NPK PH1 User manual

HYDRAULIC HAMMER
OPERATORS MANUAL
PH SERIES HAMMERS
PH1 PH2
PH3 PH4
“Use Genuine NPK Parts”
© Copyright 2016 NPK Construction Equipment, Inc. www.npkce.com H050-9660C PH1, PH2, PH3,
PH4 Operators Manual 3-16
7550 Independence Drive
Walton Hills, OH 44146-5541
Phone [phone]
Toll-free [phone]
Fax [phone]

- 1 -
CONTENTS
SAFETY..........................................................................................................................3
INTRODUCTION.............................................................................................................5
CARRIER MACHINE COMPATIBILITY ..........................................................................6
HAMMER SPECIFICATIONS .........................................................................................7
STRUCTURE..................................................................................................................8
STRUCTURAL DRAWING..........................................................................................8
HAMMER SERIAL NUMBER LOCATION.......................................................................9
SERIAL NUMBER LOCATION (sn1) ......................................................................... 9
HYDRAULIC INSTALLATION.......................................................................................10
PREVENTION OF CONTAMINATION......................................................................12
HYDRAULIC QUICK DISCONNECTS......................................................................13
MOUNTING INSTALLATION........................................................................................15
REMOVAL FROM THE CARRIER............................................................................ 15
REMOVAL FROM THE SKID STEER.......................................................................16
MOUNTING TO THE CARRIER...............................................................................16
MOUNTING TO THE SKID STEER..........................................................................16
LUBRICATION..............................................................................................................17
GREASING PROCEDURE....................................................................................... 17
CORRECT GREASE AND GREASE INTERVALS...................................................18
CORRECT GREASE FOR HYDRAULIC HAMMERS............................................... 19
NPK HAMMER GREASE.......................................................................................19
AUTO LUBE SYSTEMS.........................................................................................19
AUTO LUBE GREASE LINE PRE-FILLING.............................................................. 20
HAMMER MOUNTED AUTO LUBE GREASE LINE PRE-FILLING.......................... 23
LUBRICATION..............................................................................................................25
LUBRICANT TERMS AND DEFINITIONS................................................................ 25
START-UP OPERATION..............................................................................................28
HAMMERS THAT ARE NEW, REBUILT, OR HAVE BEEN INACTIVE ....................28
BEFORE STARTING THE HAMMER.......................................................................29
DAILY START-UP PROCEDURE............................................................................. 29
OPERATION.................................................................................................................30
OPERATING TECHNIQUES & PRECAUTIONS ...................................................... 31
IMPACT ENERGY TRANSMISSION THROUGH TOOLS............................................36
IMPACT STRESS WAVES AT THE END OF THE TOOL........................................ 37
TOOL BREAKAGE........................................................................................................38
TOOL BREAKAGE DUE TO EXCESSIVE BENDING MOMENT.............................. 38
TOOL BREAKAGE DUE TO EXCESSIVE WEAR OF THE TOOL HOLDER
BUSHINGS............................................................................................................... 39
CHIPPING IN RETAINING PIN SLOT ...................................................................... 41
DEFORMATION OF THE RETAINING PIN SLOT SIDES........................................ 41
DEFORMATION OF THE TOOL TIP........................................................................ 42
CHIPPING OF A MOIL POINT TOOL TIP................................................................ 43
CHIPPING OF A CHISEL TOOL TIP........................................................................ 43
TEMPERATURE RELATED TOOL PROBLEMS...................................................... 44
TOOL BREAKAGE DUE TO CORROSION..............................................................45
TOOL BREAKAGE DUE TO DEFECTIVE MATERIAL............................................. 45

- 2 -
CONTENTS
ROUTINE INSPECTION AND MAINTENANCE............................................................ 46
WEEKLY INSPECTION ................................................................................................47
TOOLS..........................................................................................................................48
STANDARD TOOLS................................................................................................. 48
ACCESSORY TOOLS .............................................................................................. 48
TOOL IDENTIFICATION...........................................................................................49
CHANGING THE TOOL............................................................................................50
MAXIMUM TOOL TO TOOL BUSHING CLEARANCE.............................................52
TOOL INSPECTION................................................................................................. 54
CHISEL TOOL RESHARPENING............................................................................. 55
STANDARD LENGTH FOR NPK TOOLS................................................................. 56
TOOL RETAINING PIN INSPECTION...................................................................... 57
GAS CHARGE .............................................................................................................. 59
NITROGEN GAS PRESSURE..................................................................................59
GAS CHARGING KIT ............................................................................................... 60
CHECKING THE GAS PRESSURE..........................................................................61
CHARGING THE HAMMER...................................................................................... 63
DISCHARGING THE GAS PRESSURE ................................................................... 64
STORAGE OF HYDRAULIC HAMMER........................................................................65
WARRANTY REGISTRATION FOR NEW UNITS ........................................................ 66
TOOL WARRANTY.......................................................................................................67
WARRANTY STATEMENTS.........................................................................................69
NOTES AND RECORDS ..............................................................................................73

- 3 -
SAFETY
Safety notices in NPK Instruction Manuals follow ISO and ANSI standards for
safety warnings:
DANGER (red) notices indicate an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING (orange) notices indicate a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION (yellow) notices indicate a potentially hazardous situation,
which, if not avoided, may result in minor or moderate injury.
ATTENTION (blue) notices in NPK Instruction Manuals are an NPK
standard to alert the reader to situations which, if not avoided, could
result in equipment damage.
WARNING and BASIC OPERATING INSTRUCTIONS decals are included with each
NPK hammer and installation kit. Decals must be installed in the cab, visible to the
operator while operating the hammer.
STAY CLEAR, PRESSURE VESSEL, GAS PRESSURE and TOOL SHARPENING
decals are installed on all NPK hammer models. Keep them clean and visible. NPK will
provide decals free of charge as needed.
1. Operator and Service personnel must read and understand the NPK INSTRUCTION
MANUAL to prevent serious or fatal injury.
2. FLYING DEBRIS CAN CAUSE SERIOUS OR FATAL INJURY.
Keep personnel and bystanders clear of hammer while in operation.
Do not operate HAMMER without an impact resistant guard between HAMMER
and operator. NPK recommends LEXANor equivalent material, or steel mesh.
Some carrier manufacturers offer demolition guards for their machine. Check
with the carrier manufacturer for availability. If not
available, please call NPK.
3. Do not hardface or sharpen the tool point with a cutting
torch. Excessive heat from torching or welding can
cause embrittlement, breakage, and flying pieces.
Resharpen by milling or grinding only, using sufficient
coolant.

- 4 -
SAFETY
4. Fully extend the tool while charging the HAMMER with nitrogen gas. Be sure that
the retaining pin is installed. STAY CLEAR OF TOOL POINT WHILE CHARGING.
5. Do not disassemble a HAMMER before discharging the hammer gas pre-charge.
6. USE NITROGEN GAS ONLY! Store and handle nitrogen tanks per OSHA
regulations.
7. Avoid high pressure fluids. Escaping fluid under pressure can penetrate the skin
causing serious injury. Relieve pressure before disconnecting hydraulic or other
lines.
8. Operate HAMMER from operator’s seat only.
9. Match HAMMER size to carrier according to NPK recommendations. The carrier
must be stable during hammer operation and during transport.
See CARRIER MACHINE COMPATIBILITY section of the NPK instruction manual.
10. Do not make any alterations to the TOOL without authorization from NPK
Engineering.
11. Use proper lifting equipment and tools when handling or servicing the HAMMER.
12. Wear ear protection and safety glasses when operating the hammer. Consult
OSHA/MSHA regulations when applicable.
13. Beware of flying metal pieces when driving mounting pins.
14. If modifications are to be made, do not alter the HAMMER without authorization
from NPK Engineering!
15. Use only genuine NPK replacement parts. NPK specifically disclaims any
responsibility for any damage or injury that results from the use of any tool or parts
not sold or approved by NPK.
For further safety information, consult the AEM Hydraulic Mounted Breakers Safety
Manual, AEM form MB-140 (NPK P/N H050-9600), which is furnished with every NPK
hammer. To request an additional copy, please contact NPK at 800-225-4379 or
Internet at www.npkce.com.

- 5 -
INTRODUCTION
NPK is a leading manufacturer of HYDRAULIC HAMMERS, and has the most complete
product line available anywhere. The success of NPK is due to our commitment to
quality, dependability and long life. The HYDRAULIC HAMMER has many unique
designed features and it is a company philosophy that the NPK HYDRAULIC HAMMER
can be brought to "like new” condition long after competitive products are scrapped.
You can feel confident that you have purchased the best value available.
This comprehensive operator’s manual contains instructions for operating and
maintaining NPK HYDRAULIC HAMMERS. This manual includes helpful information for
obtaining the full potential and efficiency from NPK HYDRAULIC HAMMERS. Please
read this manual thoroughly to understand the NPK HAMMER and its operating
principles before using it.
For additional information or help with any problem encountered, please contact your
NPK authorized dealer.
Whenever repair or replacement of component parts is required, only NPK parts should
be used. NPK is not responsible for failures resulting from substitution of parts not sold
or approved by NPK.
This manual will also assist NPK Dealers and Customers to obtain the longest possible
life from the NPK Demolition Tools.
Customers can use this manual to take corrective action when tool breakage occurs.
Dealers can use this manual to determine if tool breakage can be claimed under
warranty.
Refer to the NPK Demolition Tool Warranty statement found later in this manual for the
specifics of the warranty coverage.

- 6 -
CARRIER MACHINE COMPATIBILITY
These carrier weight ranges are intended as a guideline only. Other factors, such as
stick length, counterweights, undercarriage, etc., must be taken into consideration.
Mounting a HAMMER that is too heavy for the carrier machine
can be dangerous and damage the machine. Verify carrier
stability with hammer before transport or operation.
Mounting a HAMMER that is too small for the carrier machine can damage the
HAMMER, cause tool breakage and void Warranties. Please consult NPK Engineering
for specific detailed information.
CARRIER WEIGHT lbs. (kg)
HAMMER MOUNTING RECOMMENDED RANGE
MODEL STYLE lb (kg)
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.

- 7 -
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)
PH1 350 550 - 1,100 Excavator 423 (192) 2.24 (57) 14.0 (356)
Skid Steer 674 (306)
PH2 500 500 - 1,200 Excavator 487 (221) 2.60 (66) 15.1 (384)
Skid Steer 735 (333)
PH3 750 500 - 1,150 Excavator 825 (374) 2.99 (76) 16.5 (419)
Skid Steer N/A
PH4 1300 400 - 1,000 Excavator 1,064 (483) 3.39 (86) 18.5 (469)
Skid Steer N/A
HAMMER OIL FLOW HYDRAULIC OPERATING MINIMUM CIRCUIT
MODEL PRESSURE1RELIEF2
gpm (lpm) psi (bar) psi (bar)
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 13 - 32 (50 - 120) 2,175 - 2,465 (150 - 170) 2,965 (204)
NITROGEN GAS PRECHARGE
HAMMER AT AMBIENT TEMPERATURE
(cold before operating) AT OPERATING TEMPERATURE (hot, after 1 to 2 hrs. operation)
MODEL
*psi (bar) *psi (bar)
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).
*Specifications subject to change without notice.
NOTES:
1. Hydraulic operating pressure maximum is inlet pressure at the hammer with the oil at
operating temperature and with the gas charge set at the hot operating pressure. See
CHECKING THE HYDRAULIC PRESSURES section in the Service Manual.
2. Circuit relief pressure is at least 500 psi (35 bar) above hammer operating pressure.
3. Cold gas charge is the initial set with the hammer at ambient temperature.
4. Hot gas charge is checked after 1 to 2 hours of running and with a system oil temperature of
140to 180F (60
 to 80  C). This is the preferred check.
5. Pressures listed are the maximum allowed. Use tolerance of minus 25 psi (2 bar).

- 8 -
STRUCTURE
STRUCTURAL DRAWING
MODELS PH1 – PH4
30 GREASE FITTING
A MAIN BODY
BB PLUNGER
D RETAINING PIN
E RETAINING RING
G TOOL BUSHING
HH TOOL
L GAS HEAD
M CHARGE VALVE
N PISTON
O MAIN BODY SLEEVE (A)
P MAIN BODY SLEEVE (B)
Z VALVE SPOOL

- 9 -
HAMMER SERIAL NUMBER LOCATION
SERIAL NUMBER LOCATION (sn1)