BHI HydroRam HK300S Operations Manual & Parts List
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BHI HydroRam HK300S Operations Manual & Parts List

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BHI
HydroRam
Hydraulic Hammer
K300S
Operation Manual
& Parts List

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Summary of Contents for BHI HydroRam HK300S

  • Page 1 HydroRam Hydraulic Hammer K300S Operation Manual & Parts List...
  • Page 2 BHI reserves the right to make changes of the product without prior notice and without assuming any responsibility to carry out the same change to products already sold or manufactured.

  • Page 3: Table Of Contents

    INDEX Ⅰ. INTRODUCTION ---------------------------------------------------------- Ⅱ. SAFETY PRECAUTION ----------------------------------------------------- 1. Safety Decals -------------------------------------------------------------------- 2 2. Installation of Hammer -------------------------------------------------------- 4 3. Before Operation --------------------------------------------------------------- 5 4. Serial number marking position ------------------------------------------------ 5 5. Tool Replacement ------------------------------------------------------------- 5 6. Hammer Operation ------------------------------------------------------------- 6 Ⅲ.

  • Page 4: Ⅰ. Introduction

    Notices indicate a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury. Notices in BHI Operation Manuals are an BHI standard to alert the reader to situations which, if not avoided, could result in the equipment damage.

  • Page 5: Safety Decals

    1. Safety Decals Sticker Description Instruction Head wearing, ear protection Use hearing protection Operation Manual Read the manual before use Service Manual Warn a danger nearby Keep away the breaking area job sites. while the hammer works Grease Injection Inject grease Caution Gas Pressurized Container Lifting...
  • Page 6 Best Hammer Industries - 3 -...

  • Page 7: Installation Of Hammer

    2. Installation of Hammer 1) When installing the hydraulic hammer, an assistant who must be instructed by the carrier operator is required. All directions and signals, etc. must be understood and agreed on beforehand. 2) Only lifting equipment like crane should be used for transporting the hydraulic hammer. 3) The hydraulic hammer should be installed to the carrier with sufficient load capacity.

  • Page 8: Before Operation

    3. Before operation 1) Check the level and contamination of hydraulic oil in the hydraulic oil tank of the carrier. In case oil is not sufficient, please fill up the same oil and never mix up oils from different manufacturers. Also if it is contaminated, drain it and fill up with new one. 2) Make sure the shut-off valve is completely open.
  • Page 9 possible injury from flying debris during the hammer operation. 2) In normal operation, the critical cases - the critical noise level of 90 dB(A) is reached or exceeded, the machine operator and any other workers in the noise area must wear personal noise protection gear.

  • Page 10: Ⅲ. Warranty

    ․ Failure, damage or defective condition due to: - overloading, negligence or improper installation, use or operation which are is not accordance with BHI's published instructions or its authorized distributors. - improper repair, alteration or adjustment made to Hydraulic hammer or its parts.
  • Page 11 After installing the Hydraulic Hammer, make sure if it is installed correctly and a copy Delivery Record with all signature should be mailed back to BHI. When it is not and hammer is broken down, we are going to charge for the needed parts.

  • Page 12: Delivery Record

    Best Hammer Industries 5-91, Daepoong-ri, Daeso-myun, Eumsung-kun Choongbook-do, Korea Tel: (82-43) 532 - 1370~1, Fax:(82-43)532-1372 Website : www.bhice.com E MAIL: qa@bhice.com DELIVERY RECORD To: ______________________________ Owner: _____________________________________ Address: ______________________________________ Distributor: _______________________________ Address: ______________________________________ Service Shop: ______________________________ Address: ______________________________________ Model of Hammer: _____________________Serial No.: _______________ Delivery Date: ___________ Model of Carrier: __________________________________________________________________________ A.

  • Page 13: Claim Application Under Warranty

    Refer to your operation manual for the methods of performing these tests and record the readings that you find on this card. Failure to supply this information or to use BHI parts and tools may result in forfeiture of warranty coverage. IV. TECHNICAL DATA...

  • Page 14: Standard Specifications

    1. Standard Specifications HK300S Tons 28-35 Recommended Carrier US Tons 61,729-77,162 Impact Energy Class ft.lbs 9,000 L:200~350 Impact Frequency H:260~420 3,000 Working Weight [lbs] [6,600] 180-260 Oil Flow [gpm] [47.6-68.7] 160-180 Operating Pressure [psi] [2,320-6,610] Tool Diameter [inch] [6.1] 3,289 Overall Length [inch] [129.4]...

  • Page 15: Principles Of Operation

    2. Principles of Operation The relation between the area(A2) affecting the pressure from the upper chamber of the piston and the area(A1) affecting the pressure from the lower chamber of the piston is A2>A1 and high pressure applies to A1. When A2 changes from high to low pressure or vice versa, piston (E) reciprocates.
  • Page 16 3) Power Stroke The difference of the area A1<A2 makes the Piston(E) move downward until Cylinder P2 Port communicates with P3 Port. When the Piston(E) comes down, descending speed accelerated by the pressure of gas in the Upper Chamber of the Piston. 4) Impact Kinetic energy...

  • Page 17: External Dimension - Power Cell And Bracket

    3. External Dimension - Power cell and Silence Bracket Best Hammer Industries - 14 -...

  • Page 18: Construction - Excavator & Hammer Bracket

    4. Construction - Excavator & Hammer Bracket ․ Top mounted and silence mounted bracket on excavator must connect with hydraulic pipe lines. Best Hammer Industries - 15 -...

  • Page 19: Torque Chart

    5. Torque Chart [ Units: kg․m / N.m] / lb-ft ] Item Torque Item Torque Accumulator Tension Bolt 350kg.m / 3432N.m / 2531 lb-ft 100kg.m / 980N.m / 723 lb-ft Assembly Bolt Accumulator 60kg.m / 588N.m / 433 lb-ft Mounting Bolt 230m / 2255N.m / 1663 lb-ft Cover Bolt Valves function...

  • Page 20: Ⅴ. Operation And Handling Of Hydraulic Hammer

    Ⅴ. OPERATION AND HANDLING OF HYDRAULIC HAMMER 1. Hammer 1) Proper Positioning The hammer must be positioned perpendicular to the material. It is especially important to follow this rule when using the hydraulic hammer so that it can correctly test the hardness of the material.
  • Page 21 Applied pressure should not lift the carrier high off the ground. As the hammer breaks through the material, the excavator will drop suddenly and harmful shock loads will be transmitted to the tool, power cell and excavator. If the hammer is too heavy for the carrier, the resulting damage will be worse.

  • Page 22: Rules To Remember

    Stop Immediately When ․The Hydraulic Hoses Jerk Violently. Abnormal surging means the nitrogen accumulator is empty. Stop the hammer immediately and repair the accumulator. ․The Tool Does Not Drop. If the visible length of the tool does not change, it usually means the tool has seized in the bushing.
  • Page 23 2) Never Use A Hammer For Activities For Which It Was Not Designed. Insure your hammer features this capacity are normally fitted with a rock hook or some type of protective structure around the chuck housing. 3) Do not use the tool or hammer space as a lifting device.
  • Page 24 After the carrier is warmed up, suspend the hammer in the air (with the tool extended) to activate the automatic stop. Activate the control to circulate the oil and warm the hammer. Warm the tool bit by operating at slow speeds for five to ten minutes. During extremely low temperatures, store the tool inside.
  • Page 25 7) Never Let The Hammer Strike On The Same Spot More Than 30 Seconds. Even 30 seconds can be too long for large Hammers. Working in one spot too long causes heat buildup in the tool, resulting in loss of tool strength and wear resistance. 8) Moves The Tool to New Positions Often.

  • Page 26: Operator's Routine Maintenance

    3. Operator's routine maintenance 1) Lubrication Grease the tool and bushings every two to four hours of operation, more than often in dusty or severe conditions, with five to ten pumps of good quality, high temperature grease. 2) Inspection Points: (1) Visual Inspection.

  • Page 27: Periodic Maintenance

    4. Periodic Maintenance (Every 100 hours) 1) Remove the tool and all grease from the tool holder bushing Do not use a pressure washer, steam, or solvents as they damage the seals. Check for chips or cracks inside the housing and on the bushing surfaces. Cracks and chips could indicate that: (1) Lubrication is insufficient (2) Grease type is not appropriate...
  • Page 28 3) Blank hammering will chip tool on the top and in the retainer area. These chops accelerate wear and tear on the tool, retainer pins, round Bushing, and the piston. 4) Proper lubrication at all times. Lack of lubrication will increase the temperature in the bushings and tool shank which ultimately causes deterioration of these components.

  • Page 29: N 2 Gas Pressure Maintenance

    6. N gas Pressure Maintenance 1) Inspection of N₂Gas Pressure Inside Head Cap ( same as the Accumulator ) (1) Remove the cap from the gas valve. (2) Turn the handle of gas charging adapter counterclockwise until it stops. (3) Connect the gas charging adapter with gas valve. (4) Fix the cap of gas charging adapter after turning it clockwise.

  • Page 30: Nitrogen Gas Charging Pressures Table

    (1) Connect the charging hose to N₂gas (2) Remove the cap of the gas charging cylinder. adapter and connect to charging hose. Turn the handle clockwise to tighten. (3) Open the main valve of gas charging (4) Turn the handle of gas charging adapter cylinder counterclockwise to reach the clockwise and stop when the pressure pressure gauge to optimum pressure.
  • Page 31 1) N Gas Charging Kit Parts List Part No. Part Name Q'ty DA698000 GAS CHARGING KIT 13105900 GAS 3-WAY VALVE ASSEMBLY 16802000 HOSE 13105910 COUPLING KIT 13105920 GAS CYLINDER DF300520 EXTENSION STICK ( OPTION) 2) Head Cap Part ( Low Pressure) Model HK300S Temp...

  • Page 32: Maintenance Of Oil Filter

    8. Maintenance of oil filter Contaminated oil results in malfunctions of the hammer as well as carrier and cause damage to parts. Pay special attention to oil contamination. Contaminated oil should be changed without delay. When changing oil, thoroughly wash oil tank, cylinder and pipes.

  • Page 33: Hydraulic Oil & Grease

    9. Hydraulic oil & grease 1) Hydraulic oil The following working materials are required to operate the hydraulic hammer. Only approved hydraulic oils should be used. All hydraulic oils recommended by the excavator manufactured are suitable for hammer operation. Use of other hydraulic fluids is subject to approval.

  • Page 34: Maintenance Checking Schedule

    10. Maintenance Checking Schedule Item Inspection ․Lubricate the working steel 2 to 5 times per shift (depending on the conditions) ․Check the Bolts During the shift - bracket pin part - bracket set bolt part - power cell tension bolt part ․Tighten screw connections ․Hydraulic hose &...

  • Page 35: Ⅵ. Trouble Shooting

    Ⅵ. TROUBLE SHOOTING Dismantle the hammer after releasing the gas from head cap. If the tension bolt is broken, all 4 bolts are to be checked for tight fitting. In case of the extension bolt of accumulator, all 4 bolts are to be checked, too. ․...
  • Page 36 Cause Required action Oil flow insufficient Adjust the speed of engine Couplings of hydraulic pipe lines are loose Tighten. Shut-off Valve is partially close. Open it fully Pressure in head cap is low Charge the gas and adjust the pressure. Check the surface of the Tool and Round tool shank is seizing or Bushing.

  • Page 37: Ⅶ. Accessory Parts List

    Ⅶ. ACCESSORY PARTS LIST 1. Tool type and part list * Tool Part Pode List Type MOIL H-WEDGE CONE BLUNT V-WEDGE SPADE-H SPADE-V HK300S DC000050 DC000080 DC000060 DC000090 DC000070 Best Hammer Industries - 34 -...

  • Page 38: Union Cap Parts List

    2. Union cap parts list UNION CAP HOSE SIZE JIC TYPE 1¼ 13007050 3. Hose plug parts list PLUG, HOSE HOSE SIZE JIC TYPE 1¼ 13008430 4. O-ring adapter parts list HOSE O-RING ADAPTER SIZE PF*JIC 1¼ 13009380 Best Hammer Industries - 35 -...

  • Page 39: Base Cover Plate Dimension

    5. Base cover plate dimension [unit : mm] MODEL HK300S Best Hammer Industries - 36 -...

  • Page 40: Ⅷ. Underwater Kit(Option)

    Ⅷ. UNDERWATER KIT(OPTION) The hydraulic hammer should never be left in or underwater with the compressed air supply switched off. Without the compressed air supply, the cylinder will fill up with water, and it will then result in serious damage. * For under water operation, please contact to us.(option) Best Hammer Industries - 37 -...

  • Page 41: Ⅸ. Autolube Kit(Option)

    Ⅸ. AUTO LUBE KIT(OPTION) Best Hammer Industries - 38 -...

  • Page 42: Ⅹ. Wear Parts And Judgment Tool

    Ⅹ. WEAR PARTS AND JUDGEMENT - Tool Tool is a wear parts and can also have various problems.  1) When damage occurs in the part where tool meets with Piston, the degree of abrasion on tool Holder Bushing and Round Bushing must be checked. In case Piston and tool are not genuine parts, damage can occur by the different hardness caused by different heating treatment(process).
  • Page 43    Wear around the End Taper Damage occurring after using Flat type Tool more than 45mm of wear    Damage occurring after using Moil. H-Wedge, V-Wedge Type more than 75mm of wear    In case Tool is pushed in by continuous hitting on hard rocks   ...

  • Page 44: Ⅺ. Parts List

    HydroRam Hydraulic Hammer K300S Parts List...
  • Page 45 ■ HK300S POWER CELL PARTS LIST Best Hammer Industries - 2 -...
  • Page 46 ■ HK300S POWER CELL PARTS LIST Part No. Part Name Q'ty Part No. Part Name Q'ty DL000190 POWER CELL ASSEMBLY DL000230 CYLINDER ADJUSTER DL000210 HEAD CAP DF000590 ADJUSTER VALVE 13006030 PT SOCKET PLUG 22402060 O-RING 13006020 PT SOCKET PLUG DA000400 PF SOCKET PLUG DK000080 POPPET VALVE 13006010...
  • Page 47 ■ HK300S POWER CELL PARTS LIST Part No. Part Name Q'ty Part No. Part Name Q'ty DL000090 BOTTOM NUT DL691110 CYLINDER SET DE000300 ACCUMULATOR ASSEMBLY DL691200 TOOL HOLDER SET DE000310 ACCUMULATOR BODY DL691400 TENSION BOLT SET DE000330 ACCUMULATOR COVER DC691300 MAIN VALVE SET DE692300 ACC.
  • Page 48 ■ HK300S SPARE SEAL KIT PARTS LIST MEMO Part No. Part Name Q'ty DL691550 SPARE SEAL KIT 22402070 O-RING 22401370 O-RING 22406730 BACK UP RING 22402210 O-RING 22401660 O-RING 22200230 GAS SEAL 22300260 STEP SEAL 22002730 DUST SEAL 22003980 U PACKING 22000250 BUFFER SEAL 22402260...
  • Page 49 ■ HK300S TOOL KIT PARTS LIST Part No. Part Name Q'ty Remarks DL691800 TOOL KITS HK300S 16502990 TOOL BOX No. 1 16500260 COMBI SPANNER 14mm 16500370 SINGLE SPANNER 32mm 16502580 SINGLE SPANNER 50mm 16502100 DOUBLE SPANNER 27X30mm 16501140 L WRENCH 16501160 L WRENCH 16501170...
  • Page 50 ■ HK300S BRACKET PARTS LIST Best Hammer Industries - 7 -...
  • Page 51 ■ HK300S BRACKET PARTS LIST ■HK300S BRACKET ■HK300S BRACKET No. Part No. Part Name Q'ty No. Part No. Part Name Q'ty DL301000 PREMIUM BRACKET ASSEMBLY DL301030 SIDE DAMPER DL301040 TOP BRACKET 20212070 HEX SOCKET HEAD BOLT 20009790 HEX HEAD BOLT 13001080 SPRING WASHER 13000150 FLAT WASHER...

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