Martillos GH9

HYDRAULIC HAMMER
SERVICE MANUAL
GH SERIES HAMMERS
GH9 GH15
GH10 GH18
GH12
"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 2008 NPK Construction Equipment, Inc. www.npkce.com h055-9630A.doc 6/08

NPK
CONTENTS
SAFETY ............................................................................................................................ 3
INTRODUCTION............................................................................................................... 5
CARRIER MACHINE COMPATIBILITY ............................................................................ 5
HAMMER SPECIFICATIONS ........................................................................................... 6
HAMMER STRUCTURE ................................................................................................... 7
HAMMER SERIAL NUMBER LOCATION......................................................................... 8
PRINCIPLE OF OPERATION ........................................................................................... 9
HYDRAULIC INSTALLATION ........................................................................................... 11
PREVENTION OF CONTAMINATION .............................................................................. 12
HYDRAULIC QUICK DISCONNECTS............................................................................... 13
MOUNTING INSTALLATION ............................................................................................ 15
REMOVAL FROM THE CARRIER..................................................................................... 16
MOUNTING TO THE CARRIER ........................................................................................ 16
LUBRICATION .................................................................................................................. 17
GREASING PROCEDURE ....................................................................................... 17
CORRECT GREASE AND GREASE INTERVALS................................................... 18
NPK HAMMER GREASE ......................................................................................... 20
AUTOLUBE SYSTEMS ............................................................................................ 20
ROUTINE INSPECTION AND MAINTENANCE................................................................ 21
TWENTY HOUR INSPECTION......................................................................................... 22
TROUBLESHOOTING ...................................................................................................... 23
UNDERSTAND THE BASICS................................................................................... 23
DETERMINE THE CAUSE OF THE PROBLEM....................................................... 23
TROUBLESHOOTING CHART ................................................................................ 23
CHECKING THE HYDRAULIC PRESSURES .......................................................... 24
CHECKING THE HYDRAULIC FLOW...................................................................... 25
OIL LEAKAGE .......................................................................................................... 26
GAS LEAKAGE ........................................................................................................ 27
EXCESS OIL IN THE GAS HEAD ............................................................................ 28
GAS CHARGE .................................................................................................................. 29
NITROGEN GAS PRESSURE.................................................................................. 29
GAS CHARGING KIT ............................................................................................... 29
CHECKING THE GAS PRESSURE ......................................................................... 30
CHARGING THE HAMMER ..................................................................................... 31
DISCHARGING THE GAS PRESSURE ................................................................... 32
HAMMER DISASSEMBLY AND ASSEMBLY ................................................................... 33
TOOLS AND EQUIPMENT REQUIRED................................................................... 33
NPK START-UP KIT................................................................................................. 34
NPK ASSEMBLY LUBRICANT................................................................................. 35
REMOVE THE HAMMER FROM THE BRACKET.................................................... 36
DISASSEMBLING THE MAIN BODY ....................................................................... 37
DISASSEMBLY OF MAIN VALVE ............................................................................ 43
INSPECTION AND REPAIR AFTER DISASSEMBLY .............................................. 45
REPLACING THE SEALS ........................................................................................ 47
PROPER CLEANING OF SEAL DRAIN PASSAGE IN MAIN BODIES .................... 49
REASSEMBLY OF THE HAMMER .......................................................................... 50
ASSEMBLY OF THE MOUNTING BRACKET .......................................................... 66
HAMMER TRAVEL LIMITER GAP ........................................................................... 67
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NPK
CONTENTS, CONTINUED
REPAIR............................................................................................................................. 68
REPAIR SECTION INTRODUCTION ....................................................................... 68
REPAIR TOOLS AND EQUIPMENT ........................................................................ 68
HAMMER SLEEVE AND PISTON RECONDITIONING TOOLS............................... 69
MAIN BODY BORE .................................................................................................. 70
USING THE NPK LONG SHAFT AIR GRINDER......................................... 71
BODY BORE REPAIR BY GRINDING AND POLISHING............................ 72
BODY BORE DEEP SCRATCH REPAIR .................................................... 75
HONING MAIN BODY BORE ...................................................................... 78
MAIN BODY MOUNTING SLOT.................................................................. 79
MAIN BODY FACTORY DIMENSIONS ....................................................... 83
PISTON .................................................................................................................... 84
PISTON ACTIVE SEAL AREA..................................................................... 84
PISTON TO SLEEVE RUNNING CLEARANCES........................................ 85
STRIKING END OF PISTON ....................................................................... 86
MAIN BODY SLEEVES ............................................................................................ 87
IMPACT BUSHINGS ................................................................................................ 88
TOOL BUSHING REPLACEMENT........................................................................... 89
TOOL HOLDER ........................................................................................................ 92
TOOL HOLDER BUSHING BORE............................................................... 92
EXTERIOR REBUILD .................................................................................. 94
MOUNTING BRACKET..................................................................................................... 95
REPAIRING A CRACKED PLATE............................................................................ 95
MOUNTING BRACKET WEAR PLATE .................................................................... 96
TOOLS .............................................................................................................................. 97
STANDARD TOOLS................................................................................................. 97
ACCESSORY TOOLS .............................................................................................. 97
CHANGING THE TOOL ........................................................................................... 98
TOOL INSPECTION ................................................................................................. 99
MAXIMUM TOOL TO TOOL BUSHING CLEARANCE............................................. 100
CHISEL TOOL RESHARPENING ............................................................................ 102
STANDARD LENGTH FOR NPK TOOLS ................................................................ 103
RETAINING PIN................................................................................................................ 104
TIE RODS ......................................................................................................................... 105
MAXIMUM ELONGATION OF TIE RODS ................................................................ 105
TIE ROD REPLACEMENT ....................................................................................... 106
TIE ROD TORQUE................................................................................................... 107
HAMMER FASTENER TORQUE ...................................................................................... 108
LIFTING EYE SPECIFICATIONS...................................................................................... 109
STORAGE OF HYDRAULIC HAMMER ............................................................................ 110
DECIMAL CONVERSION CHART .................................................................................... 111
REBUILD SPECIFICATIONS CHECK SHEETS ............................................................... 112
NOTES AND RECORDS .................................................................................................. 119
-2-
NPK
SAFETY
Safety notices in NPK Operators 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 Operators 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 OPERATORS
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-
NPK
SAFETY, CONTINUED
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 Operators Manual.
10. Do not make any alterations to the TOOL without authorization from NPK
Engineering.
11. Use proper lifting equipment and tools when handling or servicing the HAMMER.
12. Wear ear protection and safety glasses when operating the hammer. Consult
OSHA/MSHA regulations when applicable.
13. Beware of flying metal pieces when driving Boom Pins.
14. If modifications are to be made, do not alter the HAMMER without authorization
from NPK Engineering!
15. Use only genuine NPK replacement parts. NPK specifically disclaims any
responsibility for any damage or injury that results from the use of any tool or parts
not sold or approved by NPK.
For further safety information, consult the AEM Hydraulic Mounted Breakers Safety
Manual, AEM form MB-140 (NPK P/N H050-9600), which is furnished with every NPK
hammer. To request an additional copy, please contact NPK at 800-225-4379 or
Internet at www.npkce.com.
-4-
NPK
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 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.
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
can damage the carrier. 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 RECOMMENDED CARRIER WEIGHT RANGE
MODEL (lb) (kg)
GH9 40,000 - 56,000 18,000 - 25,000
GH10 46,000 - 66,000 20,000 - 30,000
GH12 56,000 - 86,000 25,000 - 38,000
GH15 66,000 - 100,000 30,000 - 45,000
GH18 70,000 - 114,000 32,000 - 52,000
*Specifications subject to change without notice.
-5-
NPK
HAMMER SPECIFICATIONS
HAMMER IMPACT WORKING TOOL
MODEL ENERGY FREQUENCY WEIGHT DIA WORKING
CLASS LENGTH
ft lb bpm lbs (Kg) in (mm) in (mm)
GH9 3000 500 - 670 3600 (1635) 5.0 (126) 24 (608)
GH10 4000 400 - 550 4200 (1900) 5.4 (136) 24.5 (620)
GH12 5500 380 - 480 5650 (2565) 5.7 (146) 25.5 (650)
GH15 8000 320 - 400 6800 (3085) 6.1 (156) 27 (690)
GH18 12000 300 - 400 7800 (3540) 6.5 (165) 29 (740)
HAMMER HYDRAULIC CIRCUIT GAS CHARGE

MODEL OIL FLOW OPERATING RELIEF PRESSURE 5
PRESSURE 1 minimum 2 Cold 3 Hot 4
gpm (L/min) psi (bar) psi (bar) psi (bar) psi (bar)
GH9 40 - 53 (150 - 200) 2600 (180) 3100 (215) 365 (25) 420 (29)
GH10 44 - 55 (165 - 210) 2600 (180) 3100 (215) 365 (25) 420 (29)
GH12 45 - 58 (170 - 220) 2650 (183) 3150 (217) 365 (25) 420 (29)
GH15 53 - 66 (200 - 250) 2600 (180) 3100 (215) 365 (25) 420 (29)
GH18 58 - 77 (220 - 290) 2500 (172) 3000 (207) 365 (25) 420 (29)
*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 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 3 to 4 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).
-6-
NPK
HAMMER STRUCTURE
NPK HAMMER MODELS GH9, GH10, GH12, GH15, GH18
A TOP NUT P PLUNGER BUSHING

B LOCK WASHER Q PLUNGER
C TIE ROD R VALVE BODY
D SLEEVE (A) S VALVE SPOOL
E MAIN BODY T VALVE BOTTOM CAP
F PISTON U CYLINDER SPACER
G SLEEVE (B) V TOOL BUSHING UPPER
H BOTTOM NUT W DRAIN PLUG
I TOOL HOLDER X UNDERWATER PORT
J TOOL BUSHING LOWER Y RETAINING PIN
K TOOL Z RETAINING PIN RING
L CHARGE VALVE AA SWIVEL ELBOW
M HEAD BB GREASE FITTING
N VALVE TOP CAP CC AUTOLUBE PORT
O PLUNGER DD LOCKWASHER
-7-
NPK
HAMMER SERIAL NUMBER LOCATION
NPK HAMMER MODELS GH9, GH10, GH12, GH15, GH18
The serial number location (A) is right of center on the body above the Autolube port.
-8-
NPK
PRINCIPLE OF OPERATION
A IN PORT D PISTON
B OUT PORT E PLUNGER
C1 NITROGEN GAS CHAMBER ABOVE PISTON F MAIN VALVE SPOOL
C2 UPPER CHAMBER OF PISTON G TOOL
C3 LOWER CHAMBER OF PISTON H NITROGEN GAS
C4 CHAMBER OF VALVE SPOOL
(1) UPSTROKE OF PISTON

Hydraulic oil supplied by the carrier hydraulic pump enters the NPK Hammer
“IN” port and is directed through passage (5) to the top of the valve plunger,
forcing the valve spool to the down position. This same inlet oil also flows
around the valve spool and into the chamber below the center diameter of the
piston (C3). The oil pressure acts on the underside radius of the piston center
diameter. This raises the piston and increases the gas pressure (C1). Oil
above the center diameter of the piston, in chamber (C2), is forced out passage
(4) and out the “OUT” port of the hammer and back to tank.
(2) VALVE SHIFT

As the piston rises, the lower chamber (C3) is open to passage (3) and
pressurized oil enters chamber (C4) of the valve. This pressurized oil pushes
on the underside of the flanged top of valve spool. The area of the flange is
greater than the area of the plunger, which is holding the valve down. This
greater resulting force raises the spool. As the spool starts to rise, the inlet oil
from the carrier is shut-off. As the spool is hollow, pressurized oil from
chamber (C3) is open to chamber (C2) and to the “OUT” port of the hammer.
This allows the pressure to drop to a level above tank return backpressure. At
this point, the spool shuts off the “OUT” port and the flow from chamber (C3) is
to (C2) only.
-9-
NPK
PRINCIPLE OF OPERATION, CONTINUED
(3) POWER STROKE

The oil pressure at (C3) and (C2) is now in balance. The compressed gas in
chamber (C1) upsets this balance and forces the piston downwards. As the
piston moves downwards, the center diameter closes off passage (3), which is
the pressure signal port to the valve spool. Oil from chamber (C3) circulates to
chamber (C2) as the piston moves downwards.
(4) IMPACT
The piston impacts the tool. Oil pressure from the valve “IN” port is still pushing
on the valve plunger. The passage (3) to the valve spool is now open to
chamber (C2). The force on the valve plunger is now greater than the force
under the valve spool flange. This allows the plunger to push the valve spool to
its down most position. Oil from the valve spool chamber is forced into piston
upper chamber (C2) above the center diameter of the piston. The inlet oil is
now free to enter piston chamber (C3) and start another cycle. Because the
(C3) chamber pressure is not allowed to drop very low, the formation of air
bubbles in the oil is reduced or eliminated. This reduces or eliminates
cavitation erosion in the hammer.
AUTOMATIC ENERGY RECYCLING: Extremely hard material will impart greater

rebound energy to the piston after it strikes the tool. This will assist the incoming oil
in raising the piston against the gas pressure in chamber (C1). This reduces
upstroke time and therefore increases hammer frequency (beats per minute). The
impact force of the hammer remains the same on each impact.
- 10 -
NPK
HYDRAULIC INSTALLATION
NPK INSTALLATION KITS are available for virtually all compatible backhoe loaders,
excavators, and skid steers. Complete parts and instructions for the hydraulic
installation of the NPK HYDRAULIC HAMMER including valving and/or controls, hoses
and fittings, accumulators, boom and stick tubing, and clamps are provided.
HAMMER LINES
Typically, the pressure line is arranged on the left side of the boom and the return line
on the right side. Flow to the hammer is controlled from an auxiliary valve on the carrier
or from an NPK supplied valve. Hydraulic oil is routed back to the tank through the
carrier’s oil cooler and filter.
ACCUMULATORS
General guideline requirements. Some installations may have special requirements.
MODEL Pressure Line Return Line

Accumulator Accumulator
GH9, GH10, GH12 1* 1
GH15, GH18 1* 2
* For gear pump machines only
HAMMER CONTROL VALVE

NPK uses two general types of control systems, depending upon the carrier model:
1. CONTROL SYSTEM USING CARRIER AUXILIARY OR SPARE VALVE SECTION.
This type of installation utilizes an existing carrier valve. Any additional parts, such
as a mechanical linkage, hydraulic pilot control valve, flow control valves, etc., are
furnished in the NPK HYDRAULIC INSTALLATION KIT. Special hydraulic pressure
control valves are not required. The NPK HYDRAULIC HAMMER operating
pressure is self-regulating.
2. CONTROL SYSTEM USING THE NPK MULTIVALVE.
For carriers not equipped with a suitable auxiliary or spare valve section, the NPK
HYDRAULIC INSTALLATION KIT includes a solenoid operated, priority flow control
valve to operate the NPK HYDRAULIC HAMMER. The NPK MULTIVALVE is
specifically designed for the operation of boom mounted attachments.
- 11 -
NPK
HYDRAULIC INSTALLATION, CONTINUED
ATTENTION 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 hydraulic oil can not only damage
the hydraulic hammer but also cause problems in the carrier, which could result in
damaged components. Care should be taken to check for contamination of the oil
and to change it if it is found contaminated. Oil sampling at regular intervals is
highly recommended.
When the hydraulic oil shows low viscosity and bubbles, this indicates that the oil
is deteriorated. If the oil is dark brown and gives off an offensive odor, it is
severely deteriorated. Change the oil immediately!
When the oil is clouded, or the oil filter has become clogged, it indicates that the
oil is contaminated. Change the oil immediately!
To change the contaminated hydraulic oil, drain the hydraulic system completely
and clean components. Do not mix new oil with the old.
2. Do not allow any contamination to mix with the oil. Take special care in preventing
contamination from entering the hydraulic system through the hose or tube
connection when changing the hydraulic hammer with the bucket.
3. Low oil level will cause heat build-up, resulting in deterioration of the oil. Also, it may
cause cavitation due to air mixing with the oil, leading to a damaged hydraulic
hammer and carrier components. Keep the oil at the proper level at all times.
4. Do not use the hydraulic hammer at an operating temperature higher than 180°F
(80°C). The proper operating oil temperature range is between 120°F (50°C) and
180°F (80°C). Since clogged 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 excavator when using a hydraulic implement. Another method is to set
up an oil sampling schedule and change accordingly.
- 12 -
NPK
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 the hydraulic hammer operating, can cause
internal pieces of non-NPK quick disconnects to disintegrate. These pieces would
migrate into the hammer, causing damage.
2. If quick disconnects are used when the hammer is removed from the excavator, the
quick disconnects should be capped to keep them clean. If this is not done,
contamination on the disconnect will be flushed into the hammer when re-connected.
This, again, can cause damage.
3. Most quick disconnects create a restriction in the circuit. NPK Hammers are not
back pressure sensitive, but restrictions cause unnecessary heating of the oil. Also,
the pressure required to operate the hammer, plus the restriction of the disconnects
may push an older, low pressure, carrier machine to the limit of its hydraulic system.
This would interfere with proper hammer operation. However, the NPK approved
quick disconnects are properly sized so that the hammer operation is not
affected.
NOT RECOMMENDED CONNECTION
APPROVED CONNECTION (A) Non-NPK Quick Disconnects (B)
NPK APPROVED CONNECTION QUICK DISCONNECTS

CONTACT YOUR NPK DEALER FOR ADDITIONAL INFORMATION ABOUT
NPK QUICK DISCONNECTS
- 13 -
NPK
HYDRAULIC QUICK DISCONNECTS continued
If hydraulic quick disconnects are used with the NPK Hammer, it is recommended that
the following precautions be followed.
1. Periodic inspection of both male
and female ends (A) is
recommended to ensure the
couplers are in good working
condition. Failure to inspect
couplers may result in pieces from
a damaged or failed coupler to
migrate into the hammer or parts of
the coupler returned to the
machine.
2. Check for dirt, dust, and debris on

both couplers before coupling.
3. Be sure that the couplers are

completely seated together (B).
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.
- 14 -
NPK
MOUNTING INSTALLATION
NPK Mounting Installation Kits include the parts required to adapt the NPK HYDRAULIC
HAMMER to the carrier. NPK mounting kits include the hammer mounting bracket, flow
control valve (if required), and hoses to connect to the carrier hydraulic system.
A TOP BRACKET
B BUSHINGS (NOT SHOWN)
C PRESSURE HOSE
D RETURN HOSE
E BOLT PACKAGE
F BRACKET I.D. PLATE
G INSIDE MALE ADAPTER FITTING
H OUTSIDE MALE ADAPTER FITTING
J JOINT FITTING WITH PLUG
K JOINT FITTING WITH PLUG
L LINK PIN
M STICK PIN
N HAMMER HOSE
Refer to HAMMER FASTENER TORQUE section for Top Bracket bolt torque.
Refer to NPK Installation Kit Manual for additional information.
- 15 -
NPK
MOUNTING INSTALLATION, CONTINUED
REMOVAL FROM THE CARRIER
1. Close pressure and return line
shut-off valves (A).
2. Disconnect hydraulic hoses (B)
before laying the hammer down.
Avoid getting hydraulic oil on
rubber mounts (C). Flush with
water if necessary.
3. Cap the pressure and return lines
on the carrier (D) and connect the
hammer whip hoses as shown.
4. Position the hammer horizontal on
wood blocks and remove boom
pins.
ATTENTION The hydraulic

lines must be
handled carefully and sealed to
prevent contamination from
entering the hammer or the carrier
hydraulic system.
The tool end of
ATTENTION 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 horizontal on
wood blocks, as shown.
2. Align the bucket pin holes. Install
the bucket pin (C) before the
cylinder link pin (D).
3. Connect hydraulic hoses (E), not
shown. Pressure is on LEFT,
return is on RIGHT.
4. Open shut-off valves (F).
- 16 -
NPK
LUBRICATION
GREASING PROCEDURE
Manual greasing for hammers without AUTOLUBE system.
IMPORTANT:
1. 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.
2. Turn the machine off.
3. Grease the hammer until grease begins to come out around the tool and lower
bushing.
APPLY DOWNFORCE TO PUSH TOOL UP INTO HAMMER
NOTE: USE A GOOD QUALITY EP #2 LITHIUM BASED GREASE WITH WEAR

INHIBITING ADDITIVES, SEE PAGES 18, 19, AND 20.
- 17 -
NPK
LUBRICATION, CONTINUED
CORRECT GREASE AND GREASE INTERVALS
Proper hammer maintenance requires a sufficient supply of the correct grease to the
tool (chisel). The tool must be pressed against a hard surface until it stops up inside the
hammer. This prevents grease from entering piston impact area and ensures proper
distribution of grease between the tool and tool bushings.
GREASE INTERVALS
If the hammer is not connected to an Autolube system, see page 20, the hammer must
be greased at regular intervals to get the best life from the tool and tool bushings.
There are two ways to determine grease intervals:
First, grease the hammer at the beginning of the job until grease comes out between
the tool and the lower tool bushing. Run the hammer until the shank of the tool starts to
look dry. This determines the time interval for the greasing of this particular hammer on
this particular job. Typically, this is 1 to 4 hours. Also, note the amount of grease
needed to re-grease the tool. This gives you the amount of grease and how often it
must be applied. An example would be that a particular hammer, on a particular job,
requires half a tube of grease every 3 hours. This would be the greasing schedule you
would set up. If this hammer was moved to another job, another grease schedule may
have to be determined.
Second, if you can’t control the grease schedule, such as rental units, then have the
operator grease the hammer once every hour of hammer operation. Again, grease the
hammer until grease comes out between the tool and tool bushing. This is usually more
often than required, but is far cheaper than replacing prematurely worn tools and tool
bushings.
CORRECT GREASE
The type of grease used is very important. NPK recommends a lithium soap base EP
(Extreme Pressure) NLGI #2 Grease, with Moly (Molybdenum Disulfide) or other
surface protecting additives. A high drop point 500° F (260° C) grease is desirable.
On the following page is a list of commonly available greases, by manufacturer and

brand name that meet NPK’s recommendations. NPK does not endorse any one brand
as being superior to another. If you or your customers use a brand not listed, please
call the NPK Service Department at 800-225-4379.
- 18 -
NPK
CORRECT GREASE FOR HYDRAULIC HAMMERS continued
MANUFACTURER BRAND NAME
Amalie Oil Co. LI-2M
Amoco Rykotac EP Grease
Amolith Grease 94601
Rykon Premium Grease EP (Grade 94108)
Rykon Premium Moly Grease (Grade 94114)
Amoco Molylith Grease 92006
Amsoil, Inc. GHD
BP Oil, Inc. Bearing Gard-2
Caterpillar Multipurpose Molydbenum Grease (MPGM)
Cato Oil and Grease Company Moly Lithflex CX AS
CITGO Citgo Extra Range Grease
Conoco, Inc. Super Lube M EP #2
Dryden Oil Company Moly EP 2
Exxon Ronex Extra Duty Moly NLGI 2
Fiske Brothers Refining Co. (Lubriplate) MO-LITH No. 2
John Deere TY6333/TY6341 Moly High Temp
Kendall L-424
Mobil Moly 372
Muscle Products Corporation (MPC) PL-10 Powerlift Grease
LP-10 Lithium EP Plus
NPK Universal Plus Lithium EP Grease
Super Duty EP Grease (water resistant)
Chisel Paste
Pennzoil Adhezolith EP 2 Grease
Phillips 66 Company Philube MW
Shell Retinax ® AM Grease 71119
Retinax ® HD Grease
Standard Oil Company Bearing Gard-2
Sun Refining & Marketing Company Prestige Moly 2 EP
Texaco, U.S.A. Molytex EP 2
Union Oil Company Unoba Moly HD #2
Unocal Unoba Moly HD #2
- 19 -
NPK
CORRECT GREASE FOR HYDRAULIC HAMMERS continued
NPK HAMMER GREASE
NPK now offers hammer grease specially formulated to meet severe job requirements.
The grease is available in three different temperature ranges - 350°, 500°, and 2000°.
All are compatible with Autolube systems.
Universal Plus and Super Duty are lithium soap based products that resists washout
and contain NPK-10 additive for surface protection in friction effected 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 NO.
14 OZ. CARTRIDGE G000-1010
120 LB. KEG G000-1020
35 LB. PAIL G000-1030
400 LB. DRUM G000-1040
SUPER DUTY NPK PART
500 deg NO.
120 LB. KEG G000-1021
35 LB. PAIL G000-1031
400 LB. DRUM G000-1041
CHISEL PASTE NPK PART
2000 deg NO.
AUTOLUBE SYSTEMS
An automatic greasing system is recommended
to reduce hammer tool and tool bushing wear.
The NPK AUTOLUBE System is designed to
automatically provide a continuous supply of
grease to the hammer tool and tool bushing –
increasing tool and tool bushing life by reducing
wear. The AUTOLUBE pump is capable of
pumping EP2 grease in cold weather. The
pump output is adjustable according to the
requirements of the hammer model and to
compensate for tool bushing wear.
NPK GH Series hammer models have a connection port (A) for an automatic greasing
system. Refer to the NPK AUTOLUBE Instruction Manual for details.
- 20 -
NPK
ROUTINE INSPECTION AND MAINTENANCE
1. VISUAL INSPECTION
Detect a potential problem early.
FASTENERS
Inspect all fasteners. Retighten as necessary. Refer to HAMMER FASTENER
TORQUE section for Top Bracket bolt torque.
WELDS
Check for cracks, repair as necessary.
HOSES AND TUBING
Check for oil leaks, loose clamps and hose abrasion.
HYDRAULIC OIL
MAINTAIN A CLEAN HYDRAULIC SYSTEM
If non-petroleum oil is used, contact 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 hammer until grease is seen coming out
between the tool and bushing.
Use a good quality, high temperature EP#2 grease
containing anti-wear additives, see LUBRICATION section.
If machine is equipped with an AUTOLUBE 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 section.
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 surface grinder or milling machine using sufficient cooling.
Please consult your authorized NPK Dealer or NPK Service Department for additional
information.
- 21 -
NPK
TWENTY HOUR INSPECTION
1. WARRANTY REGISTRATION
Complete and send to NPK after initial 20 hour inspection.
2. WELDS
Check for cracks, repair as necessary. 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 section. 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,
section.
5. GAS CHARGE
Check and adjust, if required, see GAS CHARGE section.
- 22 -
NPK
TROUBLESHOOTING
UNDERSTAND THE BASICS
1. 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. 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. 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 circuit must be set to provide the correct flow
to the hammer.
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.
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 closed. Valve position Open valve.
Relief valve set too low Hyd. Pressure Adjust or replace.
(must be 400 to 500 psi above
hammer operating pressure).
Hyd. temperature too high Oil Reduce throttle, clean or
(over 180°F). Temperature add oil cooler.
Hydraulic pump volume too low. Oil Flow Increase circuit flow.
Excess oil in gas head. Gas Pressure Reseal hammer.
Oil level of carrier too low. Oil Level Add hydraulic oil.
Erratic running or Defective pump or control valve. Hyd. Pressure Repair or replace.
stops running. Shut-off valve closed. Hyd. Pressure Open valve.
Hoses reversed. Hyd. Pressure Pressure is on left.
Return is on right.
Return line blocked. Hyd. 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.
Excess oil in gas head. Gas Pressure Reseal hammer.
Hammer main valve Hyd. Pressure Call NPK Service Dept.
malfunction.
Piston not cycling. Hyd. Pressure Call NPK Service Dept.
- 23 -
NPK
TROUBLESHOOTING, CONTINUED
CHECKING THE HYDRAULIC PRESSURES
Install pressure gauges in the hammer
pressure (B) and return lines (C). The
NPK INSTALLATION KIT provides
pressure test ports (H) in the hammer
shut-off valves (D) mounted on the
dipper stick. Generally, the pressure
line is on the left and the return line is
on the right. A glycerin filled gauge
should be installed on a hose that is
long enough to be clear of the hammer
and flying debris.
1. Determine Return Line Pressure

Open (F) both shut-off valves (D)
and operate the hammer. The
return line pressure should not
exceed 300 psi (21 bar).
2. Determine System Relief Valve

Pressure
Close (G) the pressure line (B)
shut-off valve. Energize the
hammer control circuit and note the
relief valve setting. Stay clear of hammer when checking line pressures.
The relief valve is only used for ultimate safety, when the hammer is removed or the
shut-off valve is closed, not to set the hammer operating pressure. Therefore, to
prevent overheating, loss of flow and reduced hammer frequency, the relief pressure
should be set a minimum of 400 to 500 psi (28 to 35 bar) above the hammer
operating pressure.
3. Determine Hammer Operating Pressure

Open both shut-off valves. Operate the hammer and note the operating pressure.
The operating pressure of the NPK HYDRAULIC HAMMER is self regulating,

determined by the gas pressure. If the operating pressure is low, check the gas
pressure.
HYDRAULIC OPERATING CIRCUIT RELIEF
MODEL
PRESSURE psi (bar) MINIMUM psi (bar)
GH9 2600 (180) 3100 (215)
GH10 2600 (180) 3100 (215)
GH12 2650 (183) 3150 (217)
GH15 2600 (180) 3100 (215)
GH18 2500 (172) 3000 (207)
- 24 -
NPK
CHECKING THE HYDRAULIC FLOW
Procedure to measure hydraulic flow available to the hammer at hammer operating
pressure.
1. Installation of Flow Meter equipped with Pressure Loading Valve.

Install the flow meter between the hammer pressure and return lines as shown.
Generally, the pressure line is on the left and the return is on the right.
2. Determine Return Line Pressure (Pressure Drop).

Open both stop valves and press the hammer foot switch. Measure the pressure
with the load valve of the pressure / flow meter in full open condition.
3. Determine Relief Valve Pressure and Oil Flow.

Measure flow and hydraulic pressure
with the flow meter. Adjust the load
valve (A) 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 Typical flow meter with pressure loading valve.
hammer specification chart for correct
flow at rated pressure for the hammer A. Load Valve
model. B. In Port
C. Out Port
D. Flow/Temperature Display
E. Flow Temperature Switch
F. Pressure Gauge
- 25 -
NPK
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 (B)
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.
PROBLEM CAUSE REMEDY

(A) Leakage thru vent plug. Seal in main body Sleeve A. Disassemble hammer and
replace seals.
(B) Leakage between tool and Seal in main body Sleeve B. Disassemble hammer and
bushing. replace seals.
(C) Leakage between main O-ring between valve and body. Replace.
body and valve. Loose bolts. Thread adhesive, tighten.
(D) Leakage between valve O-ring under valve cap. Replace.
body and valve top cap. Loose bolts. Tighten.
(E) Leakage between valve O-ring under valve cap. Replace.
body and valve bottom cap. Loose bolts. Tighten.
(F) Leakage between valve and O-ring under swivel. Replace.
swivel.
(G) Leakage between hose and Loose or damaged hose fitting. Tighten or replace.
swivel.
(H) Leakage between swivel Seal in swivel. Replace.
and flange.
- 26 -
NPK
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.
Note: To locate gas leak, apply soapy water (N) at the points indicated.
PROBLEM CAUSE REMEDY

(J) Leakage from top of O-ring in check valve. Replace.
charge valve. Damaged check valve in charge valve. Replace.
(K) Leakage between charge O-ring in charge valve. Replace.
valve and head. Loose charge valve. Thread adhesive, tighten.
(L) Leakage between head O-ring in head. Disassemble hammer and
and main body. replace seals.
(M) Leakage thru vent plug. Seal in main body Sleeve A. Disassemble hammer and
replace seals.
(N) Soapy Water N/A N/A
- 27 -
NPK
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.
GAS CHARGE PRESSURE 3

1
COLD HOT 2
MODEL PRE-CHARGE AT LOAD PRE-CHARGE AT LOAD
psi bar psi bar psi bar psi bar
GH9 365 25 410 28.5 420 29 480 33
GH10 365 25 410 28.5 420 29 470 32.5
GH12 365 25 420 29 420 29 480 33
GH15 365 25 420 29 420 29 480 33
GH18 365 25 420 29 420 29 480 33
NOTES:
1. Cold gas charge is the initial set with the hammer at ambient temperature.
2. Hot gas charge is checked after 3 to 4 hours of running and with a system oil
temperature of 140° to 180°F (60° to 80°C).
3. Pressures listed are maximum. Use tolerance of minus 25 psi (2 bar).
- 28 -
NPK
GAS CHARGE
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 at maximum operating temperature. The chart
showing values for “Operating Temperature” should be used, see below.
ALTERNATE METHOD
The nitrogen gas pressure can be measured or charged at ambient temperature (cold),
before operating the hammer. See the chart “Ambient Temperature” below.
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 SPECIFICATIONS
AT AMBIENT TEMPERATURE AT OPERATING TEMPERATURE
(cold, before operating)
MODEL PSI (BAR) PSI (BAR)
(plus 0, minus 25) (plus 0, minus 25)
GH9
GH10
GH12 365 (25) 420 (29)
GH15
GH18
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)
are required. These can be obtained from your local welding supply house. A regulator
valve is available from NPK.
1. HOSE (PART NO. 20118010)
2. PLUG (PART NO. 30102050)
3. CHARGE ADAPTER (PART NO. 30604040)
4. CHARGING KIT BOX (PART NO. 35001030)
5. CAP (PART NO. 30100500)
6. OPTIONAL REGULATOR VALVE
(PART NO. 21101050)
- 29 -
NPK
GAS CHARGE, CONTINUED
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. Remove the tool or
position the hammer with the tool fully extended. THE HAMMER MUST NOT BE
RESTING ON THE POINT.
2. Remove the charge 3. Turn the NPK charge 4. Install the NPK charge
valve cap (A). adapter T-handle (A) adapter (A) on the
full counterclockwise. hammer charge valve
(B).
Remove the valve cap only, not the charge valve assembly!
6. Turn the T-handle (A)
5. Tighten the charge
clockwise. As the T-
adapter cap (A).
handle (A) is screwed in, a
resistance is encountered.
By turning the T-handle (A)
further, the nitrogen gas
pressure will be indicated
on the pressure gauge (B).
Stop turning the T-handle
(A) when the gauge (B)
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 pressure is 25 psi (2 bar) or more
below specification, proceed to NITROGEN GAS CHARGING PROCEDURE. 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.
- 30 -
NPK
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. Remove the cap from the charge adapter.
3. Install a pressure 4. Connect a hose (D) from 6. Turn the handle on the tank
regulator (A) on a the pressure regulator (A) regulator (A)
tank of nitrogen gas on the nitrogen tank (B) to counterclockwise to full
(B). the charge adapter (C). closed.
5. Turn the T-handle (E) on 7. Open the valve (B) on the
the charge adapter (C) nitrogen tank (C) by turning
clockwise. the handle counterclockwise.
8. Slowly adjust the regulator on the nitrogen tank to the correct
pressure by turning clockwise. Refer to NITROGEN GAS
PRE-CHARGE chart in the NITROGEN GAS PRESSURE
section.
9. Charge nitrogen gas (see gas charge decal (E) until the
pressure gauge (A) on the charge adapter (B) is at the
correct setting, then turn the T-handle (C) counterclockwise
all the way out.
10. Close the nitrogen tank valve and then remove the hose (D)
from the charge adapter.
Nitrogen gas may be trapped in the hose. Loosen fittings
slowly to release pressure.
11. Remove the charge adapter from the hammer charge valve.
12. Replace the charge valve cap.
- 31 -
NPK
DISCHARGING THE GAS PRESSURE
PROCEDURE
1. Remove the charge 2. Turn the NPK charge 3. Install the NPK charge
valve cap (A). adapter T-handle (A) adapter (A) on the
full counterclockwise. hammer charge valve
(B).
4. Tighten the charge 5. Turn the T-handle (A) 6. Loosen the charge adapter
adapter cap (A). clockwise. As the T- cap (A) VERY SLOWLY.
handle (A) is screwed The gas pressure will
in, a resistance is gradually decrease to zero;
encountered. By then REMOVE THE CAP
turning the T-handle (A).
(A) further, the
nitrogen gas pressure 7. Remove the charge adapter
will be indicated on the (B) from the hammer and
pressure gauge (B). reinstall charge valve cap.
Stop turning the T-
handle (A) when the
gauge (B) reads
pressure. Do not over
tighten.
- 32 -
NPK
HAMMER DISASSEMBLY AND ASSEMBLY
TOOLS AND EQUIPMENT REQUIRED
HOIST NYLON ROD, PART NO. H010-7510
The minimum hoist capacity should be Used to drive Sleeves and Piston into
determined by the hammer weight. and out of Main Body bore.
See HAMMER SPECIFICATIONS.
LIFTING HOOK, P/N H010-7501 NPK GAS CHARGING KIT
For removing and installing Tool Holder. Supplied with the NPK hammer.
SOCKET WRENCHES CLEANING SOLVENT
See HAMMER FASTENER TORQUE for sizes.
SLEDGE HAMMER NPK ASSEMBLY LUBRICANT
Size according to hammer model.
PLASTIC HAMMER SUITABLE NYLON SLING
ADJUSTABLE WRENCH DRAIN PAN
PORTA POWER HYD. PUMP & CYLINDER
With chain accessory attachments.
HEX KEY WRENCHES

SHCS HEX NPK
SIZE SIZE PART NO.
M10 8mm 25004080
M12 10mm 25004100
M16 14mm 25004140
M20 17mm 25004170
M24 19mm 25004190
M27 19mm 25004190
LONG HEX KEY SOCKETS

When repairing NPK hammers, it is sometimes
necessary to remove the Socket Head Cap
Screws on the Main Valve. NPK has available 1”
drive long sockets (A) to aid disassembly. Use
with a hex key wrench (B) modified into a straight
key by cutting (C) off the short end of the wrench
as shown.
HEX SOCKET NPK

SIZE PART NO.
14mm 35004590
17mm 35004600
19mm 35004610
- 33 -
NPK
HAMMER DISASSEMBLY AND ASSEMBLY,
CONTINUED
NPK START-UP KIT
A start-up kit is furnished with every hammer and contains the following:
Gas Charging Kit (Red Box) Manuals, Decals & Warranty

Information
Two (2) tubes of NPK grease for start-up Caps and Plugs
- 34 -
NPK
CONTINUED
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.
- 35 -
NPK
CONTINUED
HAMMER DISASSEMBLY
A sturdy work bench is recommended for disassembly and assembly of an NPK
HYDRAULIC HAMMER.
REMOVE THE HAMMER FROM THE BRACKET

1. Place the hammer on blocks. Make sure the
hammer is stable.
NOTE: DO NOT REMOVE TOOL FROM
HAMMER AT THIS TIME!
2. Remove the bracket bolts and bracket

support blocks.
3. Remove rubber mounts, on one side only,

preferably the side with the bracket bolt nuts.
Take care not to contaminate the rubber

mounts with oil. Flush with water, if
necessary.
4. Remove hydraulic hoses. Plug hose ends and hammer ports to prevent
contamination from entering.
5. Lift the hammer from the bracket. Using a hoist, attach a chain to the hammer
and lift it out of the bracket.
- 36 -
NPK
CONTINUED
DISASSEMBLING THE MAIN BODY
Check first to ensure that the nitrogen gas has been
completely discharged. See GAS CHARGE section of
the Operators Manual for procedure.
1. Remove the lock rings. The lock ring has an

indent to facilitate removal. Turn the lock ring
to an easy-to-pull position.
a. Insert a bar or screwdriver (B) into the lock

plate (A) and top nut to prevent the lock ring
from turning.
b. Drive the lock ring out with a hammer (E).
2. Remove the lock plates (A). If the lock plates

are tight against the boss on the gas head (B),
turn the top nut (C) in the opposite direction.
This will facilitate removal of the lock plates (A).
3. Remove the top nuts. Loosen the pair A and D or B and C first. Then, loosen
the remaining pair uniformly until the spacer spring tension is relieved.
4. Remove the lock washers (A).
- 37 -
NPK
CONTINUED
DISASSEMBLING THE MAIN BODY continued
5. Remove the gas head and spacer
springs.
a. Pull the out the gas head (A) using

screwdrivers or pry bars (B) as
levers. Care should be exercised
so as not to apply undue force.
Remove the gas head from the tie
rods.
When the gas head is

removed, hydraulic oil will flow
out of the body bore.
HAVE OIL PANS READY.
b. Remove the spacer springs (C).
6. Sling the tool holder or use the

NPK lifting hook, or lifting eye on
the GH10 through GH18.
The tool holder must be kept
level and square to the main
body.
- 38 -
NPK
CONTINUED
7. Remove the tie rods.

Loosen the tie rods with a wrench by hand. If a tie rod should fail to turn, rap the
end of the tie rod with a hammer. Loosen all four of the tie rods before removing any
of them. This will help prevent the threaded inserts in the tool holder from coming
out with the tie rods. Pull out the tie rods.
8. Remove the tool holder. 9. Remove the dowel pins (A) and
collars (B) from the spacer section.
Hoist the tool holder by a crane to

remove it from the main body.
10. Remove the spacer section. Hoist

the spacer section by a sling to
remove it from the main body.
- 39 -
NPK
CONTINUED
11. Remove the dowel pins (A & B) from the main body (C) and from main body sleeve
“B” (D).
12. Remove the piston and sleeves (A) as one unit.

a. Bump a nylon bar (B) on the end of
the piston at the tool holder end of
the main body (C) and drive the
bushings and piston out.
Hydraulic oil comes out of the

body each time the sleeves
move. Direct the port of the
swivel adapter downward.
b. To prevent damage to the body
bore, support sleeve “A” as it
comes out.
Use a nylon strap to support

the piston and sleeves as they
are removed from the body
bore.
- 40 -
NPK
CONTINUED
12. (continued)
Alternate method of piston and sleeve removal with portable power unit (A).
c. Pin chain (C) to diagonally opposite tie rod holes (D) in main body (E) at tool end
(F). String chain (C) through tie rod holes (D) and wrap around back of portable
power RAM cylinder (G). Hold chain in place with pins, or screwdrivers (B).
d. Push piston and sleeves (H) from the tool end of body (F) and out gas end (J).
e. Keep the sleeves level by adjusting tension on the sling.
When the sleeves come out of the body, hydraulic oil flows out.
HAVE AN OIL PAN READY!
- 41 -
NPK
CONTINUED
12. (continued)
f. Change the supporting position on
the sleeves and piston and remove
them from the body bore.
When removing the sleeves and piston as

a unit, the point of balance will be on the
“B” Sleeve near where the “A” Sleeve
joins.
13. Remove the piston from the “A” and “B” Sleeves. Lay piston (E) and Sleeve “A”
(A) and “B” (B) assembly on a table (D) covered with cardboard (C) or suitable
protection. Separate the piston (E) from the “B” Sleeve (B) by rapping the
striking end of the piston with a plastic faced hammer (F). The piston will slide
out of the “B” Sleeve. Separate Sleeve “A” from the piston by tapping the
bushing with a plastic faced hammer.
- 42 -
NPK
CONTINUED
DISASSEMBLY OF MAIN VALVE
1. Remove the bottom cap.
a. Remove the cap screws from the b. Remove the bottom cap (A). Use
bottom plate with a hex wrench. screwdrivers, or pry bar (E) to
remove bottom cap (A).
Do not force the bottom cap (A) when

removing it, otherwise, the valve body
will be damaged, causing oil leaks.
2. Remove the top cap, plunger bushing and valve spool.
a. Remove cap screws from the top b. Use a nylon bar (A) in the main valve
cap with a hex wrench. body (B) at the bottom cap end and
drive the top cap (C), the plunger
bushing (D), and the valve spool (E)
out of the case with a hammer.
- 43 -
NPK
CONTINUED
DISASSEMBLY OF MAIN VALVE continued
2. (continued)
c. Remove the valve spool from the d. Remove the plungers (A) from the
valve body. plunger bushing (B).
3. Remove the swivel adapters.

a. Remove the snap ring (A) with snap
ring pliers. Pull the swivel adapters
(B) off of the swivel flange.
b. Remove the cap screws (D) from
the swivel flanges (C) and then
remove the swivel flanges from the
valve body (E).
4. Remove the main valve body (A)

from the main hammer body (B).
It is rarely necessary to remove the
valve body from the main body.
If disassembly is needed for any reason,
proceed as follows. Long hex key
sockets are available from NPK to aid
disassembly, see TOOLS AND
EQUIPMENT section.
Attach a 6 ft. (2 meter) long extension
pipe to the wrench and loosen each cap
screw. There is thread adhesive on each
bolt. Use heat on the head of any bolt to
soften thread adhesive if it is difficult to
remove.
DO NOT HEAT EXCESSIVELY!!

DO NOT HEAT THE VALVE OR THE
HAMMER BODY!!
- 44 -
NPK
CONTINUED
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 below, 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 - b. Sleeves (A) and (B) -
Check the sliding areas for Check the inner surface for damage
damage and the striking area for and repair or replace if necessary.
damage or deformation. Repair
or replace, if necessary.
c. Valve spool - d. Valve Case -
Check the sliding area for Check the inner surface for damage
damage, deformation, or wear or wear and repair or replace, if
and repair or replace, if necessary.
necessary.
- 45 -
NPK
CONTINUED
INSPECTION AND REPAIR AFTER DISASSEMBLY continued
3. SWIVEL FLANGE AND SWIVEL ELBOW
Check for scratches or scoring on the swivel flange and swivel elbow in the cross-
hatched seal contact areas shown. The sealing area can be visually identified by
the discoloration. For actual location, see chart below.
Repair any shallow scratch or score by polishing with 200 grit emery cloth. If the
damage is too deep to be polished out, replace the part.
DIMENSIONS inch (mm)
Model a b c
.33 1.8 .5
GH9
(8.5) (45.5) (12)
.33 1.8 .5
GH10
(8.5) (45.5) (12)
.33 1.8 .5
GH12
(8.5) (45.5) (12)
.33 1.8 .5
GH15
(8.5) (45.5) (12)
.33 1.8 .5
GH18
(8.5) (45.5) (12)
4. TOOL AND TOOL BUSHING WEAR -

See page MAXIMUM TOOL TO TOOL BUSHING CLEARANCE section of
Service Manual.
5. GENERAL -
a. Check for damage, breakage, deformation, wear and rust and repair or replace if
necessary.
b. Check for contamination and, if any, remove.
- 46 -
NPK
CONTINUED
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.
Small nicks may be removed with a suitable hone.
When large or deep nicks are found, replace the part.
A. TOOL END
B. GAS END
C. SLEEVE (B)
D. SLEEVE (A)
E. U-CUP SEAL
F. U-CUP DIRT SEAL
G. WEAR BAND
(DEFECTIVE SEALS)
ALL DEFECTIVE SEALS SHOULD BE
REPLACED WITH NEW ONES.
A. O-RINGS DEFORMED, WORN,
WARPED, DAMAGED OR
DETERIORATED.
B. BACKUP RINGS WORN OR
DEFORMED.
C. U-CUP SEALS WORN OR
DETERIORATED.
Some minor leakage may be found for awhile after

new oil seals are installed. The oil leak will stop
when the seal seats itself in use.
- 47 -
NPK
CONTINUED
REPLACING THE SEALS continued
1. INSTALLING THE U-CUP SEALS
a. One method of folding u-cup seals (A) is illustrated below.
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 AND BACK-UP RINGS

NOTE: Before installing the o-rings on the sleeves, check the fit of the sleeves
in the main body bore. See REASSEMBLY OF THE HAMMER, step 2a.
a. Install the o-rings.
b. Curl the back-up rings, as shown below, and install.
c. After installing, coat the o-rings and back-up rings with grease.
Inspect sleeves to verify that the o-rings, back-up

rings, and u-cup seals are correctly arranged.
- 48 -
NPK
CONTINUED
PROPER CLEANING OF SEAL DRAIN PASSAGE IN MAIN
BODIES
1. Remove plug from lower face of

body. Note: If the use of heat is
required to loosen thread adhesive,
only heat the plug. DO NOT HEAT
THE BODY! If the plug is heated,
replace the plug.
2. Using a pressure washer or solvent

sprayer, thoroughly clean this
passage.
3. After cleaning this passage using

compressed air, thoroughly blow out
any remaining water/solvent from
this passage.
4. Clean the plug using a fast drying

solvent. Apply one (1) drop of
thread sealer. Reinstall the plug as
shown.
- 49 -
NPK
CONTINUED
REASSEMBLY OF THE HAMMER
Reassemble the hydraulic hammer in the reverse order of disassembly.
INSTALL PISTON AND SLEEVES INTO THE MAIN BODY
1. Clean all parts carefully and place the hammer main body on a sturdy workbench.
The hydraulic hammer is a precision machine, dust or dirt adversely affects the
performance of the hammer.
2. Install Sleeve “B”.

a. Check the fit of Sleeve “B” in the
hammer main body.
Lightly oil the body bore. Before
installing the o-rings on the Sleeve,
slide it through the bore from one end
to the other. The Sleeve should
move smoothly without binding.
b. Apply hydraulic oil on the seals and

install into Sleeve “B”, see
REPLACING THE SEALS, step 2a.
Apply hydraulic oil to the bore of the
main body.
c. Using a sling (E), push Sleeve “B” (B)

into the main body bore from the gas
head end with the “Timing” port,
“Pressure” port and “Tank” port (A)
facing upward. Keep the Sleeve level
as it enters the bore.
With a plastic faced hammer (D) or a
nylon bar, continue pushing the
Sleeve until the seals enter the body
bore (C).
d. Remove the sling and bump the

Sleeve (A) into the body bore (B) until
it is almost flush with the end of the
body. Use a lock plate (C) as a stop.
- 50 -
NPK
CONTINUED
REASSEMBLY OF THE HAMMER continued
3. Install the piston.
a. Apply hydraulic oil or NPK assembly
lube to Sleeve “B” inside diameter.
b. Insert the piston into Sleeve “B” by
moving the free end up and down.
Take care to prevent damage to Sleeve

“B” when maneuvering the piston.
4. Install dowel pins in Sleeve (B).

Apply a small amount of grease on two
dowel pins (B) and install them in Sleeve
“B” (A). The grease holds the pins in
place.
5. Install Sleeve “A”.

a. Install the seals in Sleeve “A”.
b. Apply hydraulic oil on the inner
surface of the Sleeve.
c. Align the dowel pin holes with the
dowel pins in Sleeve “B” and insert
Sleeve “A”.
d. Push Sleeve “A” over the piston until
it contacts Sleeve “B” and traps the
dowels.
6. Push Sleeve “A”, piston, and Sleeve “B”

into position.
a. Remove lock plate from Sleeve “B”
and bump Sleeve “A”, piston, and
Sleeve “B” into position. Take care to
watch o-rings and back-up rings on
Sleeve “A” as they enter the bore.
Use the dimensions in the chart on
page 55 to locate final position.
Be sure the “A” and “B” Sleeves have no gap between them
before pushing them into the main body.
- 51 -
NPK
CONTINUED
ALTERNATE METHOD OF INSTALLING THE PISTON AND SLEEVES
This is the preferred method, using a portable power unit and keeping the piston and
sleeves together as one unit. The steady push of the power unit reduces the possibility
of cutting o-rings or back-up rings.
1. Attach chain (A) to hammer main body.

a. Pin (B) chain to diagonally opposite tie
rod holes (D) in main body at tool end
(C).
b. String chain (A) through tie rod holes (D)

and wrap around back of the cylinder
(E).
2. Install Sleeve “B”.

a. Check the fit of Sleeve “B” in the
hammer main body.
Lightly oil the body bore. Before
installing the o-rings on the Sleeve,
check the fit of the Sleeve by sliding it
through the bore from one end to the
other. The Sleeve should move
smoothly without binding.
b. Apply hydraulic oil on the seals and
install them in Sleeve “B”, see
REPLACING THE SEALS, step 2a.
Apply hydraulic oil to the bore of the
main body.
c. Using a sling (D), push Sleeve “B” (B)
into the main body bore from the gas
head end with the “Timing” port,
“Pressure” port and “Tank” port (A)
facing upward. Keep the Sleeve level
as it enters the bore. Continue pushing
the Sleeve until the seals enter the body
bore.
- 52 -
NPK
CONTINUED
continued
2. (continued)
d. Push Sleeve “B” (A) into position with
power unit (B).
Attach push plate (C) to the power unit

ram (D).
Watch o-rings and back-up rings as
they enter bore. If seal starts to
extrude, stop and push seal back into
groove.
Stop pushing Sleeve “B” (A) into body

bore (B) before it is flush. Use a lock
plate (C) as a stop.
3. Install the piston.

a. Apply hydraulic oil or NPK assembly
lube to the inner surface of Sleeve
“B”.
b. Insert the piston into Sleeve “B” by
moving the free end up and down.
Take care to prevent damage to

Sleeve “B” when maneuvering the
piston.
- 53 -
NPK
CONTINUED
continued
4. Install dowel pins (B) in Sleeve “B” (A).

Apply a small amount of grease on two
dowel pins and install them in Sleeve
B. The grease holds the pins in place.
5. Install Sleeve “A”.

Apply lubricating oil to inside and
outside diameters of Sleeve “A”. Align
dowel pin holes and insert Sleeve “A”
onto piston, flush with Sleeve “B”.
Be sure there is no gap between the

Sleeves.
6. Push Sleeve “A” (A), piston, and

Sleeve “B” into position.
a. Use the power unit (B) to push
Sleeve “A”, piston, and Sleeve “B”
into position. Take care to watch o-
rings and back-up rings on the
sleeves as they enter the bore.
Use the dimensions in the chart on
page 55 to locate final position.
- 54 -
NPK
CONTINUED
6. a.(continued)
Push the piston and sleeves (C) and (D)
into the body bore until the Pressure (F)
and Tank (E) ports in Sleeve “B” line up
with the ports in the main body.
Check dimension L2 to be sure sleeves are in their correct location. Check L1. If
L1 is less than the value shown, then Sleeve “A” is not fully engaged into Sleeve
“B”. Hold Sleeve “B” (D) and try and bump Sleeve “A” (C) into position. If this
doesn’t work, the sleeves must be backed out of the bore until Sleeve “A” (C)
comes clear. The problem can then be identified and corrected. See chart below
for installation dimensions of correctly installed sleeves.
SLEEVE LOCATION DIMENSIONS
MODEL L1 L2
inch (mm) inch (mm)
GH9 1.62 (41) 1.50 (38)
GH10 1.14 (29) 1.69 (43)
GH12 1.62 (41) 1.77 (45)
GH15 1.75 (44.5) 1.65 (42)
GH18 1.62 (41) 1.89 (48)
b. Apply a small amount of grease on two dowel pins and install them in the tool end
of Sleeve “B”.
- 55 -
NPK
CONTINUED
7. Apply a thin coat of grease on the o-

ring (A) and push it into the body bore
(B) and up against the end of the
Sleeve “B” (C).
8. Install the two o-rings into the counter

bore of the grease and air passages of
the spacer section. Seal the o-rings
into place with a bead of RTV Silicone.
9. Install the spacer section. Aligning the

dowel pins in Sleeve “B” with the
dowel pin holes in the spacer section.
Align the grease passage hole in the
main body with that in the spacer
section.
10. Make sure the spacer section is snug

to the body. If the spacer section is
not square to the body, it is because
the sleeves are slightly rotated out of
position. Take a hammer and rap
sharply on the high corner of the
spacer section. This will rotate the
spacer section and sleeves into
correct position.
- 56 -
NPK
CONTINUED
11. Install the dowel pins (A) and collars

(B) in the spacer section.
12. Install the tool holder and tie rods.
a. Hoist the tool holder (A) by a

crane, using slings or a lifting
hook, and install it onto the spacer
section with the rubber plug (B)
facing upward as shown.
The tool holder must be level

and square to the main body.
b. Install tie rods (A).

Apply never seize or equivalent to
the lower threads of the tie rods
and install into the body from the
gas head end (B).
- 57 -
NPK
CONTINUED
12. (continued)
c. Place a bottom nut (A) into each

groove in the tool holder (B), then
turn each of the tie rods (C)
clockwise with a hand wrench (D)
until several threads are engaged.
Turn each tie rod until it bottoms,
then back off 90°.
13. Install the spring washers (D).

Apply a thin coat of grease (E) on the
spring washers (D) and install them
with the gap at edge as shown below.
14. Install the gas head.
a. Pour specified synthetic oil (G) in

past Sleeve “A” (F). Use a 10W-
40 or 15W-50 synthetic motor oil.
If the carrier is using a fire
resistant hydraulic fluid, such as
water/glycol, use a petroleum
based 10W-30 or 10W-40 motor
oil.
OIL CAPACITY
CAPACITY
MODEL
ounce (cc)
GH9 10 (300)
GH10 10 (300)
GH12 14 (400)
GH15 16 (500)
GH18 24 (700)
- 58 -
NPK
CONTINUED
14. (continued)
b. Install the o-ring on the boss of the
gas head. Apply grease on the
surface of the o-ring before
installing it on the gas head. Then
install the gas head into the body
bore.
Be careful pushing the gas head

into position so as not to disturb
the spring washers.
15. Install the lock washers and top nuts.
a. Install a lock washer (A) on one of

the tie rods. The tie rod may have
to be rotated so that the square
hole in the lock washer fits over the
square shoulder on the tie rod.
b. After a lock washer has been set on

one tie rod, set a lock washer on
the tie rod that is diagonally
opposite. Apply grease on the
lock washer faces and tie rod
threads.
- 59 -
NPK
CONTINUED
15. (continued)
c. Install two top nuts (A) on to the tie
rods (B) with lock washers (C) and
tighten them up evenly by hand. If
the top nut stops abruptly, when
tightened, it indicates that the square
hole in the lock washer is not aligned
with the square shoulder of the tie
rod. Re-adjust the lock washer and
the tie rod so that the lock washer
slides over the shoulder on the tie
rod.
d. Install the lock washers and top nuts

on the other two tie rods.
e. If a clearance of about .31 - .38 inch

(8 to 10 mm) is formed between the
cylinder (A) and the head cap (B)
when the top nuts are tightened fully
by hand, the setting may be regarded
as normal. The clearance larger than
the mentioned dimension suggests
that the spacer springs have fallen
out of position.
16. Tighten the top nuts and install the lockplates and the lock rings.
a. Tighten four top nuts uniformly until all body section gaps are drawn up tight.
b. Follow the tie rod torque procedure shown in the tie rod torque section on page
106.
c. Install the lockplates onto the top nuts. If the lockplates don’t slide into place,
tighten the top nuts until they do.
d. Install the lock rings.
- 60 -
NPK
CONTINUED
17. Assemble the main valve.
17.1 Install the o-rings (C).
a. Install the o-rings and the back-up

rings (D) on the main body (B).
b. Install the o-ring and the back-up ring

on the underside of the valve body.
c. Apply a thin coat of grease on the o-

rings and the back-up rings.
17.2 Install the valve body.
a. De-grease the bolts and tapped holes

in the main body.
b. Install the valve body (A) on the main

body (B).
c. Apply adhesive on the bolts and

tighten evenly to the specified torque,
see HAMMER FASTENER TORQUE
section.
17.3 Install the bottom cap.
a. Apply a thin coat of grease on the

o-rings (A) and install them on the
bottom cap. (Curl the back-up ring
(B) to form a small circle before
installing).
- 61 -
NPK
CONTINUED
17.3 (continued)
b. Insert the bottom cap into the valve

body by carefully tapping it with a
plastic hammer.
c. Tighten the bolts evenly to the

specified torque, see HAMMER
FASTENER TORQUE section.
17.4 Install the valve spool.

Apply hydraulic oil to the surface of the
valve spool. Then insert the valve
spool from the top side. Make sure
that the valve spool moves smoothly.
17.5 Install the plunger bushing (A), the

long plunger (D), the short plunger (C),
and the top cap (B).
a. Apply a thin coat of grease on the o-

rings (E) and the back-up rings (F) and
install them on the plunger bushing.
(Curl the back-up ring to form a small
circle before installing.)
- 62 -
NPK
CONTINUED
17.5 (continued)
b. Apply grease to the surface of the

plungers. Insert grease into the plunger
bores of the plunger bushing (A). Then
insert the short plunger (C) and long
plunger (D) into the plunger bushing.
c. Insert the plunger bushing in the valve

body with the plunger operation pilot
hole upward.
d. Install the top cap (B) onto the plunger

bushing with a plastic hammer.
e. Tighten the bolts evenly to the specified

torque, see HAMMER FASTENER
TORQUE section.
- 63 -
NPK
CONTINUED
17.6 Install the swivel adapters.
a. Apply grease to the o-ring and the

back-up ring, then install them on the
swivel flange. Install the swivel flange
on the valve body.
b. Tighten the bolts evenly to the

specified torque, see HAMMER
FASTENER TORQUE section.
c. Apply grease to the o-rings and the

back-up rings. Install them in the
swivel adapter. Install the seal rings
(G), the swivel adapter (E), and the
washer (F) on the swivel flange.
The JIC fitting on the swivel

adapter is offset to clear the
swivel flange bolts.
d. Using snap ring pliers, install the snap

ring (A) on the swivel flange (B).
- 64 -
NPK
CONTINUED
18. Install the tool and retaining pin.
19. Charge with nitrogen gas and inspect for gas leaks.
a. Charge nitrogen gas to the specified gas pressure. See GAS CHARGE -
CHARGING THE HAMMER section.
b. Check for gas leaks. See TROUBLESHOOTING - GAS LEAKAGE section.
20. Pour hydraulic oil into swivel elbows to fill hammer. Then connect hammer hoses.
21. Grease the tie rods.
a. Remove the two pipe plugs on each side (toward the tool end) of the main body
section.
b. Grease the two fittings on each side (toward the gas head end) of the main body
section.
c. Pump in an NLGI #2 (or thicker) grease until it comes out the pipe plug holes.
d. Reinstall pipe plugs.
FAILURE TO ADD GREASE TO TIE ROD CHAMBERS COULD ALLOW

PREMATURE TIE ROD FAILURES TO OCCUR!
22. Install the hammer into the hammer bracket.
- 65 -
NPK
CONTINUED
ASSEMBLY OF THE MOUNTING BRACKET
Reassemble the hammer into the hammer mounting bracket in a sequence opposite to
disassembly.
1. Install the hammer in the hammer bracket. Lift the hammer with a hoist and lower it,
slowly, until the hammer contacts the bracket side plates.
2. Inspect rubber mounts. Surface checking on the rubber is acceptable. Any cracks
into the rubber indicates that the mount must be replaced before using the hammer.
Any grease or oil on the mounts must be washed off.
3. Install rubber mounts (A). Align the rubber mounts with the bracket (B) and grooves
in the hammer body (C), as shown. Secure the mounts with hex bolts (E) and nut
bars (D). Make sure the nut bars are installed correctly, see the Parts Manual
drawing for assembly.
Tighten to specified torque, see HAMMER FASTENER TORQUE section.
4. Install the support blocks. Secure the support blocks in the bracket with the bolts,
nuts and washers. Tighten to specified torque, see HAMMER FASTENER TORQUE
section.
The rubber mounts must be installed with the offset in correct direction!
AA = HEAD END, BB = TOOL END
5. Install hydraulic hoses. Use a back-up wrench to prevent twisting of the hose.
A kinked hose will shorten the service life of the hose!
- 66 -
NPK
CONTINUED
ASSEMBLY OF THE MOUNTING BRACKET continued
HAMMER TRAVEL LIMITER GAP

NPK Hammers models GH-9 thru GH-18 are equipped with a travel limiter assembly (A)
to protect the hammer rubber mounts from being over-stretched from excessive carrier
downforce. Experience has shown that a gap of 3/8” (10 mm) (D) between the travel
limiter nylon stopper (B) and the hammer gas head (C) can improve rubber mount life.
NPK hammers GH9 thru GH18 are factory assembled with permanent shims to obtain a
3/8” (10 mm) gap.
- 67 -
NPK
REPAIR
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 ENGINEERING DEPARTMENT. Call toll free 1-800-225-4379.
Whenever repair or replacement of component parts is required, 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
- 68 -
NPK
REPAIR, CONTINUED
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 air
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

1 NHG-65LD LONG SHAFT STRAIGHT GRINDER
2 25026050 POLISHING WHEEL – used for cleaning seal
grooves in sleeves. (Green)
3 25026030 POLISHING WHEEL – used for final polishing of
piston, sleeves and main body bore. (Gray)
4 25026020 GRINDING WHEEL – used to grind weld. (Red)
5 T050-7500 CUT-OFF WHEEL – used to clean and repair
pressure balancing grooves in the sleeve land
area.
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.
- 69 -
NPK
REPAIR, CONTINUED
MAIN BODY BORE
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 (A) 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 BODY BORE REPAIR
BY GRINDING AND POLISHING section.
4. If score in o-ring area is too deep to polish and blend, the body may be welded in
these areas and hand ground / polished, see BODY BORE DEEP SCRATCH
REPAIR BY WELDING AND POLISHING section.
- 70 -
NPK
REPAIR, CONTINUED
MAIN BODY BORE continued
USING THE NPK LONG SHAFT 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 (A), part no. 25026030 (gray) (and taper each side so
that the wheel is “V” shaped (B). 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, see HONING MAIN
BODY BORE section of Service Manual.
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.
- 71 -
NPK
REPAIR, CONTINUED
BODY BORE REPAIR BY GRINDING AND POLISHING
The areas (A) of the bore that are sealed by o-rings can be located by the discoloration.
To prevent oil and/or gas leakage, special care must be taken to obtain a smooth, even
finish in the o-ring areas. If you are unsure of where the o-ring areas are located,
measure these areas on the outside of the sleeves and mark in the body using a
permanent marker to show o-ring areas.
If a deep score (B) or scratch (deeper than .006 inch (.15 mm), that cannot be
repaired by grinding is found in the body bore, repair this by welding, see Repairing
Body Bore By Welding and Polishing.
1. Identify o-ring areas (A).
- 72 -
NPK
REPAIR, CONTINUED
BODY BORE REPAIR BY GRINDING AND POLISHING continued
2. Grind (A) rough edges of the entire 3. Polish (B) areas of scratch to a
length of scratch. smooth surface in the o-ring areas (A).
Blend this area to the surrounding
surface.
DO NOT OVER POLISH!
BEFORE REPAIR AFTER REPAIR
- 73 -
NPK
REPAIR, CONTINUED
BODY BORE REPAIR BY GRINDING AND POLISHING continued
4. Check bore dimension with a bore

gauge (A). Compare with body bore
specifications, see MAIN BODY
FACTORY DIMENSIONS section of
the Service Manual.
A. GROUND AREA – NO O-RINGS HERE

B. REPAIRED O-RING – CONTACT SURFACE
5. After polishing, remove all o-rings (B) from Sleeve “B” (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.
- 74 -
NPK
REPAIR, CONTINUED
BODY BORE DEEP SCRATCH REPAIR BY WELDING AND POLISHING
If a deep score (B) or scratch (deeper than .006 inch (.15 mm), that cannot be
repaired by grinding is found in the body bore, repair this by welding.
The areas of the bore (A) that are sealed by o-rings can be located by the discoloration.
To prevent oil and/or gas leakage, special care must be taken to obtain a smooth finish
with no pinholes, undercut, or uneven finish in the o-ring areas. If you are unsure of
where the o-ring areas are located, measure these areas on the outside of the sleeves
and mark in the body using a permanent marker to show o-ring areas.
REPAIR PROCEDURE:
1. Carefully grind the score until it is flush (A) with the surface, especially in the o-ring
rest areas.
- 75 -
NPK
REPAIR, CONTINUED
REPAIRING DEEP BODY BORE SCRATCHES BY WELDING AND
POLISHING continued
2. Clean the area and mark where the o-ring contact (weld should extend 1/2” on either
side of the o-ring contact area). Preheat the area(s) to be welded to approximately
300°F. This will remove oil and insure a better weld. Weld using a small diameter
welding rod such as: AWS 6013 or AWS 7018 (or equivalent). Mask the area
around the location to be welded. This will prevent “spatter” damage to the
remaining bore area. Use care to prevent an undercut.
3. After welding, grind weld until almost flush with the

bore. Change to a fine polishing stone and finish
until flush (A) or just below flush. The seal areas of
the o-rings cannot tolerate undercut and/or rough
surfaces. DO NOT HONE BODY WITH A FIXED
HONE! USE A BALL HONE ONLY MAKING NO
MORE THAN 6 PASSES.
NPK #25026020 Grinding Wheel (B)
AFTER WELDING, BEFORE GRINDING AFTER GRINDING AND POLISHING
4. After polishing area, remove all o-rings

and backup rings from B Sleeve. Push
B Sleeve through body to check for high
spots. If sleeve will not go through
body, identify high spots and continue
polishing.
- 76 -
NPK
REPAIR, CONTINUED
REPAIRING DEEP BODY BORE SCRATCHES BY WELDING AND
POLISHING continued
5. After polishing, remove all o-rings (B) from Sleeve “B” (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.
A. GROUND AREA – NO O-RINGS HERE

B. REPAIRED O-RING – CONTACT SURFACE
- 77 -
NPK
REPAIR, CONTINUED
HONING MAIN BODY BORE

Generally, honing of the main body is not recommended because the I.D. of the body
must be maintained as close as possible to the factory standard (new) dimension.
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 coating of NPK Assembly Lubricant, p/n H010-5010 or equivalent oil.
2. Using the proper size hone, push / pull the hone through the body 6 – 8 times using
even strokes.
3. Clean bore of the body. Check dimensions of I.D and compare to bore
specifications in MAIN BODY FACTORY DIMENSIONS chart in the Service Manual.
If dimensions are within useable limits, reassemble the hammer.
If dimensions are outside the allowable range, contact NPK Service Department at
1-800-225-4379 for assistance.
- 78 -
NPK
REPAIR, CONTINUED
MAIN BODY MOUNTING SLOT
In the event that the sides of the mounting slots in the main body become worn, the
following procedure can be used to repair this area. This repair is to the sides of the
slots only, not the bottom. If the bottom of the slots become worn, contact the NPK
Service Department for repair procedure.
1. Cut pad slots oversize as shown in Figure #1, page 80.
2. Weld the short sides of each slot as shown on Figure #2, page 81. Pre-heat the
weld areas to 250° - 300°F (120° - 150°C). Use one of the following rods or equal:
Stoody 2110
Certanium 245
Cronatron 7770
Eutectic 3205
Hobart Smootharc MC
3. Finish machine slots as shown on Figure #3, page 82.
4. Measure body bore in weld repair areas. See MAIN BODY FACTORY
DIMENSIONS section in Service Manual for new and maximum bore dimensions. If
bore has shrunk or distorted, use a ridged power hone to bring bore up to size in
affected areas only, and blend repaired areas. Take off as little metal as possible.
Re-check each area taking measurements at 90°.
- 79 -
NPK
REPAIR, CONTINUED
MAIN BODY
MOUNTING SLOT REPAIR continued
FIGURE 1 – CUT SLOTS (F) ON EACH SIDE OF BODY OVERSIZE AS SHOWN

C = GAS HEAD END OF HAMMER
MODEL DIMENSION A DIMENSION B

inch mm inch mm
GH9 2.46 63.5 5.62 142.8
2.56 63.8 5.63 143.00
GH10 2.06 53.5 7.00 177.8
2.16 53.8 7.01 178.0
GH12 2.61 67.5 7.00 177.8
2.71 67.8 7.01 178.0
GH15 2.46 63.5 7.79 197.8
2.56 63.8 7.80 198.0
GH18 2.06 53.5 10.11 256.8
2.16 53.8 10.12 257.0
- 80 -
NPK
REPAIR, CONTINUED
MAIN BODY continued
FIGURE 2 – WELD SHORT SIDE (E) OF EACH SLOT

D = SURFACE TO BE REPAIRED
- 81 -
NPK
REPAIR, CONTINUED
MAIN BODY continued
FIGURE 3 – FINISH MACHINING

DIMENSION A DIMENSION B DIMENSION D DIMENSION E

MODEL
inch mm inch mm inch mm inch mm
GH9 2.761 70.13 5.122 130.1 9.13 232 .78 20
2.751 69.87 5.130 130.3
GH10 2.367 60.13 6.500 165.1 9.84 250 .78 20
2.357 59.87 6.508 165.3
GH12 2.918 74.13 6.500 165.1 10.31 262 .78 20
2.908 73.87 6.508 165.3
GH15 2.761 70.13 7.287 185.1 11.22 285 .78 20
2.751 69.87 7.295 185.3
GH18 2.367 60.13 9.610 244.1 12.17 309 1.06 27
2.357 59.87 9.618 244.3
- 82 -
NPK
REPAIR, CONTINUED
MAIN BODY FACTORY DIMENSIONS
A B C
MAIN BODY MAIN BODY MAIN BODY HONE HONE
MODEL BORE - NEW BORE - MAX* LENGTH SIZE PART NO.
inch mm inch mm inch mm
GH9 6.693 170.00 6.705 170.30 33.23 844.0 7” T050-7620
6.695 170.05 33.25 844.5
GH10 7.283 185.00 7.295 185.30 35.20 894.0 7.5” T050-7625
7.285 185.05 35.22 894.5
GH12 7.677 195.00 7.689 195.30 38.35 974.0 8” T050-7630
7.679 195.05 38.37 974.5
GH15 8.465 215.00 8.477 215.30 41.93 1065.0 8.5” T050-7635
8.467 215.05 41.95 1065.5
GH18 9.252 235.00 9.264 235.30 42.13 1070.0 9.5” T050-7645
9.254 235.05 42.15 1070.5
NOTE:
*Body bore maximum I.D. is not to exceed .010 (.25mm) above standard (new)
dimension. If the bore is at or above this dimension, call the NPK Service Department
at 1-800-225-4379.
- 83 -
NPK
REPAIR, CONTINUED
PISTON
PISTON ACTIVE SEAL AREA
REPAIR PROCEDURE
Pistons with scratches or scoring in the active seal areas, denoted as “C” and “D” in the
illustration, may be repaired by polishing if the damage is less than 0.1mm (.004 inch)
deep. Damage more than 0.1mm (.004 inch) deep requires piston replacement. Note
that scratches in area “E” are not as critical, but the diameter of area “E” is.
After repairing a piston in areas “C”, “D”, or “E”, measure the diameters with a
micrometer and contact the NPK Service Department to confirm that the piston is still
within usable specifications. Areas “A” and “B” are not critical. Light buffing to smooth
out scratches is all that is required.
A B C D
MODEL
GH9 4.45 113 3.54 90 8.58 218 7.83 199
GH10 4.69 119 4.41 112 8.50 216 8.39 213
GH12 5.10 129.5 4.90 124.5 9.19 233.5 8.92 226.5
GH15 6.06 154 6.00 152.5 9.29 236 9.04 229.5
GH18 6.54 166 5.98 152 9.41 239 9.33 237
- 84 -
NPK
REPAIR, CONTINUED
PISTON continued
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. Note, in the NPK Hydraulic
Hammer Service Manual, the drawing of a piston shown in the piston repair section.
There are three critical surfaces marked “C”, “E”, and “D”. 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 1-800-225-4379 for recommendations on parts
replacement.
C D E
MODEL
GH9 .015 0.37 .012 0.30 .006 0.15
GH10 .015 0.37 .012 0.30 .006 0.15
GH12 .015 0.37 .012 0.30 .006 0.15
GH15 .015 0.37 .012 0.30 .006 0.15
GH18 .015 0.37 .012 0.30 .006 0.15
- 85 -
NPK
REPAIR, CONTINUED
PISTON continued
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.
NEW “A” MINIMUM “B”

MODEL
inch mm inch mm
GH9 28.07 713 27.68 703
GH10 30.43 773 30.04 763
GH12 33.07 840 32.68 830
GH15 35.43 900 35.04 890
GH18 36.61 930 36.22 920
- 86 -
NPK
REPAIR, CONTINUED
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.
Tools for repairing and reconditioning the Sleeves are available from NPK, see
HAMMER SLEEVE AND RECONDITIONING TOOLS section of the Service Manual.
NPK #25026050 Polishing Wheel (Green) NPK #25026030 Polishing Wheel (Gray)
NPK #T050-7500 Cut-Off Wheel
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.
- 87 -
NPK
REPAIR, CONTINUED
IMPACT BUSHINGS
The impact bushing is the stop for the tool when down pressure is applied to the
hydraulic hammer. In time, the impact bushing will wear through contact with the tool.
The two main wear surfaces are the center bore and the beveled stop surface.
The chart below gives the new and maximum dimensions. A tape measure is all that is
required. You do not need a micrometer. Any measurement, at or above the
maximum, requires that the impact bushing be replaced for the hammer to operate to its
designed specifications. Do not weld repair the impact bushing.
NEW MAXIMUM NEW MAXIMUM

MODEL A B C D
GH9 4.02 102 4.65 118 4.11 104.5 4.43 112.5
GH10 4.09 104 4.72 120 4.24 107.8 4.57 116
GH12 4.41 112 5.20 132 5.47 139 5.79 147
GH15 4.80 122 5.75 146 5.10 129.5 5.43 138
GH18 5.12 130 6.14 156 6.30 160 6.61 168
- 88 -
NPK
REPAIR, CONTINUED
TOOL BUSHING REPLACEMENT
TOOL BUSHING REMOVAL
The tool bushings can be removed with a carbon arc or with a hydraulic press.
BUSHING LOCK PIN

Before the lower tool bushing is removed, the
bushing lock pin must be driven out.
NOTE:
The lock pin has thread adhesive applied at
assembly. Heat the pin before attempting to drive
it out.
A. CUTTING METHOD
Upper and lower tool bushings (A) can be cut out with carbon arc (B) or oxygen and
acetylene (C). Start cutting in areas “1” and “2” (away from the bushing retaining pin
(D) first, and then go to areas “3” and “4”.
Exercise care when cutting to avoid damaging the tool holder. If the tool holder bore is
cut accidentally, grind the surface smooth to remove sharp edges and high spots.
- 89 -
NPK
REPAIR, CONTINUED
TOOL BUSHING REPLACEMENT continued
TOOL BUSHING REMOVAL continued
B. HYDRAULIC PRESS METHOD

All tool bushings may be removed with a hydraulic press. Weld a steel plate (A) to
the bushing and press out as shown.
HYDRAULIC PRESS REQUIREMENT:

100 ton minimum – GH9, GH10
150 ton minimum – GH12, GH15, GH18
- 90 -
NPK
REPAIR, CONTINUED
TOOL BUSHING REPLACEMENT continued
TOOL BUSHING INSTALLATION
New tool holder bushings can be installed with either a hydraulic press, or shrink fitted
with liquid nitrogen.
A. HYDRAULIC PRESS METHOD

1. Clean the bore of the tool holder. The surface must
have no sharp edges or high spots. Grind smooth, if
necessary.
2. Apply a liberal coating of an anti-seize compound to the
bushing and tool holder bore. Press the bushing all the
way in.
HYDRAULIC PRESS REQUIREMENT:

100 ton minimum – GH9, GH10
150 ton minimum – GH12, GH15, GH18
B. LIQUID NITROGEN METHOD

1. Clean the bore of the tool holder. The surface must
have no sharp edges or high spots. Grind smooth, if
necessary.
Wear protective clothing, a safety face shield

and heavy gloves!
2. Fill an adequately sized steel or heavy plastic bucket
with liquid nitrogen. Attach two pair of vise grip type
pliers to the tool bushing. Fully submerge the tool
bushing for several minutes. Remove the bushing from
the liquid nitrogen, after the nitrogen stops boiling.
Position the bushing over the tool holder bore. The
bushing should drop easily in place. Use a hand sledge
and block to firmly seat the bushing.
BUSHING LOCK PIN

After the lower bushing is installed, apply medium strength adhesive to the lower tool
bushing lock pin and drive it into place.
- 91 -
NPK
REPAIR, CONTINUED
TOOL HOLDER
TOOL HOLDER BUSHING BORE
If the lower tool bushing bore in the tool holder becomes oversized and will no longer
maintain a press fit to the tool bushing, the following repair must be made. The tool
holder requires its bore to be cut oversize, then welded, then cut to original size.
1. Cut the bore oversize to Dimension “A”.
MODEL DIMENSION “A”

inch mm
GH9 6.94 176.4
GH10 7.34 186.4
GH12 7.97 202.4
GH15 8.32 211.4
GH18 8.91 226.4
2. Weld the bore undersize to Dimension “B”. Pre-heat the bore to 250°F (120°C). Use
one of the following wires (or rod equivalent):
Cronatron Cronalloy 7940 DIMENSION “B”
MODEL
Eutectic 3010A inch mm
Lincoln Lincore 33 GH9 6.45 164
Postal Postalloy 2892 SPL GH10 6.84 174
Stoody Built Up
GH12 7.47 190
Or Equal
GH15 7.82 199
GH18 8.41 214
- 92 -
NPK
REPAIR, CONTINUED
TOOL HOLDER continued
TOOL HOLDER BUSHING BORE continued
3. Machine the bore to Dimension “C”.
DIMENSION C
MODEL
inch mm
GH9 6.693 170.00
6.695 170.05
GH10 7.087 180.00
7.089 180.05
GH12 7.717 196.00
7.719 196.05
GH15 8.071 205.00
8.073 205.05
GH18 8.661 220.00
8.663 220.05
4. Dimension “D” is the diameter of the .25 (6 mm) undercut at the bottom of the
bushing bore.
DIMENSION D
MODEL
inch mm
GH9 6.73 171.1
6.72 170.9
GH10 7.33 181.1
7.32 180.9
GH12 7.72 197.1
7.71 196.9
GH15 8.11 206.1
8.10 205.9
GH18 8.51 221.1
8.50 220.9
5. Dimension “E” is the distance from the center of the bushing retaining pin bore to the
bottom of the bushing bore. This dimension must be maintained to ensure that the
retaining pin groove around the outside of the tool bushing lines up with the bushing
retaining pin in the tool holder.
DIMENSION E
MODEL
inch mm
GH9 1.78 45.1
1.77 44.9
GH10 1.78 45.1
1.77 44.9
GH12 1.89 65.1
1.88 64.9
GH15 1.97 54.1
1.96 53.9
GH18 2.13 58.1
2.12 57.9
- 93 -
NPK
REPAIR, CONTINUED
TOOL HOLDER continued
EXTERIOR REBUILD
When the hammer has been used for a long period of time, or operated with penetration
of the tool holder into the material being broken, the exterior of the tool holder may
become worn.
REBUILD PROCEDURE
1. Underlayment - Underlayment weld is necessary to build up the base material or
over existing hardface weld. NOTE: You cannot hardface directly over old
hardfacing.
a. 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.
b. Dry welding rod at 300°F +.
c. Pre-heat the tool holder weld area to 150°F and maintain this temperature during
the welding operation. It is very important to maintain this temperature in cold
environments.
d. Adjust weld current to rod manufacturer’s specification.
e. Peen each layer.
f. Cool slowly. Cover weld in cold environments.
2. Hardface - Hardface can only be applied over base material or underlayment weld.
Never hardface existing hardface.
a. 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.
b. Dry welding rod at 300°F +.
c. Pre-heat the tool holder weld area to 350°F and maintain this temperature during
the welding operation. It is very important to maintain this temperature in cold
environments.
d. Adjust weld current to rod manufacturer’s specification.
e. Peen each layer. Do not exceed 2-3 layers of hardface.
f. Cool slowly. Cover weld in cold environments.
A. DOWEL PIN A. GRIND SMOOTH

Leave sufficient clearance around the dowel pin hole B. GRIND SMOOTH (no overlapping)
for removal or assembly. If necessary, a short length C. HARDFACING
of 1 inch pipe can be welded in position over the hole D. UNDERLYING WELD
to provide clearance. Grind flush after welding.
B. REPAIR WELDMENT (see detail)
- 94 -
NPK
MOUNTING BRACKET
REPAIRING A CRACKED 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
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 E7018 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. “A” is the direction of grinding, “B” is the direction of
principle stress.
- 95 -
NPK
MOUNTING BRACKET, CONTINUED
MOUNTING BRACKET WEAR PLATE
Wear plates (A), used on hammer models GH9 – GH18, guide the motion of the
hammer in the mounting bracket. If there is .06 inch (1.5 mm) wear or more between
the wear plates and the hammer body, SHIMS CAN BE OBTAINED FROM NPK TO
RESTORE ORIGINAL THICKNESS. Operating the hammer with wear exceeding this
limit can result in rubber mount failure or wear of the slots in the main body. NOTE:
Standard thickness of wear pad is 19 mm (.75”). Pads found to be worn to 15 mm
(19/32) should be replaced.
- 96 -
NPK
TOOLS
STANDARD TOOLS
DEMOLITION TOOL SHAPE APPLICATIONS
• Controlled breakage of concrete
CHISEL • Layered sedimentary rock
Crosscut (FX) – trenching, oversize
• General demolition
• Cutting casting gates
• Concrete structures – columns, etc.
MOIL (P) • Soft material
• Concrete slab, bridge decking

BLUNT (E) • Oversize
• Slag removal
• Hard rock
CORE (PC) • General demolition
*The crosscut (FX) tool cuts at right angle, or crosswise, to the stick and boom of the excavator.
ACCESSORY TOOLS
SPECIALTY TOOL SHAPE APPLICATIONS
FROST CUTTER • Edge of trenching
for E201 thru E205 • Frost cutting
Crosscut (SX)
In-Line (SY)
ADAPTER TOOLS • For attachments listed

for E201 thru E205 below
(use with Tamper Plate and
Post/Pipe Drivers)
TAMPER PLATE • Soil compaction

for E201 thru E205 • Driving sheeting
(use with adapter tool)
E201 (9-1/2” x 9-1/2”)

E202, E203 (12” x 12”)
E204, E205 (16” x 16”)
POST and PIPE DRIVERS • Driving guard rails
for E201 thru E205 • Driving fence posts
(use with adapter tool)
- 97 -
NPK
TOOLS, CONTINUED
CHANGING THE TOOL
REMOVAL
1. Remove the retaining ring by using pliers or screwdrivers, see Figures 1 and 2. It
will easily come out if pulled at an angle as shown in Figure 2.
2. Screw an M12 bolt or cap screw into the retainer pin.
3. Pull out retainer pin. If the retainer pin is jammed, use a hammer and drift from the
opposite side.
Figure 1 Figure 2
RE-INSTALLATION
1. Clean the retainer pin housing hole and retaining ring groove.
2. Coat the surface of the tool with grease, then install.
3. Apply grease to the retaining ring housing groove.
4. Coat the retaining pin with grease, then install.
5. Install the retaining ring in the following manner:
a. While deforming the retaining ring as shown in Figure 3, partially force it into the
groove.
b. Using the handle of the pliers or screwdriver, press the rest of the ring into the
groove, see Figure 4.
Figure 3 Figure 4
- 98 -
NPK
TOOLS, CONTINUED
TOOL INSPECTION
1. Deformation may occur on the tool in the retaining pin contact area or on thrust
surface (A). If these areas are mushroomed, the tool may become difficult to
remove from the tool holder. Dress with a grinder.
2. Excessive blank hammering may cause chipping (A) in the retaining pin contact
area. If neglected, the chipping may reduce the life of the retaining pin. Dress with
a grinder (B).
3. If chipping (A) is found at the top of the tool, replace the tool. If neglected, the piston
impact surface will be damaged.
(C) is normal
(D) is chipped
- 99 -
NPK
TOOLS, CONTINUED
MAXIMUM TOOL TO TOOL BUSHING CLEARANCE
Replace the tool bushing (A), and/or tool (B), 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 (C) with the hammer horizontal, as illustrated below. If
the clearance is at or greater than the charted maximum clearance, move on to the next
steps.
MAXIMUM CLEARANCE
MODEL
inch (mm)
GH9 3/8 (10)
GH10 3/8 (10)
GH12 1/2 (13)
GH15 1/2 (13)
GH18 1/2 (13)
Step 2
Remove the tool from the tool holder. Measure the diameter (D) 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.
NEW TOOL DIAMETER MINIMUM TOOL DIAMETER
MODEL
(D) inch (mm) inch (mm)
GH9 5.0 (126) 4.6 (116)
GH10 5.4 (136) 5.0 (126)
GH12 5.7 (146) 5.2 (132)
GH15 6.1 (156) 5.6 (142)
GH18 6.5 (165) 6.0 (152)
- 100 -
NPK
TOOLS, CONTINUED
MAXIMUM TOOL TO TOOL BUSHING CLEARANCE continued
Step 3
Measure the inside diameter of the lower and upper tool bushings. 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.
NEW BUSHING MAXIMUM BUSHING

MODEL INSIDE DIAMETER INSIDE DIAMETER
inch (mm) inch (mm)
GH9 5.0 (126) 5.4 (136)
GH10 5.4 (136) 5.8 (146)
GH12 5.7 (146) 6.2 (159)
GH15 6.1 (156) 6.6 (169)
GH18 6.5 (165) 7.0 (178)
Step 4
Compare the tool and bushings 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. Obviously, replacing both the tool and bushings would bring
the clearance back to new.
- 101 -
NPK
TOOLS, CONTINUED
CHISEL TOOL RESHARPENING
Worn chisel tools can be resharpened by machining to the dimensions below.
DO NOT hardface or sharpen the tool point with a cutting torch! Resharpen only with a
lathe or milling machine using sufficient coolant.
A B
MODEL inch mm inch mm
GH9 .62 15.7 4.88 124
GH10 .75 19 5.12 125
GH12 .75 19 5.50 140
GH15 .75 19 5.91 150
GH18 .75 19 6.42 160
- 102 -
NPK
TOOLS, CONTINUED
STANDARD LENGTH FOR NPK TOOLS
L = Length of tool from top to bottom.

W = Length of tool exposed from bottom of tool bushing to end of tool.
D = Diameter of bearing surface of tool.
NEW TOOL NEW TOOL NEW TOOL

MODEL DIAMETER (D) LENGTH (L) WORKING LENGTH
(W)
GH9 4.96 126 47.2 1200 24 608
GH10 5.35 136 51.4 1306 24.5 620
GH12 5.75 146 55.4 1407 25.5 650
GH15 6.14 156 59.1 1502 27 690
GH18 6.50 165 63.2 1606 29 740
NOTE:
Minimum tool length is determined by the depth of material penetration that is required.
- 103 -
NPK
RETAINING PIN
Deformation may occur on the retaining pin in the tool contact area (A). If this area is
mushroomed, the retaining pin may become difficult to remove. Dress with a grinder.
- 104 -
NPK
TIE RODS
MAXIMUM ELONGATION OF TIE RODS
Tie rods may become stretched due to severe operating conditions or age in normal
operating conditions. When the maximum length is reached, the tie rod must be
replaced. The chart below gives the new and maximum lengths. A tape measure is all
that is required.
MODEL NEW LENGTH A MAXIMUM LENGTH B

inch mm inch mm
GH9 53.58 1361 53.82 1367
GH10 57.76 1467 58.03 1474
GH12 62.80 1595 63.07 1602
GH15 67.72 1720 67.95 1726
GH18 69.72 1771 70.00 1778
- 105 -
NPK
TIE RODS, CONTINUED
TIE ROD REPLACEMENT
A loose Tie Rod is susceptible to stretching or breakage. NPK Tie Rods are designed
with a locking plate to prevent the Tie Rod nut from turning and loosening.
PROCEDURE:
If a failed Tie Rod is replaced immediately, only the failed Tie Rod must be replaced.
If the hammer has been operated with a failed Tie Rod for more than one hour, all four
Tie Rods should be magna-fluxed in the thread areas to check for stress cracks caused
by the 3 remaining Tie Rods taking the extra load created when one Tie Rod breaks.
The following procedure is for the replacement of a single Tie Rod.
1. Remove all SNAP RINGS and LOCK PLATES.
2. Remove the TIE ROD to be replaced.
3. Apply “Anti-Seize” compound on the bottom threads of the new TIE ROD. Assemble
into the hammer and thread into the BOTTOM NUT.
4. Apply “Anti-Seize” compound to the top thread of the TIE ROD and on the WASHER
faces. Place the WASHER over the top of the TIE ROD. On some hammer models,
a pilot diameter fits into the head.
5. Tighten the TOP NUT.

Refer to Figure 1 and the TURN-OF-NUT METHOD chart in the TIE ROD TORQUE
section of the Operators Manual:
a. Tighten the nut of the new tie rod to full torque, as shown in the tie rod torque
section.
b. Loosen the tie rod nut diagonally across from the new tie rod. Follow the full
torque sequence, as shown in the tie rod torque section.
c. Loosen the third and forth nuts, one at a time, and follow the full torque sequence
on each.
6. Install the LOCK PLATES. If a LOCK PLATE does not drop into place, tighten the
nut until it does.
7. Install the SNAP RINGS.
8. Check the gas charge. See GAS CHARGE - CHECKING THE GAS PRESSURE
section of the Service Manual.
- 106 -
NPK
TIE RODS, CONTINUED
TIE ROD TORQUE
See TIE ROD REPLACEMENT section of Operators Manual for complete
procedure when replacing a Tie Rod.
1. Tighten all TOP NUTS with a TORQUE WRENCH to the recommended pre-torque
specification shown in CHART 1. (It may take several passes at each top nut to
achieve this.) Check that no gap is noted between the sections.
2. Mark all the TOP NUTS and HEAD as shown in figure 1.
3. Further tighten all the TOP NUTS to step #1 as shown in figure 1.
4. Further tighten all the TOP NUTS to step #2 as shown in figure 1.
5. Further tighten all the TOP NUTS to step #3 as shown in figure 1 using Chart 1
below for the appropriate number of flats per hammer model.
Figure 1.
Mark all Step #1. Step #2. Step #3.

Top Nuts. First turn Second turn Final turn
(3 flats) (3 more flats) (see Chart 1)
CHART 1.
Pre- Total No. of Total No. of Socket Size
MODEL
Torque Flats Flats (in) (mm)
Using *Sweeney Using standard
Anti-seize anti-seize
GH9 200 7 7.5 2-3/4” 70
GH10 200 7 7.5 2-3/4” 70
GH12 200 8 8.5 3-1/8” 77
GH15 400 8.5 9 3-1/8” 77
GH18 400 9.5 10 3-3/8” 85
*Sweeney 503 Anti-seize recommended.
If you have any questions call NPK Service Department at 800-225-4379.
- 107 -
NPK
HAMMER FASTENER TORQUE
If hammer or hammer bracket fasteners are found to be loose, use the following charts.
Medium strength thread adhesive should be used on all the valve assembly bolts and
the gas charge valve. All other bolts should be lubed with anti-seize compound.
SOCKET HEAD CAP SCREWS (SHCS)

VALVE TOP AND
VALVE CASE SWIVEL ADAPTER
BOTTOM CAP
MODEL
SHCS TORQUE SHCS TORQUE SHCS TORQUE
DIA ft/lb (Nm) DIA ft/lb (Nm) DIA ft/lb (Nm)
GH9 M24 900 (1220) M22 710 (960) M12 110 (150)
GH10 M24 900 (1220) M22 710 (960) M12 110 (150)
GH12 M24 900 (1220) M22 710 (960) M12 110 (150)
GH15 M27 1300 (1750) M24 900 (1220) M14 175 (240)
GH18 M27 1300 (1750) M24 900 (1220) M14 175 (240)
See HAMMER DISASSEMBLY AND ASSEMBLY – TOOLS AND EQUIPMENT section

of Operators Manual for NPK hex key wrench part numbers.
HEX HEAD BOLTS

HAMMER BRACKET RUBBER MOUNTS TOP ADAPTER
MODEL BRACKET
BOLT TORQUE BOLT TORQUE BOLT TORQUE
DIA ft/lb (Nm) DIA ft/lb (Nm) DIA ft/lb (Nm)
GH9 1-1/4” 1100 (1490) M16 155 (210) 1” 550 (745)
GH10 1-1/4” 1100 (1490) M20 300 (410) 1” 550 (745)
GH12 1-1/2” 2000 (2710) M20 300 (410) 1-1/4” 1100 (1490)
GH15 1-1/2” 2000 (2710) M20 300 (410) 1-1/4” 1100 (1490)
GH18 1-1/2” 2000 (2710) M20 300 (410) 1-1/4” 1100 (1490)
- 108 -
NPK
LIFTING EYE SPECIFICATIONS
(B) (A)
MODEL LIFTING EYE THREAD
M Thread Pitch
GH9 NONE ---
GH10 16mm 2
GH12 16mm 2
GH15 20mm 2.5
GH18 20mm 2.5
- 109 -
NPK
STORAGE OF HYDRAULIC HAMMER
For short term storage between jobs, place the hammer horizontal on wood blocks (A).
Be sure the tool (F) is liberally greased and the hydraulic hoses (C) are capped. Cover
with a waterproof tarp (D), not shown.
If the NPK HYDRAULIC HAMMER is not to be used for a long period of time (months),
the following storage procedure is recommended:
1. Discharge the gas pressure (E).
2. Remove the Tool (F) and push the Piston (G) all the way in.
3. Grease the exposed end of the Piston (H).
4. Grease and reinstall the tool at bushing areas (B).
5. Plug the hydraulic hoses (C).
6. Cover with a waterproof tarp (D), not shown.
7. Set the hammer on wood blocks (A).
- 110 -
NPK
DECIMAL CONVERSION CHART
FRACTIONS DECIMALS FRACTIONS DECIMALS
th th
32nds 64 s 2 Place 3 Place 32nds 64 s 2 Place 3 Place
1 .02 .016 33 .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
- 111 -
NPK
REBUILD SPECIFICATIONS CHECK SHEETS
When rebuilding an NPK Hydraulic Hammer, it may be necessary to inspect the
piston (F), body (A), sleeve “A” (H), sleeve “B” (G), impact ring (H Series only)/impact
bushings (B or C) for wear, tool (D), and tool bushings (E), or to check tolerances
after these components have been repaired or polished.
MEASURE CRITICAL AREAS
The diagrams on the following pages show the critical locations that should be
measured. Carefully measure the areas shown with bore gages and micrometers.
FAX DIMENSIONS TO NPK SERVICE DEPARTMENT
Fill in the dimensions and fax this information to the NPK Service Department at
(440) 232-6294 for reusability evaluation.
- 112 -
NPK
REBUILD SPECIFICATIONS CHECK SHEETS,
CONTINUED
DEALER__________________________ BRANCH________________________
NAME____________________________ TITLE__________________________
TELEPHONE______________________ FAX____________________________
CUSTOMER_______________________ DATE___________________________
NPK HAMMER MODEL______________ SERIAL NO.______________________
MAIN BODY
REFERENCE: A – TOOL END, B – GAS END

DIAMETER LENGTH
D1 D2 D3 L
Dimensions to 0.000 inch (0.00 mm)
COMMENTS:
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
- 113 -
NPK
CONTINUED
IMPACT BUSHING DIMENSIONS
E200 THRU E207
D
Indentation
Ref “X” = Tool Side “Y” = Piston Side
COMMENTS:
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
- 114 -
NPK
CONTINUED
TOOL:
S = STAMPING
___________________
___________________
___________________
DIAMETER
D1 D2
UPPER TOOL BUSHING:_______ I.D. (A)

LOWER TOOL BUSHING: ______ I.D. (B)

COMMENTS:
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
- 115 -
NPK
CONTINUED
PISTON
PISTON SERIAL NO.____________
REFERENCE: A – TOOL END, B – GAS END

DIAMETER LENGTH
D1 D2 D3 L
COMMENTS:
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
- 116 -
NPK
CONTINUED
SLEEVE “A”
SLEEVE SERIAL NO.____________
REFERENCE: B – GAS END

INSIDE DIAMETER “D3”
COMMENTS:
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
- 117 -
NPK
CONTINUED
SLEEVE “B”
SLEEVE SERIAL NO.____________
REFERENCE: A – TOOL END, B – SLEEVE “A” END

INSIDE DIAMETER
D1 D2 D3
COMMENTS:
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
FAX ALL SHEETS TO THE NPK SERVICE DEPARTMENT (440) 232-6294
- 118 -
NPK
NOTES AND RECORDS
NPK HYDRAULIC HAMMER MODEL NUMBER _______________
SERIAL NUMBER _______________
NPK INSTALLATION KIT NUMBER ___________________________
CARRIER MANUFACTURER
MODEL NUMBER
SERIES
SERIAL NUMBER
DATE OF INSTALLATION _________________
DATE OF 20 HOUR INSPECTION ___________ WARRANTY REGISTRATION SENT
- 119 -
© Copyright 2008 NPK Construction Equipment, Inc. www.npkce.com h055-9630A.doc 6/08

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HYDRAULIC HAMMER

"Use Genuine NPK Parts”

7550 Independence Drive

© Copyright 2008 NPK Construction Equipment, Inc. www.npkce.com h055-9630A.doc 6/08

DANGER (red) notices indicate an imminently hazardous situation

WARNING (orange) notices indicate a potentially hazardous situation

CAUTION (yellow) notices indicate a potentially hazardous situation,

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

CARRIER MACHINE COMPATIBILITY

CARRIER WEIGHT lbs. (kg)

GH15 8000 320 - 400 6800 (3085) 6.1 (156) 27 (690)

GH18 12000 300 - 400 7800 (3540) 6.5 (165) 29 (740)

HAMMER HYDRAULIC CIRCUIT GAS CHARGE

NPK HAMMER MODELS GH9, GH10, GH12, GH15, GH18

A TOP NUT P PLUNGER BUSHING

(1) UPSTROKE OF PISTON

(2) VALVE SHIFT

(3) POWER STROKE

AUTOMATIC ENERGY RECYCLING: Extremely hard material will impart greater

MODEL Pressure Line Return Line

HAMMER CONTROL VALVE

CHANGING THE FILTER ELEMENT AND HYDRAULIC OIL

NPK APPROVED CONNECTION QUICK DISCONNECTS

2. Check for dirt, dust, and debris on

3. Be sure that the couplers are

4. When replacing couplers, be sure

ATTENTION The hydraulic

MOUNTING TO THE CARRIER

2. Turn the machine off.

APPLY DOWNFORCE TO PUSH TOOL UP INTO HAMMER

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

On the following page is a list of commonly available greases, by manufacturer and

3. TOOL and TOOL BUSHING WEAR

3. TOOL RETAINING PIN

DETERMINE THE CAUSE OF THE PROBLEM

1. Determine Return Line Pressure

2. Determine System Relief Valve

3. Determine Hammer Operating Pressure

The operating pressure of the NPK HYDRAULIC HAMMER is self regulating,

1. Installation of Flow Meter equipped with Pressure Loading Valve.

2. Determine Return Line Pressure (Pressure Drop).

3. Determine Relief Valve Pressure and Oil Flow.

PROBLEM CAUSE REMEDY

PROBLEM CAUSE REMEDY

GAS CHARGE PRESSURE 3

DO NOT OVERCHARGE THE HAMMER!

Exceeding the gas pre-charge specifications can result in damaging hammer

GAS CHARGING KIT / PART NO. 7300588

HEX KEY WRENCHES

LONG HEX KEY SOCKETS

HEX SOCKET NPK

Gas Charging Kit (Red Box) Manuals, Decals & Warranty

DIRECTIONS FOR USE

REMOVE THE HAMMER FROM THE BRACKET

2. Remove the bracket bolts and bracket

3. Remove rubber mounts, on one side only,

Take care not to contaminate the rubber

1. Remove the lock rings. The lock ring has an

a. Insert a bar or screwdriver (B) into the lock

b. Drive the lock ring out with a hammer (E).

2. Remove the lock plates (A). If the lock plates

4. Remove the lock washers (A).

a. Pull the out the gas head (A) using