NPK NPH-3500 User manual

PNEUMATIC HAMMER
INSTRUCTION MANUAL
NPH HAMMERS
NPH-3500
NPH-4500L
“Use Genuine NPK Parts”
© Copyright 2020 NPK Construction Equipment, Inc. www.npkce.com H000-9620- NPH3500,
NPH4500L Pneumatic Hammer Instr Manual 8-20
7550 Independence Drive
Walton Hills, OH 44146-5541
Phone [phone]
Fax [phone]

CONTENTS
- 1 -
SAFETY .......................................................................................................................... 2
INTRODUCTION ............................................................................................................. 4
BASIC OPERATING INSTRUCTIONS ............................................................................ 4
PRECAUTIONS FOR USING THE NPK PNEUMATIC HAMMER .................................. 5
CARRIER MACHINE COMPATIBILITY .......................................................................... 6
HAMMER SPECIFICATIONS ......................................................................................... 7
STRUCTURE .................................................................................................................. 8
STRUCTURAL DRAWING.......................................................................................... 8
HAMMER SERIAL NUMBER LOCATION ....................................................................... 9
SERIAL NUMBER LOCATION (sn1) .......................................................................... 9
PRINCIPLE OF OPERATION ....................................................................................... 10
INSTALLATION ............................................................................................................. 15
OPERATION ................................................................................................................. 16
LUBRICATION .......................................................................................................... 16
CLEANING THE AIR HOSE ..................................................................................... 16
OPERATING PROCEDURE ..................................................................................... 17
AUTOMATIC SHUT OFF .............................................................................................. 19
LUBRICATION .............................................................................................................. 20
NPK HAMMER GREASE .......................................................................................... 20
LUBRICANT TERMS AND DEFINITIONS ................................................................ 21
INSPECTION AND MAINTENANCE ............................................................................. 23
STORAGE OF PNEUMATIC HAMMER ........................................................................ 24
DISASSEMBLY PROCEDURE ..................................................................................... 26
INSPECTION PROCEDURE ........................................................................................ 29
INSPECTION ............................................................................................................ 29
REASSEMBLY PROCEDURE ...................................................................................... 30
TROUBLESHOOTING .................................................................................................. 32
WARRANTY REGISTRATION FOR NEW UNITS ........................................................ 33
TOOL WARRANTY ....................................................................................................... 34
WARRANTY STATEMENTS ......................................................................................... 36
NOTES AND RECORDS .............................................................................................. 39

- 2 -
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 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.

- 3 -
SAFETY
4. Operate HAMMER from operator’s seat only.
5. 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.
6. Do not make any alterations to the TOOL without authorization from NPK
Engineering.
7. Use proper lifting equipment and tools when handling or servicing the HAMMER.
8. Wear ear protection and safety glasses when operating the hammer. Consult
OSHA/MSHA regulations when applicable.
9. Beware of flying metal pieces when driving mounting pins.
10. If modifications are to be made, do not alter the HAMMER without authorization
from NPK Engineering!
11. 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.
12. All air line components must be rated 150% greater than maximum system
pressure.
13. Never attempt to do any maintenance work on the compressor while it is running.
14. Keep compressor well ventilated, do not cover the compressor during use.
15. Drain tank daily and after use. Internal rust causes tank failure.
16. Do not use the air hose to move the compressor.
17. Release the pressure in the tank before moving.
18. Do not, under any circumstances, point air at or in the direction of someone.
Discharging air pressure is capable of putting out eyes, bursting eardrums, causing
serious skin burns, and other injuries.

- 4 -
INTRODUCTION
This comprehensive instruction manual contains instructions for repairing and
maintaining NPK PNEUMATIC HAMMERS. This manual includes helpful information
for obtaining the full potential and efficiency from NPK PNEUMATIC HAMMERS.
Please read this manual thoroughly to understand the NPK PNEUMATIC 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.
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 with loose or missing fasteners, tie rods, etc.
• DO NOT SUBMERGE HAMMER UNDERWATER

- 5 -
PRECAUTIONS FOR USING THE NPK
PNEUMATIC HAMMER
• Perform daily inspections.
• 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.
• Operate the hammer carefully. Do not hit the boom of the carrier with the hammer.
• Operate the hammer in a safe manner.

- 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 PNEUMATIC 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 PNEUMATIC HAMMER that is too small for the carrier machine can
damage the PNEUMATIC 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
lbs.
(kg)
NPH-3500
EXCAVATOR
12,000 - 18,000
(5,500 – 8,200)
NPH-4500L
EXCAVATOR
20,000 - 32,000
(9,000 - 14,500)
*Specifications are subject to change without notice.

- 7 -
HAMMER SPECIFICATIONS
HAMMER
NUMBER
OF
PISTON
LENGTH W/O
MODEL
BLOWS
diameter
stroke
weight
CHISEL
b.p.m.
in
(mm)
in
(mm)
lbs
(kg)
in
(mm)
NPH-3500
530
4.5
(116)
7.87
(200)
55
(25)
47.3
(1202)
NPH-4500L
500
5.1
(130)
9.65
(245)
66
(30)
54.8
(1392)
HAMMER
NET WEIGHT
MAX AIR
AIR
HOSE
MODEL
WITH TOOL
CONSUMPTION
PRESSURE
DIAMETER
lbs
(kg)
cfm
(m3/min)
psi
(bar)
in
(mm)
NPH-3500
537
(260)
177
(5)
9
(1)
1
(25)
NPH-4500L
1070
(485)
254
(7)
9
(1)
2
(38)
*Specifications subject to change without notice.
*Working weights may vary with bracket configuration.

- 8 -
STRUCTURE
STRUCTURAL DRAWING
5
EXHAUST
6
INLET
A
MAIN BODY
AT
COLLAR
C
TOOL HOLDER
CF
FITTING ELBOW
D
RETAINING PIN
F
UPPER BUSHING
HH
TOOL
J
IMPACT RING
N
PISTON
PB60
FILTER ELEMENT
ph11
INLET BUSHING
ph3
VALVE
ph4
VALVE CAP (UPPER)
ph5
VALVE CAP (LOWER)
ph6
COTTER PIN
ph7
HEAD
Q
TIE ROD
R
NUT (TOP)
S
LOCK PLATE
TT
RUBBER PLUG
U
WASHER
U1
ASSISTANT COLLAR
V
NUT (BOTTOM)

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

- 10 -
PRINCIPLE OF OPERATION
(1) PISTON UP
The compressed air from the inlet port flows through the head chamber #2
through port #1. It reaches the lower chamber #9 through ports #3, #4, #5, #6,
#7, and #8, which makes the piston (N) go up.

- 11 -
PRINCIPLE OF OPERATION
(2) PISTON UP-VALVE UP
After the piston (N) opens up port #10, the compressed air of the lower
chamber #9 goes into valve’s lower chamber #13 through ports #11 and #12,
so the valve (ph3) goes up.

- 12 -
PRINCIPLE OF OPERATION
(3) PISTON UP-VALVE UP
The piston (N) and valve (ph3) go up when the piston opens lower chamber to
exhaust port #14. Compressed air exhausts to the outside through port #14.

- 13 -
PRINCIPLE OF OPERATION
(4) PISTON DOWN
The compressed air of the lower chamber exhaust and compressed air is
supplied to the upper chamber of the piston (N) through ports #3, #4, #5, and
#15 so that the piston goes down.

- 14 -
PRINCIPLE OF OPERATION
(5) PISTON DOWN – VALVE DOWN
After the piston goes down, it opens the upper chamber to port #17.
Compressed air of the upper chamber is supplied to the valve upper chamber
#21 through ports #18, #19, and #20 so the valve goes down. Before the valve
goes down completely, the piston (N) hits the tool (HH).

- 15 -
INSTALLATION
bs10
CONTROL VALVE
ds60
LINE UNIT
g14
PINS
HH
TOOL
KK
HAMMER
LL
BRACKET
ph10
AIR HOSE
ph12
COMPRESSOR
ph9
EXHAUST PORT

- 16 -
OPERATION
LUBRICATION
Fill the oiler with oil before operation of the hammer. Lack of oil will cause premature
component wear. During new hammer start-up, set the oiler knob to position 4 for the
first 10 hours of operation. Oil flow numbers on the oiler knob must be aligned with the
arrow on the body of the unit. Oil will not flow if the numbers are not properly aligned
with the arrow.
• When refilling the line unit, the oil valve must be set to position 0 “Stop”. Failure
to do so will allow compressed air to blow out the fill port.
• When the oil level drops to the red mark (arrow indicates red line in drawing),
refill oil immediately!
• Use the recommended oil: SAE 5W, ISO 22 Grade, or equivalent oil in quality.
CLEANING THE AIR HOSE
Before connecting to the hammer, blow out water and contamination.

- 17 -
OPERATION
OPERATING PROCEDURE
a) Place tool on the material and apply down force to the hammer.
b) Operate the hammer with tool in solid contact with the material.
c) Shut off hammer immediately after breaking material.
DOWN FORCE
OPERATE
STOP
DO NOT USE THE HAMMER TOOL AS A PRY BAR

- 18 -
OPERATION
OPERATING PROCEDURE
DO NOT USE THE HAMMER AS A HOIST

- 19 -
AUTOMATIC SHUT OFF
The hammer is provided with a unique internal cushioning arrangement which absorbs
energy released when blank hammering occurs. The exhaust port allows air to exit the
main body which ensures the hammer from any damage caused by blank hammering.
AH6
AIR CUSHION
AH7
EXHAUST
HH
TOOL