECKING THE GAS PRESSURE.
2. Install a pressure regulator (g7) on a

tank (g9) of nitrogen gas.
3. Connect a hose (g4) from the

pressure regulator (g7) on the
nitrogen tank (g9) to the charge
adapter (g1).
4. Turn the T-handle (g2) on the charge
adapter (g1) clockwise.
5. Turn the handle (g7) on the tank

regulator counterclockwise to a fully
closed position. Do not over
tighten!
6. Open the valve (g10) on the nitrogen
tank (g9) by turning the handle
counterclockwise.
- 51 -
GAS CHARGING THE HAMMER
7. Slowly adjust the regulator on the nitrogen tank to the correct pressure by turning
the handle clockwise. Refer to the NITROGEN GAS PRE-CHARGE chart in the
NITROGEN GAS PRESSURE SECTION.
8. Charge the nitrogen gas, per the gas

charge decal (g11), until the pressure
gauge (g8) on the charge adapter (g1)
is at the correct setting, then turn the
T-handle (g2) counterclockwise all the
way out.
9. Close the nitrogen tank valve (g10),
and then remove the hose (g4) from
the charge adapter (g1).
- 52 -
TOOLS AND EQUIPMENT REQUIRED FOR
HAMMER DISASSEMBLY AND ASSEMBLY
HOIST
The minimum hoist capacity should be determined by the hammer model. Refer to
“HAMMER SPECIFICATIONS”, page 9 for hammer weights.
TORQUE WRENCH
SOCKET WRENCHES
See “GAS HEAD BOLT TORQUE” and “TORQUE VALUES FOR HAMMER
FASTENERS”.
SLEDGE HAMMER
Size accordingly to hammer model.
PLASTIC OR DEAD BLOW HAMMER
ADJUSTABLE WRENCH
HEX KEY WRENCHES
SHCS HEX NPK
SIZE SIZE PART NO.
M16 14mm 25004140
M18 14mm 25004140
M20 17mm 25004170
M22 17mm 25004170
M24 19mm 25004190
M27 19mm 25004190
LONG HEX KEY WRENCHES
When repairing NPK PH Series hammers, it is necessary to remove the socket head
cap screws that hold the gas head to the main body of the hammer. NPK has available
1 inch drive long sockets (t24) to aid disassembly. Use this socket with a hex key
wrench (t25) modified into a straight key by cutting off the short end as shown.
HEX NPK
SOCKET PART
SIZE NO.
14mm 35004590
17mm 35004600
19mm 35004610
- 53 -
TOOLS AND EQUIPMENT REQUIRED FOR
HAMMER DISASSEMBLY AND ASSEMBLY
NYLON ROD, P/N H010-7510
Is used to drive piston and sleeve “A” out of the main body bore.
NPK GAS CHARGING KIT
Is part of the NPK hammer start-up kit, see “NPK START-UP KIT” next page.
NITROGEN BOTTLE AND REGULATOR
CLEANING SOLVENT
NPK ASSEMBLY LUBRICANT
SUITABLE NYLON SLING

DRAIN PAN
EXTRACTOR TOOL
PH06 – PH07 PH1, PH2, PH3, PH4
- 54 -
NPK START-UP KIT
All new NPK Hammers are shipped with a start-up kit, part number H251-5100. This kit
will contain the following:
Gas Charging Kit (Red Box) Two (2) tubes of NPK grease for start up
Also, all NPK hammers are supplied with a customer instruction CD, operator’s manual,
operating instructions, safety information and warranty information.
- 55 -
NPK ASSEMBLY LUBRICANT
NPK ASSEMBLY LUBRICANT is specially formulated to provide quick, positive
lubrication. Oil rich ingredients, plus a free-flowing light lithium grease, offer top
lubrication, as well as long lasting protection against rust and corrosion. NPK
ASSEMBLY LUBRICANT even “creeps” into remote, normally inaccessible areas to
lubricate and safeguard interior metal surfaces. NPK ASSEMBLY LUBRICANT is ideal
for use on all metal-to-metal surfaces.
DIRECTIONS FOR USE
1. Wipe off exposed surfaces.

2. Shake vigorously to thoroughly mix contents.
3. Spray liberally on areas requiring lubrication.
NPK ASSEMBLY LUBRICANT contains NPK-10 Metal Treatment and is ideal for use
in the assembly of all NPK products. NPK ASSEMBLY LUBRICANT comes in a 16
ounce bottle with sprayer and can be ordered using part number H010-5010.
- 56 -
DISASSEMBLY PROCEDURE
A sturdy work bench is recommended for disassembly and assembly of NPK hydraulic
hammers.
MODELS PH06 - PH07
REMOVE THE HAMMER FROM THE BRACKET ASSEMBLY
1. Place the hammer on the table or work

bench. Make sure the hammer
assembly is stable. Remove the
bracket bolts (m11), nuts (m12),
washers (m13), and support tube (FW)
from the hammer bracket assembly
(LL).
2. Lift the hammer assembly (KK) from the

bracket (LL).
- 57 -
MODELS PH1 THROUGH PH4
REMOVE THE HAMMER FROM THE STANDARD BRACKET ASSEMBLY
1. Place the hammer on wood blocks (t20) (optional). Make sure the
hammer/bracket assembly (DR) is stable. Remove the bracket bolts (m11), nuts
(m12), washers (m13), support block (FV), and wear pad (AC) from the hammer
bracket assembly.
2. Install a (customer supplied) threaded rod (m35) or equal into the upper holes of
the key plates (GS), as shown. Using a wrench (t6), snugly tighten to the hammer
housing with hex nuts (m12). Make sure the threaded rod; hex nut assembly
cannot be removed by hand.
- 58 -
REMOVE THE HAMMER FROM THE STANDARD BRACKET ASSEMBLY
3. Remove the top two support tubes (FW).
4. Lift the hammer (KK) out of the

bracket (LL) with the key plates (GS),
threaded rod and hex nuts in place (as
shown). Lift the hammer assembly
only. Do not lift using the key plates
or threaded rod.
5. Set the hammer (KK) on blocks, or a secure flat surface.
6. Remove the threaded rod (m35) and

key plates (GS).
REMOVE THE HAMMER FROM THE ENCLOSED BRACKET
1. Place the hammer on wood blocks (t20) (optional). Make sure the
hammer/bracket assembly (DR) is stable.
2. Remove the bracket bolts (m11), nuts

(m12), support block (FV), wear pad
(AC), spacer plate (DE), top bracket
(m7), stopper (m31) and washer from
the hammer bracket assembly.
- 59 -
REMOVE THE HAMMER FROM THE ENCLOSED BRACKET
3. Lift the hammer assembly (KK) from

the bracket assembly (LL).
4. Remove the dampers (ph1 and ph2)

from the hammer assembly (KK).
- 60 -
DISCHARGING THE GAS PRESSURE
THE NITROGEN GAS MUST BE DISCHARGED FROM THE
HAMMER BEFORE DISASSEMBLY!
PROCEDURE
1. Remove the charge 2. Turn the NPK 3. Install the NPK charge
valve cap (M1) from the charge adapter T- adapter (g1) onto the
charge valve (M). Do handle (g2) to a full hammer charge valve
not remove the charge counterclockwise located on the hammer
valve assembly! position. gas head (L).
REMOVE THE VALVE CAP ONLY, NOT THE CHARGE
VALVE ASSEMBLY!
4. Tighten the charge 5. Turn the T-handle (g2) 6. Loosen the charge
adapter cap (g6). clockwise. As the T- adapter cap (g6)
handle is screwed in, a VERY SLOWLY!
resistance is The gas pressure will
encountered. By turning gradually decrease to
the T-handle, the zero. When it gets to
nitrogen gas pressure zero, remove the cap.
will be indicated on the
pressure gauge (g8).
Stop turning the T-
handle when the gauge
reads pressure. Do not
over tighten!
7. Remove the charge adapter (g1) from the gas charge valve on the hammer gas
head (L), then, reinstall the charge valve cap.
- 61 -
DISASSEMBLING THE MAIN BODY
Check to see that the nitrogen gas has been
completely discharged.
1. Loosen and remove the four socket head cap screws (OO) that attach the gas head
(L) to the main hammer body.
2. Remove the gas head.
a. Pry off the gas head (L) from the main body (A) using screwdrivers or pry bars as
levers, if necessary. Care should be exercised so as not to apply undue force.
b. Remove the plunger (BB) from the gas head (L).
c. Remove gas charge valve.
When the gas head is removed, hydraulic oil will

flow out of the body bore. Therefore, have oil pans
ready.
- 62 -
3. Remove piston and sleeves.
When the sleeves come out of the body, hydraulic

oil flows out. Have an oil pan ready to catch it.
a. Bump a nylon bar (t3) on the end of the b. Separate the “A” sleeve from the piston
piston (N) at the tool end (1) of the (N) by tapping the sleeve with a plastic
hammer and drive sleeve “A” (O) and or dead blow hammer (t2).
the piston out.
Do not use a steel bar to drive “A” and “B” sleeves

apart!
c. Use the sleeve extractor (t65a) to remove sleeve “B” from the main body (A).
1. Install the extractor into sleeve “B” (P).
2. The bolt head (per chart below) should be inserted into the first port (153) of
sleeve “B”.
HAMMER BOLT EXTRACTOR USE
MODEL HEAD PART NO.
PH06 P04 T190016 SLEEVE EXTRACTION
- 63 -
PH06, PH07 PH1, PH2, PH3, PH4
3. Turn the excavator bolt (tp06) clockwise, using protection (179) between it and
the main body to pull the sleeve out of the main body.
4. Using a magnet (t64), pull the main spool (Z) out of the main body (A).
5. Remove all plugs from the main body, if necessary.
- 64 -
INSPECTION AND REPAIR AFTER
DISASSEMBLY
As a rule, disassembly of the hydraulic hammer is only required when a problem occurs.
Periodic disassembly for inspection is not required.
1. Sealing materials - any sealing

material that is found deformed, worn
or damaged as shown, must be
replaced.
a. Deformed, worn, distorted, damaged or

deteriorated o-ring.
b. Worn or deformed backup ring. c. Worn or deteriorated u-cup seal.
2. Hammer Internals
a. Piston - 3. Tool and Tool Bushing Wear -
Check the sliding areas for damage See the “MAXIMUM TOOL TO TOOL
and the striking area for damage or BUSHING CLEARANCE” section of
deformation. Repair or replace, if this manual.
necessary.
b. “A” and “B” sleeves – 4. General -
Check the inner surface for damage a. Check for damage, breakage,
and repair or replace if necessary. deformation, wear and rust and
Complete hammer check sheets repair or replace, if necessary.
and fax to NPK for advice on reuse b. Check for contamination and
of main components. remove, if any.
c. Valve spool –
Check the sliding area for damage,
deformation, or wear and repair or
replace, if necessary.
d. Valve spool bore –
Check the inner surface for damage
or wear and repair or replace, if
necessary.
- 65 -
REPAIR SECTION INTRODUCTION
The NPK HYDRAULIC HAMMER is a rugged boom-mounted demolition tool which, by
its application, is subjected to severe repeated shock forces. Based on long years of
experience, NPK has carefully selected the best materials, heat treatment, and
machining to obtain the longest life possible. All critical components are 100%
inspected and identified by serial number. However, as with all machines, it is
necessary to perform periodic maintenance and repairs. The personal attention and
cost required for maintenance will be repaid many times over in trouble-free, low cost
operation.
The NPK replaceable sleeve concept is an exclusive feature that greatly extends the
useful service life of the NPK HYDRAULIC HAMMER. When competitive products
without this exclusive feature must be scrapped, the NPK HYDRAULIC HAMMER can
be completely rebuilt. This comprehensive SERVICE MANUAL contains detailed
instructions for repairing major components to achieve the extended life. Please read
this SERVICE MANUAL thoroughly before attempting any major repair of the hammer.
For additional information or help with any complex problem encountered, please
contact the NPK SERVICE DEPARTMENT. Call toll free 1-800-225-4379.
NOTE: Whenever repair or replacement of component parts is required, it is

recommended that only parts sold by NPK should be used. NPK is not
responsible for failures resulting from substitution of parts not sold or approved
by NPK.
REPAIR TOOLS AND EQUIPMENT
Air or electric handheld grinder (NPK brand air grinder is recommended, p/n NHG-65LD).
NPK Assembly Lube, p/n H010-5010.
Polishing wheel (available from NPK, p/n 25026030).
Oil stone
Emery cloth (200 grit)
Cleaning solvent
- 66 -
HAMMER SLEEVE AND PISTON
RECONDITIONING TOOLS
When repairing NPK Hammers, it is sometimes necessary to polish the piston, sleeves
or main body bore. NPK has available for purchase, a hand held, long shaft straight
grinder. NPK also sells the appropriate polishing and groove cleaning wheels to be
used in reconditioning these parts. The part numbers are provided below for ordering
purposes.
ITEM PART NO. DESCRIPTION

t1 NHG-65LD LONG SHAFT STRAIGHT GRINDER
POLISHING WHEEL – used for cleaning
t7 25026050 seal grooves in sleeves. (Green)
POLISHING WHEEL – used for final
t8 25026030 polishing of piston, sleeves and main
body bore. (Gray)
CUT-OFF WHEEL – used to clean and
t10 T050-7500 repair pressure balancing grooves in the
sleeve land area.
- 67 -
HAMMER SLEEVE AND PISTON
RECONDITIONING TOOLS
(t7) 25026050 POLISHING WHEEL (GREEN) (t8) 25026030 FINISH POLISHING WHEEL (GRAY)
USE THIS WHEEL FOR CLEANING OUT SEAL USE THIS WHEEL FOR FINAL POLISHING OF
GROOVES IN NPK “A” AND “B” SLEEVES. PISTON, MAIN BODY AND GLAND RING AREA OF
NPK “A” AND “B” SLEEVES.
(t10) T050-7500 CUT-OFF WHEEL

USE CUT-OFF WHEEL TO CLEAN AND REPAIR PRESSURE BALANCING GROOVES IN NPK “A”
AND “B” SLEEVES.
NOTE: WHEN RECONDITIONING PARTS, IF YOU ARE UNSURE OF THE

PROPER PROCEDURES, CONSULT THE NPK SERVICE MANUAL OR
CONTACT THE NPK SERVICE DEPARTMENT AT 1-800-225-4379.
- 68 -
MAIN BODY BORE REPAIR
INSPECTION AND GENERAL POLISHING OF MAIN BODY
After disassembly and cleaning of the hammer components, it is important to carefully
inspect the hammer main body bore.
1. Using a light, look into the bore and identify all locations (9) of the o-rings that seal
the sleeve O.D. to the body. These areas can be recognized by the black markings
left in the bore from the o-rings resting in these areas.
2. If no damage is noted in the o-ring areas, use a ball hone to break the glaze in the
bore of the body. DO NOT USE A FIXED HONE! USE ONLY 6 STROKES OF A
BALL HONE!
REMEMBER: ONCE THE SLEEVES ARE INSTALLED, THE O-RINGS BECOME

STATIONARY AND DO NOT MOVE OUT OF THE AREA THEY REST
IN.
3. If a scratch runs across several o-ring areas:
a. Polish o-ring rest areas to blend with surrounding area.

b. If scratches are not removed by use of a ball hone, see Repairing Body Bore
By Grinding and Polishing.
4. If score in o-ring area is too deep to polish and blend, the body must be replaced.
DO NOT WELD IN MAIN BODY BORE.
- 69 -
NPK RECONDITIONING TOOL
USING THE NPK AIR GRINDER
If cavitation erosion is found in the main body, in most instances it can be addressed by
light polishing in the area of erosion. DO NOT HONE THE BODY!
1. Take an NPK polishing wheel, part no. 25026030 (gray) (t8) and taper (45) each
side so that the wheel is “V” shaped. This can be done by holding the wheel against
the edge of a metal surface for several seconds.
2. Using a rocking motion, polish the erosion groove until the rough edges are
removed. This must be done so that the o-rings on the O.D. of the sleeves will not
be damaged during installation.
3. Clean bore using a ball hone making no more than 6 strokes. DO NOT HONE
USING A FIXED HONE!
4. After polishing, clean main body bore to remove all grinding debris.
NOTE: WHEN REASSEMBLING THE HAMMER, USE A LIBERAL AMOUNT OF

GREASE IN THE POLISHED AREA.
- 70 -
REPAIR OF BODY BORE BY GRINDING AND POLISHING
a. Locate the areas (9) of the bore that
are sealed by o-rings. These areas
can be located by the discoloration
from the o-rings. If you are unsure
of where the o-ring areas are
located, measure these areas on
the outside of the sleeves (“A” and
“B”) and mark on the inside bore of
the body using a permanent marker
to show the o-ring areas.
b. Locate the scratch or scratches

(11). The scratches must be less
than .006 inch (.15 mm) deep.
NOTE: SCRATCHES MORE THAN .006

inch (.15 mm) CANNOT BE
REPAIRED.
DO NOT WELD IN MAIN BODY BORE!
c. Grind the rough edges of the entire

length of the scratch. Use the gray
polishing wheel (t8).
d. Polish the scratches in the o-ring areas (9) to a smooth surface (10). Blend this
area to the surrounding surface. DO NOT OVER POLISH!
- 71 -
REPAIR OF BODY BORE BY GRINDING AND POLISHING
e. Check the bore dimension with a

bore gauge (t11). Compare with
the specifications shown in the
chart on page 74.
After polishing, remove all o-rings from the “B” sleeve (longest sleeve). Apply a light
coat of NPK Assembly Lubricant, part no. H010-5010.
Pass the sleeve in and out through the bore to check for any high spots, which require
additional polishing.
9. REPAIRED O-RING – CONTACT SURFACE

12. GROUND AREA – NO O-RINGS HERE
- 72 -
HONING MAIN BODY
Generally, honing of the main body is not recommended. This is due to trying to
maintain the I.D. of the body as close to the new standard dimension as possible.
However, when honing is required, the use of a ball hone is recommended. Using a
fixed power hone is not recommended, (consult NPK before using a fixed power hone).
The guidelines for using a ball hone are outlined below:
1. Apply a light coat of NPK Assembly Lubricant, p/n H010-5010 or equivalent oil.
2. Using the proper size hone as shown in the following chart, push / pull the hone
through the body no more than 6 times using even strokes.
3. Clean bore of the body. Check dimensions of I.D. Compare to the chart on next
page.
If dimensions are within usable limits, reassemble the hammer. If dimensions are
outside the allowable range, contact NPK for assistance.
- 73 -
MAIN BODY BORE DIMENSIONS
PH SERIES HAMMERS
HAMMER d5 d6 BALL BALL HONE

MODEL MAIN BODY BORE MAIN BODY BORE HONE PART
NEW *MAXIMUM SIZE NUMBER
in (mm) in (mm)
PH06 2.560 (65.035) 2.562 (65.100) N/A N/A
2.559 (65.000)
PH07 2.950 (74.925) 2.952 (74.980) N/A N/A
2.948 (74.901)
PH1 3.348 (85.035) 3.350 (85.100) 4" T050-7600
3.346 (85.000)
PH2 3.742 (95.035) 3.744 (95.100) 4" T050-7600
3.740 (95.000)
PH3 4.332 (110.035) 4.335 (110.100) 4-1/2" T050-7605
4.331 (110.000)
PH4 4.923 (125.035) 4.925 (125.100) 6" T050-7610
4.921 (125.000)
NOTE: *Body bore maximum I.D. is not to exceed .004” (.25mm) above standard (new)
dimension. If bore is at or above this dimension, call the NPK Service
Department at 1-800-225-4379.
- 74 -
PISTON ACTIVE SEAL AREA REPAIR
PISTON REPAIR PROCEDURE
Pistons with scratches or scoring in the active seal areas, denoted as d10 and d11 in
the illustration below, may be repaired by polishing as long as the running clearances
shown on next page are met. Damage that causes the piston to sleeve running
clearance to go beyond maximum allowed specifications will require piston
replacement. After repairing the piston in areas d10, d11 and d12, measure the
diameters with a micrometer, then contact the NPK Service Department via email or fax
(use the rebuild specification check sheets in the back of this manual) to confirm that
the piston is still within useable specifications. Areas d8 and d9 are not critical. Light
buffing to smooth out scratches is all that is required.
HAMMER d8 d9 d10 d11

MODEL in (mm) in (mm) in (mm) in (mm)
PH06 0.51 (13) 1.02 (26) 4.72 (120) 4.09 (104)
PH07 0.47 (12) 1.26 (32) 5.20 (132) 4.53 (115)
PH1 0.51 (13) 1.34 (34) 5.47 (139) 4.61 (117)
PH2 0.51 (13) 1.85 (47) 5.43 (138) 5.04 (128)
PH3 1.14 (29) 1.54 (39) 6.30 (160) 6.02 (153)
PH4 0.98 (25) 2.13 (54) 7.99 (203) 6.61 (168)
- 75 -
PISTON TO SLEEVE RUNNING CLEARANCES
The clearances shown below are to be used in determining if the internal components of
the hammer are reusable. Measure the inside diameter of the sleeve and subtract the
outside diameter of the piston at each location shown d10, d11 and d12. Each surface
has a corresponding “Land” in the “A” or “B” sleeve through which the piston rides.
These lands can be recognized by the multiple oil control grooves.
If the measurements are smaller than the values shown in the chart below, the piston
and sleeves are reusable. If any of the measurements exceed the values shown, call
the NPK Service Department at 800-225-4379, for recommendations on parts
replacement.
HAMMER d10 d11 d12

MODEL in (mm) in (mm) in (mm)
PH06 .016 (.400) .010 (.250) .004 (.110)
PH07 .016 (.400) .010 (.250) .004 (.110)
PH1 .016 (.400) .010 (.250) .004 (.110)
PH2 .016 (.400) .010 (.250) .005 (.120)
PH3 .016 (.400) .010 (.250) .005 (.120)
PH4 .016 (.400) .010 (.250) .005 (.130)
- 76 -
REPAIR THE STRIKING END OF PISTON
The NPK piston is designed for maximum fatigue resistance to failure of the striking
face. The striking face can become indented and mushroomed when the hammer has
been used for a long time or operated with worn-out tool bushings. To repair the piston,
dress the tool striking end with a grinder. If the measurement is below the minimum
shown, replace the piston.
HAMMER d13 - NEW d14 - MINIMUM

MODEL in (mm) in (mm)
PH06 13.07 (332) 12.87 (327)
PH07 14.17 (360) 14.02 (356)
PH1 14.37 (365) 14.17 (360)
PH2 15.47 (393) 15.24 (387)
PH3 17.91 (455) 17.64 (448)
PH4 20.87 (530) 20.59 (523)
MAIN BODY SLEEVES

REPAIR OF SLEEVE INSIDE DIAMETER
Scoring or galling may occur when the hammer has been
used for a long period of time; or operated with worn-out
tool bushings, loose tie rods, overheated hydraulic system,
or contaminated hydraulic oil. If the sleeve has slight
scratches or scoring, then repair by polishing. Call NPK for
detailed information.
If the sleeve is damaged from scoring or galling in the axial

direction, the oil grooves may be filled with metallic
particles. The oil grooves must be cleaned or they will
cause additional scoring.
- 77 -
REPLACING THE SEALS
If the gas pressure drops more than 25 psi (2 bar) a day or a large oil leak is found,
replace the seals.
 Check the seals, seal grooves, and piston active seal areas for damage.
1. Small nicks may be removed with a suitable hone.
2. When large or deep nicks are found, replace the part.
A. MAIN BODY
O. “A” SLEEVE
P. “B” SLEEVE
PP. U-CUP SEAL
QQ. DIRT SEAL
RR O-RING
1. TOOL END
2. GAS END
(DEFECTIVE SEALS)
ALL DEFECTIVE SEALS SHOULD BE
REPLACED WITH NEW ONES.
41. O-RINGS DEFORMED, WORN,

WARPED, DAMAGED OR
DETERIORATED
41.
42. BACKUP RINGS WORN OR

DEFORMED
42.
43. U-CUP SEALS WORN OR

DETERIORATED
43.
Some minor leakage may be found for a while after new oil
seals are installed, the oil leak will stop when the seal seats
itself in use.
- 78 -
REPLACING THE SEALS
1. INSTALLING THE U-CUP SEALS
a. One method of folding u-cup seals (PP) is illustrated below. Insert flat side into
groove.
HOW TO HOLD THE U-CUP SEAL

b. Installation should be performed quickly, taking care to observe the correct
direction. Taking too much time might let the u-cup take a set, which could
cause leaks.
c. Care should be exercised as not to damage the lip when installing the u-cup seal.
Installation of damaged u-cup seals will cause oil leaks.
d. After installing u-cups in the sleeve, coat them with grease to assist with piston
installation.
2. INSTALL THE O-RINGS.

a. Install the o-rings.
b. After installing, coat the o-rings with grease.
Inspect sleeves to verify that the o-rings and u-cup

seals are correctly arranged.
- 79 -
REASSEMBLY OF THE HAMMER
GENERAL
Reassemble the hydraulic hammer in the reverse order of disassembly.
1. Before reassembly, clean all parts carefully. Since the hydraulic hammer is a
precision machine, dust or dirt adversely affects its performance.
2. Reassemble the main body.
a. Place the main body (A) on a workbench (t31) or other secure, clean surface.
b. Reinstall gas charge valve at this time. Torque to 579 ft. lbs. (800 Nm).
c. Install the grease fitting (if it was removed) into the hammer body. Torque to
specification per torque charts on the following pages.
NOTE: Do not use Teflon tape on the grease fitting threads.
d. Apply oil to the threaded area and the o-ring of the JIS plugs. Install the plugs
and tighten to the torque specified in the port chart per hammer model.
e. Use thread sealant on the threads of the BSPT plugs and tighten to the torque
specified in the port chart per hammer model.
- 80 -
GENERAL
PORT CHART - PH06

ITEM PART PORT TORQUE O-RING
NUMBER NUMBER SIZE ft. lb. (Nm) P/N
pta 22001040 2 JIS 15 (30) N/A
ptb 22002040 4 JIS 30 (40) L1177-6010
ptd 22004050 8 JIS 75 (100) K556-6000
ptf 22001010 1/8" BSPT 11 (15) N/A
ptg 22002010 1/4" BSPT 22 (30) N/A
pth 22003010 3/8" BSPT 33 (45) N/A
ptm 11015831 1/8" BSPT 11 (15) N/A
pto₁ 11076569 6 JIS 52 (70) K030-6000
30₂ 25302030 1/4" BSPT 22 (30) N/A
1. See "ANTI-BLANK FIRE FEATURE", page 38 for plug installation.
2. Do Not use Teflon tape on grease fitting threads.
- 81 -
GENERAL
PORT CHART - PH07

pta 22001040 2 JIS 15 (30) N/A
ptb 22002040 4 JIS 30 (40) L1177-6010
ptd 22004050 8 JIS 75 (100) K556-6000
ptf 22001010 1/8" BSPT 11 (15) N/A
ptg 22002010 1/4" BSPT 22 (30) N/A
pth 22003010 3/8" BSPT 33 (45) N/A
ptm 11015831 1/8" BSPT 11 (15) N/A
ptn₁ 11076720 4 JIS 30 (40) L1177-6010
30₂ 25302030 1/4" BSPT 22 (30) N/A
1. See "ANTI-BLANK FIRE FEATURE", page 38 for plug installation.
- 82 -
GENERAL
PORT CHART - PH1

pta 22001040 2 JIS 15 (30) N/A
ptb 22002040 4 JIS 30 (40) L1177-6010
ptd 22004050 8 JIS 75 (100) K556-6000
ptf 22001010 1/8" BSPT 11 (15) N/A
ptg 22002010 1/4" BSPT 22 (30) N/A
pth 22003010 3/8" BSPT 33 (45) N/A
ptk₁ 11071818 4 JIS 30 (40) L1177-6010
ptl₂ 11071826 4 JIS 30 (40) L1177-6010
ptm 11015831 1/8" BSPT 11 (15) N/A
30₃ 25302030 1/4" BSPT 22 (30) N/A
1. Long plug, See "ANTI-BLANK FIRE FEATURE", page 38 for plug installation.
2. Short plug, See "ANTI-BLANK FIRE FEATURE", page 38 for plug installation.
- 83 -
GENERAL
PORT CHART - PH2

pta 22001040 2 JIS 15 (30) N/A
ptb 22002040 4 JIS 30 (40) L1177-6010
ptd 22004050 8 JIS 75 (100) K556-6000
ptf 22001010 1/8" BSPT 11 (15) N/A
ptg 22002010 1/4" BSPT 22 (30) N/A
pth 22003010 3/8" BSPT 33 (45) N/A
ptk₁ 11071818 4 JIS 30 (40) L1177-6010
ptl₂ 11071826 4 JIS 30 (40) L1177-6010
ptm 11015831 1/8" BSPT 11 (15) N/A
30₃ 25302030 1/4" BSPT 22 (30) N/A
- 84 -
GENERAL
PORT CHART - PH3

pta 22001040 2 JIS 15 (30) N/A
ptb 22002040 4 JIS 30 (40) L1177-6010
ptc 22003040 6 JIS 52 (70) K030-6000
pte 22006050 12 JIS 118 (160) 61100240
ptg 22002010 1/4" BSPT 22 (30) N/A
pth 22003010 3/8" BSPT 33 (45) N/A
ptk₁ 11071818 4 JIS 30 (40) L1177-6010
ptl₂ 11071826 4 JIS 30 (40) L1177-6010
ptm 11015831 1/8" BSPT 11 (15) N/A
30₃ 25302030 1/4" BSPT 22 (30) N/A
- 85 -
GENERAL
PORT CHART - PH4

pta 22001040 2 JIS 15 (30) N/A
ptb 22002040 4 JIS 30 (40) L1177-6010
ptc 22003040 6 JIS 52 (70) K030-6000
pte 22006050 12 JIS 118 (160) 61100240
ptg 22002010 1/4" BSPT 22 (30) N/A
pth 22003010 3/8" BSPT 33 (45) N/A
ptj 22004010 1/2" BSPT 45 (61) N/A
ptk₁ 11071818 4 JIS 30 (40) L1177-6010
ptl₂ 11071826 4 JIS 30 (40) L1177-6010
ptm 11015831 1/8" BSPT 11 (15) N/A
30₃ 25302030 1/4" BSPT 22 (30) N/A
- 86 -
PH06 – PH07
1. Check the fit of the “B” sleeve into the main body bore.
a. Lightly oil the main body bore (d5).
b. Before installing the o-rings on the sleeve (P), check the fit of the sleeve by
sliding it fully into the bore of the main body. The sleeves should move smoothly
without binding.
2. Install the “B” sleeve.

a. Apply hydraulic oil on the o-rings (RR), piston seals (PP) and dirt seal (QQ), then
install them into the “B” sleeve (P).
b. Apply hydraulic oil or NPK assembly lube (p/n H010-5010) into the bore of the
main body.
- 87 -
PH06 – PH07
c. Lube and install the final o-ring (RRf) at the tool end of the “B” sleeve. Next,
install the “B” sleeve (P) into the main body (A) with the sleeve projections (163)
in the 3 o’clock – 9 o’clock position facing the gas end of the hammer. Move the
“B” sleeve in until it reaches the main body’s inlet port (6). Make sure that no o-
rings are protruding. Then, use a dead blow hammer or rubber mallet to tap the
sleeve in until the last groove (25) is showing.
3. Install the piston.

a. Apply hydraulic oil or NPK assembly lube to the inner surface of the already
installed “B” sleeve.
b. Insert the piston (N) into the “B” sleeve (P). Use an up and down motion to move
it past the piston and dirt seals.
Care should be exercised so as not to damage the “B” sleeve

or piston with the above up and down motion.
- 88 -
PH06 – PH07
4. Install the “A” sleeve.
a. Apply hydraulic oil on the o-rings (RR) and piston seals (PP), and then install
them into the “A” sleeve (O).
b. Apply hydraulic oil or NPK assembly lube to the inner surface of the “A” sleeve.
c. Insert the “A” sleeve onto the piston, and then align the notches (164) with the
projections (163) on the “B” sleeve (P).
d. NOTE: The flat surfaces (fs) on the “A” sleeve (O) must be in the 6 o’clock –
12 o’clock position.
- 89 -
PH06 – PH07
Be sure that the “A” and “B” sleeves have no gap between
them before they are pushed into the main body.
5. Tap the “A” sleeve, “B” sleeve and piston into the main body (A) as a unit, using a
dead blow hammer (t2) or a rubber mallet.
6. Ensure that the piston and sleeves are fully engaged into the main body.
a. Make sure that the “A” sleeve (O), “B” sleeve (P), piston (N) assembly is seated
all the way into the main body bore (d5). Check dimension “d2” at the gas end
(2) of the hammer body. If “d2” is more than the value shown, either the “A”
sleeve is not fully engaged into the “B” sleeve or the o-ring on the tool end of the
“B” sleeve is out of place. Rotate the “A” sleeve slightly and push in toward the
“B” sleeve. If this doesn’t work, the sleeves and piston must be pulled out until
the “A” sleeve comes clear to check for “A” sleeve engagement into the “B”
sleeve. If sleeve engagement is good, the piston sleeve assembly must be
completely disassembled (the “B” sleeve o-ring is out of place).
HAMMER DIMENSION d2
MODEL in. (mm)
PH06 0.79 (20)
PH07 0.79 (20)
- 90 -
PH06 – PH07
7. Reassemble valve and gas head.
a. Apply hydraulic oil or NPK assembly lube on the main valve spool (Z), and then
install it into the main hammer body (A). NOTE: Make sure the spool moves
freely in the body bore, and then push it to the bottom of the bore.
b. Apply a thin coat of grease on the two o-rings (RR). Install on the main body
face.
c. Apply hydraulic oil or NPK assembly lube on the plunger (CC), and then install it
into the gas head (L). NOTE: Make sure the plunger moves freely in the gas
head.
d. Apply a thin coat of grease on the o-ring (RR), then install over on the protruding
portion of the “A” sleeve (O).
e. Pour the specified amount of synthetic oil into the gas head (L). 10W-40 or
15W-50 synthetic motor oil (47) is acceptable.
HAMMER OIL CAPACITY

MODEL oz. (cc)
PH06 0.7 (20)
PH07 1.2 (20)
- 91 -
PH06 – PH07
8. Mount the gas head to the hammer main body.
a. Mount the gas head (L) to the main body making sure to fit the notch of the gas
head into the projection of the “A” sleeve. If the gas head does not align to the
main body (A), tap and rotate the gas head with a dead blow hammer (t2) or a
rubber mallet until the gas head aligns (161) with the body.
If there is a gap (d94) present when mounting the gas head,

there is the possibility that either the projections and notches
at the “A” sleeve, “B” sleeve mating surface or at the “A” sleeve gas head mating
surface are not lined up. Also, there is a possibility that the o-ring on the tool end
of the “B” sleeve is out of place. Disassembly of the gas head, “A” and “B”
sleeves will be necessary.
9. Install gas head cap screws.

a. Apply never seize to the four cap screws (OO).
b. Install two of the cap screws diagonally and evenly tighten them by hand.
c. Repeat the procedure with the other two cap screws.
d. Torque per instructions on page 124.
- 92 -
PH06 – PH07
10. Charge the hammer with nitrogen gas and inspect for leaks.
a. Charge with nitrogen gas to the specified pressure setting. See “Gas Charging
the Hammer” on pages 48 and 51.
b. Check for gas leaks. See “Gas Leakage” on page 46.
11. Fill the hammer assembly (KK) with hydraulic oil.

a. Remove the large plug (AS) from the top of the hammer body. Remove the cap
(AR) from the “IN” port (6) of the hammer. Pour oil from a container (t52) into
the port where you removed the plug.
b. Let air that is trapped in the assembly purge out. Continue to fill with oil if
necessary.
c. Re-install plug and torque to specification, see pages 81 to 86.
12. Install the hammer assembly into the hammer bracket.
- 93 -
PH1 – PH2
sliding it fully into the bore of the main body. The sleeve should move smoothly
without binding.

main body.
- 94 -
PH1 – PH2
install the “B” sleeve (P) into the main body (A) with the sleeve projections (163)
in the 3 o’clock – 9 o’clock position facing the gas end of the hammer. Move the
sleeve in until the last port groove (25) is showing.


- 95 -
PH1 – PH2
c. Insert the “A” sleeve onto the piston, and then align the notches (164) with the
projections (163) on the “B” sleeve (P).
5. Tap the “A” sleeve, “B” sleeve and piston into the main body (A) as a unit, using a
dead blow hammer (t2) or a rubber mallet.
- 96 -
PH1 – PH2
all the way into the main body bore. Check dimension “d2” at the gas end (2) of
the hammer body. If “d2” is less than the value shown, either the “A” sleeve is
not fully engaged into the “B” sleeve or the o-ring on the tool end of the “B”
sleeve is out of place. Rotate the “A” sleeve slightly and push in toward the “B”
sleeve. If this doesn’t work, the sleeves and piston must be pulled out until the
“A” sleeve comes clear to check for “A” sleeve engagement into the “B” sleeve. If
sleeve engagement is good, the piston sleeve assembly must be completely
disassembled (the “B” sleeve o-ring is out of place).
HAMMER DIMENSION d2
MODEL in. (mm)
PH1 0.51 (13)
PH2 0.59 (15)

face.
- 97 -
PH1 – PH2
head.
d. Apply a thin coat of grease on the o-ring (RR), then install on the gas head.
15W-50 synthetic motor oil is acceptable.
HAMMER OIL CAPACITY

MODEL oz. (cc)
PH1 1.2 (30)
PH2 1.2 (30)

a. Mount the gas head (L) to the main body making sure to fit the notch of the gas
head into the projection of the “A” sleeve. If the gas head does not align to the
main body (A), tap and rotate the gas head with a dead blow hammer (t2) or a
rubber mallet until the gas head aligns (161) with the body. NOTE: Make sure
the gas head does not come out of the projection of the “A” sleeve.
- 98 -
PH1 – PH2

there is the possibility that either the projections and notches
at the “A” sleeve, “B” sleeve mating surface or at the “A” sleeve gas head mating
surface are not lined up. Also, there is a possibility that the o-ring on the tool end
of the “B” sleeve is out of place. Disassembly of the gas head, “A” and “B”
sleeves will be necessary.

- 99 -
PH1 – PH2
necessary.
- 100 -
PH3 – PH4
sliding it fully into the bore of the main body. The sleeve should move smoothly
without binding.

main body.
- 101 -
PH3 – PH4
install the “B” sleeve (P) into the main body (A) with the dowel pin holes (Kh) in
the 3 o’clock – 9 o’clock position, facing the gas end of the hammer. Move the
sleeve in until the last groove (25) is showing.


- 102 -
PH3 – PH4
c. Insert dowel pins into “B” sleeve.
d. Insert “A” sleeve onto piston and align the dowel pins (already installed) with the
dowel pin holes on the “A” sleeve.
5. It is suggested to use a portable power unit (t33) to push “A” sleeve (O), piston, and
“B” sleeve into position from the gas end (1). Use the dimensions in the chart on the
next page to locate final position. Take care to watch o-rings and back up rings on
the sleeves as they enter the bore.
- 103 -
PH3 – PH4
all the way into the main body bore. Check dimension “d2” at the gas end (2) of
the hammer body. If “d2” is less than the value shown, either the “A” sleeve is
not fully engaged into the “B” sleeve or the o-ring on the tool end of the “B”
sleeve is out of place. Rotate the “A” sleeve slightly and push in toward the “B”
sleeve. If this doesn’t work, the sleeves and piston must be pulled out until the
“A” sleeve comes clear to check for “A” sleeve engagement into the “B” sleeve. If
sleeve engagement is good, the piston sleeve assembly must be completely
disassembled (the “B” sleeve o-ring is out of place).
HAMMER DIMENSION d2
MODEL in. (mm)
PH3 0.87 (22)
PH4 0.87 (22)

face.
- 104 -
PH3 – PH4
head.
d. Apply a thin coat of grease on the o-ring (RR), then install on the gas head.
15W-50 synthetic motor oil is acceptable.
HAMMER OIL CAPACITY

MODEL oz. (cc)
PH3 2.0 (50)
PH4 2.0 (50)

a. Install dowel pins into “A” sleeve.
b. Mount the gas head (L) to the main body making sure to align the dowel pins
(previously inserted into “A” sleeve) with the dowel pin holes in the gas head. If
the gas head does not align to the main body (A), tap and rotate the gas head
with a dead blow hammer (t2) or a rubber mallet until the gas head aligns with
the body. NOTE: Make sure the gas head does not come out of the projection
of the “A” sleeve.
- 105 -
PH3 – PH4

there is the possibility that the dowels pins at the “A” sleeve,
“B” sleeve mating surface or at the “A” sleeve gas head mating surface are out of
place. Also, there is a possibility that the o-ring on the tool end of the “B” sleeve
is out of place. Disassembly of the gas head, “A” and “B” sleeves will be
necessary.

- 106 -
PH3 – PH4
necessary.
- 107 -
START-UP OPERATION
HAMMERS THAT ARE NEW, REBUILT, OR HAVE
BEEN INACTIVE
Before using a new hammer for the first time, the first time after rebuild, or a
hammer that has been inactive for a long period of time:
1. Check the nitrogen gas pressure.
The nitrogen gas pre-charge is factory checked before shipment. However, it is
recommended the pressure be checked before using the NPK HYDRAULIC
HAMMER for the first time. For the inspection procedure, see CHECKING THE
GAS PRESSURE.
2. At idle (THP1), raise the hammer off the ground.
Place the hammer vertical and activate the hammer hydraulic circuit for 3 – 5 second
intervals. Continue for an additional 3 – 4 times to ensure that all the air has been
purged from the hoses and the hammer before first use. Failure to do this could
result in damage to the hammer’s internal components.
3. Place the hammer firmly against the material to be broken (see “PRELOAD
THE TOOL BEFORE STARTING”).
Operate the hammer in a vertical position for approximately 10 minutes at one-half
(THP2) engine speed. Increase the engine speed to three-quarters (THP3) and
continue operating at this speed for another 10 to 20 minutes. Increase to full
engine speed (THP4). Maintain vertical position for the duration of the operation.
- 108 -
START-UP OPERATION
BEFORE STARTING THE HAMMER
PRE-OPERATION INSPECTION AND WARM UP

Before operating the NPK HYDRAULIC HAMMER, be sure to perform the specified
inspection, see “ROUTINE INSPECTION AND MAINTENANCE”.
Warm up the NPK HYDRAULIC HAMMER, see below, and the base machine in
accordance with the machine manufacturer’s instruction manual. This is especially
important during cold weather operation.
DAILY START-UP PROCEDURE

Operate the NPK HYDRAULIC HAMMER in the vertical position, at 3/4 engine throttle
setting, for about 1-2 minutes. During this period, inspect the NPK HYDRAULIC
HAMMER and INSTALLATION KIT for leaks or loose connections.
Do not operate on a
slanted surface during
the start-up operation.
- 109 -
STANDARD TOOLS
DEMOLITION TOOL SHAPE APPLICATIONS
 Trenching
CHISEL (FX)  Cutting casting gates
The cross cut (FX) tool  Breaking oversize
cuts at right angle, or  General demolition
crosswise, to the stick and
boom of the excavator.
 Concrete breaking
MOIL (P)  Highway construction
 General demolition
 Secondary breaking
BLUNT (E)  Breaking oversize
 Slag removal
ACCESSORY TOOLS
SPECIALTY TOOL SHAPE APPLICATIONS
FROST CUTTER  Edge of trenching
Cross cut (SX), In Line (SY)  Frost cutting
for PH1 – PH4
ADAPTER TOOL  For attachments listed

for PH1 – PH4 below
TAMPER PLATE  Soil compaction

(use with adapter tool)  Driving sheeting
12” x 12” for PH1 – PH2
16” x 16” for PH3 – PH4
POST and PIPE DRIVER  Driving guard rails

(use with adapter tool)  Driving fence posts
for PH1 – PH4
- 110 -
TOOLS
TOOL IDENTIFICATION
NPK demolition tools can be identified by the numbers found stamped in the retaining
pin slot area. These numbers must be included in all warranty correspondences
regarding a broken tool. Photos must also be included.
- 111 -
TOOLS
CHANGING THE TOOL
TOOL REMOVAL
1. Remove the two socket head cap

screws (OO) that attach the retaining
pin stopper plate (GK) to the
hammer bracket. Remove the
retaining pin stopper plate.
Figure 1
2. Remove the retaining pin ring (E) by using a screwdriver (t22), see Figures 2
and 3. It will easily come out if pried at an angle as shown in Figure 3.
Figure 2 Figure 3
3. Remove the retaining pin ring (E).
Figure 4
4. Screw a 6mm hex head bolt (AF) or cap screw into the retaining pin (D).
5. Pull the retaining pin out. If the

retaining pin is jammed, use a
hammer and drift pin to drive it out
from the opposite side.
Figure 5
- 112 -
TOOLS
CHANGING THE TOOL
TOOL REMOVAL
6. Remove the tool (HH).
Figure 6
TOOL INSTALLATION
1. Clean the retaining pin bore.
2. Coat the surface of the tool (HH) with

grease, then install.
Figure 7
3. Coat the retaining pin (D) with grease, then install.
4. Install the retaining pin ring (E) by using the handle of a screwdriver (t22) as
shown in Figure 9.
Figure 8 Figure 9
5. Install the retaining pin stopper plate

(GK). Torque bolts (OO) to 85 ft lbs
(115 Nm).
Figure 10
- 113 -
TOOLS
MAXIMUM TOOL TO TOOL BUSHING CLEARANCE
Replace the tool bushing (BF), and/or tool (HH), when the tool to bushing gap reaches
the maximum clearance. To determine whether the bushing or tool requires
replacement, follow the instructions and charts shown below:
Step 1
Measure the tool to bushing gap (d15) with the hammer horizontal, as illustrated below.
If the clearance is at or greater than the charted maximum clearance, then move on to
the next steps.
MAXIMUM
HAMMER CLEARANCE
MODEL in (mm)
PH06 1/8 3
PH07 1/8 3
PH1 1/4 6
PH2 1/4 6
PH3 1/4 6
PH4 1/4 6
Step 2
Remove the tool from the tool holder. Measure the diameter (d16) of the bearing
surface of the tool, which is located on each side of the retaining pin groove. The
minimum tool diameter is compared to a new tool bushing only. If the tool is at or below
the charted value, the tool must be replaced.
HAMMER NEW TOOL MINIMUM TOOL

MODEL DIAMETER DIAMETER
in (mm) in (mm)
PH06 1.65 (42) 1.54 (39.2)
PH07 1.85 (47) 1.74 (44.2)
PH1 2.24 (57) 2.02 (51.2)
PH2 2.60 (66) 2.37 (60.2)
PH3 2.99 (76) 2.76 (70.2)
PH4 3.38 (86) 3.16 (80.2)
- 114 -
TOOLS
MAXIMUM TOOL TO TOOL BUSHING CLEARANCE
Step 3
Measure the inside diameter of the tool bushing. The maximum tool bushing inside
diameter is compared to a new tool only. If the tool bushing dimensions are at or above
the charted value, the bushing must be replaced.
HAMMER NEW BUSHING MAXIMUM BUSHING

MODEL INSIDE DIAMETER INSIDE DIAMETER
in (mm) in (mm)
PH06 1.66 (42.2) 1.77 (45)
PH07 1.86 (47.2) 1.97 (50)
PH1 2.25 (57.2) 2.48 (63)
PH2 2.61 (66.2) 2.83 (72)
PH3 3.00 (76.2) 3.23 (82)
PH4 3.39 (86.2) 3.62 (92)
Step 4
Compare the tool and bushing to the charts in Step 2 and Step 3. Choose the new
component (tool or bushing) that will bring the maximum clearance to below the value
seen in the chart of Step 1. Replacing both the tool and bushing would bring the
clearance back to new.
- 115 -
TOOLS
TOOL INSPECTION
1. Deformation may occur on the tool in the retaining pin contact area (15) or thrust
surface (31). If these areas are mushroomed, the tool may become difficult to
remove from the tool holder. Dress with a grinder.
2. Excessive blank hammering will cause chipping (16) in the retaining pin contact area
(15). If neglected, the chipping may reduce the life or cause failure of the tool
retaining pin (D). Dress with a grinder.
3. If chipping (16) is found at the top of the tool, replace the tool. If neglected, the
piston impact surface will be damaged (13 is normal, 14 needs to be replaced).
- 116 -
TOOLS
STANDARD LENGTH FOR NPK TOOLS
d23 = Length of tool from top to bottom.

d22 = Length of tool exposed from bottom of tool bushing to end of tool.
d16 = Diameter of bearing surface of tool.
NOTE:
Minimum tool length is determined by the depth of material penetration that is required.
HAMMER NEW TOOL NEW TOOL NEW WORKING

MODEL DIAMETER (d16) LENGTH (d23) LENGTH (d22)
in (mm) in (mm) in (mm)
PH06 1.65 (42) 20.1 (510) 12.6 (320)
PH07 1.85 (47) 20.8 (529) 13.3 (339)
PH1 2.24 (57) 23.6 (599) 14.0 (356)
PH2 2.60 (66) 25.5 (648) 15.1 (384)
PH3 2.99 (76) 28.5 (724) 16.5 (419)
PH4 3.38 (86) 33.0 (838) 18.5 (469)
- 117 -
TOOLS
CHISEL TOOL SHARPENING
Worn chisel tools can be sharpened by machining according to the

dimensions below. DO NOT hard face or sharpen the tool point
with a cutting torch! Sharpen only with a lathe or milling machine
using sufficient coolant.
HAMMER d21 d16a (ref.)

MODEL in (mm) in (mm)
PH06 .39 (10) 1.65 (42)
PH07 .39 (10) 1.85 (47)
PH1 .39 (10) 2.24 (57)
PH2 .39 (10) 2.60 (66)
PH3 .39 (10) 2.99 (76)
PH4 .79 (20) 3.38 (86)
- 118 -
ADAPTER TOOL REPLACEMENT
Adapter tools used with tamper plates will break due to improper operation. (See
“HYDRAULIC HAMMER OPERATORS MANUAL, PH SERIES HAMMERS”.)
Adapter Tool
Tamper Plate
TOOL REPLACEMENT
1. Set broken tool (HH) and tamper plate (CN) upside down in a press.
2. Put a steel bar (t57) through the access hole (180) in the bottom of the tamper plate
(CN) and press the broken tool out.
- 119 -
ADAPTER TOOL REPLACEMENT
3. If the tool will not press out.
a. Burn a hole (91) through the center of the broken tool.
NOTE: An air arc (t12) is the preferred way to cut. An oxygen/acetylene torch (t13) can
also be used.
Do not cut into the mating surfaces of the tool or tamper plate!
b. Allow the tool to cool to room temperature.
c. Repeat step 2 above.
4. Use a small die grinder (t1) to polish out the bore (180).
- 120 -
RETAINING PIN
The tool retaining pin (D) serves to keep the tool in place when the hammer is raised off
the ground for repositioning. The retaining pin will become worn during normal use.
Figure “A” shows the retaining pin when it is new. NOTE: the two guide grooves (AN).
The guide groove areas and the area (122) between the guide grooves are the areas
where wear will take place. If large, flat areas are found here, the pin must be replaced.
This would indicate that the hammer is not being greased frequently enough.
Figure “A”
Buildup (20) will occur on the pin as shown in Figure “B”. Grind this area on a bench
grinder or with a disc grinder to remove any burrs. Reuse the pin.
Figure “B”
- 121 -
TOOL BUSHING REPLACEMENT
1. TOOL BUSHING REMOVAL
a. Check the tool to tool bushing clearance. (Check the “MAXIMUM TOOL TO
TOOL BUSHING CLEARANCE” section of this manual.)
b. If the clearance is not to specification, use the sleeve extractor (t65a) to remove
the tool bushing (G) from the main body (A).
1. Install the extractor into the tool bushing.
2. The bolt head (per chart below) should be inserted into the tool retaining pin
hole (178) in the bushing.
HAMMER BOLT EXTRACTOR USE

MODEL HEAD PART NO.
PH06 P04 T190016 BUSHING EXTRACTION
Bolt P03 is not used for bushing extraction
PH06, PH07 PH1, PH2, PH3, PH4
3. Turn the extractor bolt clockwise, using protection (179) between it and the
main body to pull the bushing out.
- 122 -
2. BUSHING BORE MAINTENANCE
a. Using a small die grinder (t1), polish the tool bushing bore (7a) of the main body
(A) lightly to remove any high spots.
NOTE: POLISH ONLY, DO NOT GRIND!
Do not weld bushing bore (7a) or exterior of the hammer body (A)!
3. TOOL BUSHING INSTALLATION

a. Apply never seize to the tool bushing bore (7a).
b. Apply a thin coat of grease on the o-ring (RR) then, install it onto the bushing.
c. Align the retaining pin hole on the tool bushing with the retaining pin hole on the
main body. Insert the tool bushing.
- 123 -
d. If the retaining pin holes do not line up after the bushing is installed, rotate the
bushing (G) by using the retaining pin (D) and a dead blow (t2) or plastic
hammer.
- 124 -
GAS HEAD BOLT TORQUE
1. Using a torque wrench (t19), tighten all four socket head cap screws (OO) that
attach the gas head to the main body to the torque specification shown in the
chart below.
Tighten the diagonally paired cap screws (either ‘A’ – ‘B’ or ‘C’ – ‘D’), then tighten the
two remaining. (NOTE: It may take several passes at each cap screw to achieve
the proper torque.)
HEX
HAMMER BOLT TORQUE BOLT SOCKET
MODEL ft. lbs. (Nm) SIZE SIZE
PH06 222 (300) M16 14 mm
PH07 222 (300) M16 14 mm
PH1 222 (300) M18 14 mm
PH2 295 (400) M20 17 mm
PH3 407 (550) M22 17 mm
PH4 520 (700) M24 19 mm
2. Check that there is no gap (d94)

between gas head (L) and main body
(A).
3. Charge the hammer with gas. Refer

to the “GAS CHARGING THE
HAMMER” section of this manual.
NOTE: NPK recommends the use of anti-seize on the threaded portion of the
socket head cap screws used to secure the gas head to the main body.
NOTE: Never over tighten cap screws! Only tighten them to the specified torque.
- 125 -
TORQUE VALUES FOR HAMMER FASTENERS
If hammer bracket fasteners are found to be loose, use the following chart:
HAMMER BRACKET *HAMMER BRACKET **ADAPTER BRACKET

BOLT BOLT
MODEL TYPE BOLT TORQUE BOLT TORQUE
DIA. ft. lbs. (Nm) DIA. ft. lbs. (Nm)
PH06 STANDARD M24-2 500 (675) 5/8"-11 165 (225)
PH07 STANDARD M24-2 500 (675) 5/8"-11 165 (225)
PH1 STANDARD 3/4"-10 280 (378) 5/8"-11 165 (225)
SKID STEER 3/4"-10 280 (378) N/A N/A
PH2 STANDARD 3/4"-10 280 (378) 5/8"-11 165 (225)
HEAVY DUTY 5/8"-11 150 (203) 5/8"-11 165 (225)
SCALING 5/8"-11 150 (203) 5/8"-11 165 (225)
SKID STEER 3/4"-10 280 (378) N/A N/A
PH3 STANDARD 1"-12 500 (675) 5/8"-11 165 (225)
HEAVY DUTY 1"-12 500 (675) 5/8"-11 165 (225)
PH4 STANDARD 1"-12 500 (675) 5/8"-11 165 (225)
HEAVY DUTY 1"-12 500 (675) 5/8"-11 165 (225)
* Torque hammer bracket bolts using anti-seize compound.
** DO NOT torque adapter bracket bolts using anti-seize compound.
- 126 -
MOUNTING PLATE
If the hammer has been overstressed due to improper operation or installed on too large
a carrier, the mounting bracket may develop a fatigue crack.
EXAMPLE OF REPAIRING A CRACKED PLATE

1. Drill 3/16” (5 mm) hole through the bracket at the end of the crack to prevent
further crack propagation.
2. Grind out the crack and weld as shown. Use AWS E7016 or equivalent welding
rod.
3a. For plate sizes up to 3/4" (20 mm) thick, use this weld joint:
3b. For plate sizes over 3/4” (20 mm) thick, use this weld joint:
4. Grind weld flush as shown. 22 is the direction of grinding, 23 is the direction of

principal stress.
- 127 -
WELDS
HARDFACING
Surfaces of your NPK hammer bracket (LL) can be hardfaced (we3). The best time to
apply or rebuild is as soon as the hardface pattern is worn off or when the hammer is
new.
It is suggested that you use a crosshatch pattern on the hammer bottom plate (as
shown) and two straight lines up each wear bar (EZ) when used.
NOTE: Hardface the hammer bracket ONLY! DO NOT hardface any surface of the
hammer assembly (KK)!
The hardfacing procedure is comprised of three steps which should be followed.
1. Surface Preparation
2. Underlayment Weld
3. Hardface Weld
SURFACE PREPARATION
Grind the entire area until it is smooth and clean. Remove all paint, grease, oil, and dirt
before welding.
- 128 -
WELDS
UNDERLAYMENT
Underlayment weld is necessary to build up the
base material (DH) or over the existing hardface
weld.
NOTE: You cannot hardface directly over old
hardfacing!
 Welding rod: Airco Austex 361, Cronatron
7770, Eutectic 3205, Postalloy 205, Stoody
2110 or equal. In Canada: NCH Canada, Inc.,
Hi-Pact #194 or equal.
 Dry welding rod at 300°F+ (150°C+).
 Pre-heat the area to be welded to 150°F (65°C) and maintain this temperature
during the welding operation. It is very important to maintain this temperature in cold
environments.
 Adjust weld current to rod manufacturer’s specification.
 Peen each layer.
 Cool slowly. Allow the welded area to
normalize slowly after welding, approximately
eight hours. Failure to do so may cause
cracking or peeling of newly applied weld.
Cover weld in cold environments.
HARDFACE
Hardface (we3) can only be applied over base
material (DH) or underlayment weld (we2).
NOTE: Never hardface existing hardface!
 Welding rod: Airco Tubecraft 1A, Cronatron 7355, Eutectic N6006, Postalloy 214,
Stoody 31 or equal. In Canada: NCH Canada, Inc., Wear-X #176 or equal. Stoody
19, 21, or 77, McKay Hardalloy 40 Tic, Hobart Smooth Arc 16.
 Dry welding rod at 300°F+ (150°C+).
 Pre-heat the weld area to 350°F (175°C) and maintain this temperature during the
welding operation. It is very important to maintain this temperature in cold
environments.
 Adjust weld current to rod manufacturer’s specification.
 Peen each layer. Do not exceed 2-3 layers of hardface.
 Cool slowly. Allow the weld area to normalize slowly after welding, approximately
eight hours. Failure to do so may cause cracking or peeling of newly applied weld.
Cover weld in cold environments.
- 129 -
STORAGE OF HYDRAULIC HAMMER
For short term storage between jobs, place the hammer horizontal on a pallet (t62). Be
sure the tool (HH) is liberally greased and the hydraulic hoses (m3 and m4) are capped.
Cover with a waterproof tarp (t21), not shown.
If the NPK HYDRAULIC HAMMER is not to be used for a long period of time (months),
it is recommended the gas pressure be discharged at the charge valve (M). The tool
(HH) should be removed, and the piston (N) pushed all the way in. Be sure the
hydraulic hoses (m3 and m4) are plugged and grease the exposed end of the piston
(N). Grease and reinstall the tool (HH). Cover with a waterproof tarp (t21), not shown.
DO NOT CLEAN the tool holder bore (111) of the hammer with
a steam cleaner or high pressure washer (t58). This could
cause rust to form then, in turn, cause damage to the hammer
piston!
- 130 -
WARRANTY REGISTRATION FOR NEW UNITS
Complete and send to NPK after installation or complete on line at www.npkce.com.
Online warranty registration can be done by the dealer or the end user.
The registration can be done in any of the following ways.

1. Mailed to:
NPKCE
7550 Independence Dr.
Walton Hills Ohio 44146
2. Faxed: 440-232-6294(U.S.) (+1)(440)232-6294(outside U.S.)
3. Completed on line at :
www.npkce.com
The online registration can be done by the dealer or the end user.
Dealers:
 In the tool bar click on DEALERS.
 Using your user name and password, log into the system.
 At the left of the next page click on REGISTRATION.
 Complete the fields with an orange diamond next to them.
 At the bottom of this area, click the START REGISTRATION box and continue.
 If the registration is completed online, there is no need to mail or fax the warranty
registration.
End users / non NPK dealers

 In the tool bar click on DEALERS
 You do NOT need to fill in user name and password.
 In the left column, click on the REGISTRATION.
 Complete the fields with an orange diamond next to them.
 At the bottom of this area, click the START REGISTRATION box and continue.
 If the registration is completed online, there is no need to mail or fax the warranty
registration.
- 131 -
WARRANTY STATEMENTS
- 132 -
WARRANTY STATEMENTS
- 133 -
WARRANTY STATEMENTS
- 134 -
WARRANTY STATEMENTS
- 135 -
DECIMAL CONVERSION CHART
DECIMAL INCH TO FRACTIONS
FRACTIONS DECIMALS FRACTIONS DECIMALS

32nds 64ths 2 Place 3 Place 32nds 64ths 2 Place 3 Place
1 .02 .016 .52 .516
1 .03 .031 17 .53 .531
3 .05 .047 35 .55 .547
1/16 .06 .062 9/16 .56 .562
5 .08 .078 37 .58 .578
3 .09 .094 19 .59 .594
7 .11 .109 39 .61 .609
1/8 .12 .125 5/8 .62 .625
9 .14 .141 41 .64 .641
5 .16 .156 21 .66 .656
11 .17 .172 43 .67 .672
3/16 .19 .188 11/16 .69 .688
13 .20 .203 45 .70 .703
7 .22 .219 23 .72 .719
15 .23 .234 47 .73 .734
1/4 .25 .250 3/4 .75 .750
17 .27 .266 49 .77 .766
9 .28 .281 25 .78 .781
19 .30 .297 51 .80 .797
5/16 .31 .312 13/16 .81 .812
21 .33 .328 53 .83 .828
11 .34 .344 27 .84 .844
23 .36 .359 55 .86 .859
3/8 .38 .375 7/8 .88 .875
25 .39 .391 57 .89 .891
13 .41 .406 29 .91 .906
27 .42 .422 59 .92 .922
7/16 .44 .438 15/16 .94 .938
29 .45 .453 61 .95 .953
15 .47 .469 31 .97 .969
31 .48 .484 63 .98 .984
1/2 .50 .500 1 1.00 1.000
- 136 -
REBUILD SPECIFICATION CHECK SHEETS
When rebuilding an NPK Hydraulic Hammer, it is necessary to inspect the hammer
body (A), cylinder spacer/impact ring (J), tool bushings (F and G), tool (HH), piston (N),
“A” sleeve (O), “B” sleeve (P) and tie rods (Q). Also, check the tolerances after these
components have been repaired or polished (when applicable).
BEFORE HAMMER DISASSEMBLY (H8X-H30X, E208-E260A, GH9-GH50 ONLY)
1. Measure the gap (d3) between the gas head (L) and the nylon stop (AX).
2. Measure the thickness of the bracket wear plates (AC).
MEASURE CRITICAL AREAS
The diagrams on the following pages show the critical locations that should be
measured. Carefully measure the areas shown with bore gauges and micrometers and
record on the following pages supplied.
FAX OR EMAIL THE DIMENSIONS TO THE NPK SERVICE DEPARTMENT
Fax this information to the NPK Service Department at 1-440-232-6294 for reusability
evaluation or contact someone in the Service Department at 1-800-225-4379 for an
email address if email is preferred.
- 137 -
NPK HYDRAULIC HAMMER
REBUILD SPECIFICATIONS CHECK SHEETS
DEALER _________________________ BRANCH _________________________
NAME ___________________________ TITLE ____________________________
TELEPHONE ______________________ FAX _____________________________
EMAIL ADDRESS ______________________________________________________
CUSTOMER ______________________ DATE ____________________________
NPK HAMMER MODEL ______________ SERIAL NO. _______________________
MAIN BODY
DIAMETER LENGTH
d5a d5b d5c d7
Dimensions to 0.000 inch (0.00 mm)

COMMENTS:
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
- 138 -
IMPACT RING DIMENSIONS: (H HAMMERS)
d78
d80
Ref 1 = Tool End 2 = Gas End
IMPACT RING DIMENSIONS: (GH06 – GH4 HAMMERS)
d78
d80
d82
COMMENTS:
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
- 139 -
IMPACT BUSHING DIMENSIONS: (GH, E HAMMERS)
d17
d19
COMMENTS:
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
TOOL:
50 = STAMPING
__________________
__________________
__________________
DIAMETER
d16a d16b
- 140 -
“H” HAMMERS “GH” AND “E” HAMMERS
UPPER TOOL BUSHING: ___________ I.D. (d41)

LOWER TOOL BUSHING: __________ I.D. (d41)

TOOL BUSHING (PH Series): ________ I.D. (d41)

COMMENTS:
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
- 141 -
PISTON:
PISTON SERIAL NO. ________
DIAMETER LENGTH
d11 d12 d10 d13

Ref. 1 = Tool End Ref. 2 = Gas End
COMMENTS:
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
- 142 -
SLEEVE “A” (GH4 thru GH50, E and H Series)
SLEEVE SERIAL NO. ________
INSIDE DIAMETER d42

Ref 1 = Tool End Ref 2 = Gas End
COMMENTS:
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
- 143 -
SLEEVE “A” (GH06 thru GH3)
INSIDE DIAMETER d45

COMMENTS:
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
- 144 -
SLEEVE “A” (GH3-2)
INSIDE DIAMETER d42

COMMENTS:
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
- 145 -
SLEEVE “A” (PH Series)
INSIDE DIAMETER d42

COMMENTS:
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
- 146 -
SLEEVE “B” (GH, E and H Series)
INSIDE DIAMETER
d43 d44a d44b

COMMENTS:
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
- 147 -
SLEEVE “B” (GH3-2)
INSIDE DIAMETER
d43 d44a d44b

COMMENTS:
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
- 148 -
SLEEVE “B” (PH Series)
INSIDE DIAMETER
d43 d44a d44b

COMMENTS:
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
- 149 -
TIE ROD LENGTHS:
TIE ROD LENGTH (d93)

Tie Rod 1 Tie Rod 2 Tie Rod 3 Tie Rod 4
Note: Check tie rods to make sure they are not bent and inspect thread area to
ensure no cracks are present.
COMMENTS:
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
- 150 -
TRAVEL LIMITER GAP:
TRAVEL LIMITER GAP (d3)
COMMENTS:
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
- 151 -
MOUNTING BRACKET WEAR PLATE THICKNESS:
THICKNESS
d92a d92b d92c d92d
- 152 -
© Copyright 2019 NPK Construction Equipment, Inc. www.npkce.com h055-9660H PH06,
PH07, PH1, PH2, PH3, PH4 Hyd Ham Service Manual 3-19

Hydraulic Hammer

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Hydraulic Hammer

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HYDRAULIC HAMMER

“Use Genuine NPK Parts”

7550 Independence Drive

© Copyright 2019 NPK Construction Equipment, Inc. www.npkce.com h055-9660H PH06,

DANGER (red) notices indicate an imminently hazardous situation

WARNING (orange) notices indicate a potentially hazardous

CAUTION (yellow) notices indicate a potentially hazardous

ATTENTION (blue) notices in NPK Instruction Manuals are an NPK

BASIC OPERATING INSTRUCTIONS

Mounting a HAMMER that is too heavy for the carrier machine

CARRIER WEIGHT - lbs. (kg)

HAMMER IMPACT FREQUENCY MOUNTING WORKING TOOL

*NITROGEN GAS PRE-CHARGE

Specifications are subject to change without notice.

MODEL PH06 - PH07

MODELS PH1 – PH4

N PISTON 33 NITROGEN GAS CHAMBER ABOVE PISTON

(1) UPSTROKE OF PISTON

BACKHOE/EXCAVATOR HAMMER LINES

SKID STEER HAMMER LINES

HAMMER CONTROL VALVE

1. CONTROL SYSTEM USING THE CARRIER

2. CONTROL SYSTEM USING THE NPK FLOW VALVE (MULTIVALVE).

CHANGING THE FILTER ELEMENT AND HYDRAULIC OIL

NPK APPROVED CONNECTION QUICK DISCONNECTS

ROFLEX COUPLING STUCCHI COUPLING

1. Periodic inspection of both male

2. Check for dirt, dust, and debris on

3. Be sure that the couplers are

4. When replacing couplers, be sure

BACKHOES and EXCAVATORS

NPK Mounting Installation Kits for skid

REMOVAL FROM THE CARRIER

MOUNTING TO THE CARRIER

MOUNTING TO THE SKID STEER

Consult the skid steer manufacturer’s operators manual to

2. Turn the carrier off.

APPLY DOWN FORCE TO PUSH TOOL UP INTO HAMMER

NOTE: USE A GOOD QUALITY EP #2 LITHIUM BASED GREASE WITH WEAR

CORRECT GREASE FOR HYDRAULIC HAMMERS

NPK HAMMER GREASE

UNIVERSAL PLUS NPK PART

SUPER DUTY NPK PART

CHISEL PASTE NPK PART

“Auto Lube Pump” “Hammer Mounted Auto Lube Pump”

PRIMING THE GREASE LINE

1. Place the hammer in a vertical position,

2. Turn the excavator/backhoe off.

3. Fill the NPK Auto Lube pump reservoir

4. Disconnect the grease line (29) from the

ITEM PART DESCRIPTION

6. Remove the grease line (29) at the

7. Attach a grease gun (t37) or power

8. Pump grease through the grease line

9. Re-attach the grease line (29) to the

10. Pump twenty more shots of grease,

11. Remove the hose fill adapter (a13) and

PRIMING THE GREASE LINE

1. Place the hammer in a vertical

2. Turn the excavator/backhoe off.

4. Disconnect the grease line (29) at the

5. Attach a grease gun (t37) or power

6. Pump grease through the pump to the

7. Re-attach the grease line (29) to the