BHI HydroRam HK300S Operations Manual & Parts List Download Page 43

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BHI

Best Hammer Industries

- 40 -

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

Damage to upper part of Tool by excessive abrasion of Tool Holder Bushing

(2) Free Repair

Breakage or flatness of upper hitting part of tool in normal usage condition

Damage to joint of Retainer Pin

Vertical cuts in Tool

(3) SEAL KIT : Oil Leaks, Tears, Cuts, Abrasion (Scratches), Hardening or Inverting of Seal Kit

Charged Repair

Oil leaks due to excessive use of Seals without replacement

Hardening of Seals due to excessive rise of oil temperature ( over 80℃ )

Discoloration of Seals to dark brown

Scratches on Seals due to inflow of particles

Damage caused by not carrying on warming ups in the beginning of operating Hammer

Inverted Seals

Free Repair

Oil leaks or Gas leaks when Piston and Cylinder are normal

Summary of Contents for HydroRam HK300S

Page 1: ...BHI HydroRam Hydraulic Hammer HK300S Operation Manual Parts List ...

Page 2: ... service workshops are equipped with the necessary special tools and well dimensioned parts stocks where only genuine parts are used for service and repairs We guarantee that a faithful compliance of the instruction will contribute to the best operational conditions Customers are therefore required to keep in mind that the manufacturer is not responsible for troubles caused by not following our in...

Page 3: ...t 16 6 Blow Speed Power Control 16 Ⅴ OPERATION AND HANDLING OF HYDRAULIC HAMMER 17 1 Hammer 17 2 Rules to Remember 19 3 Operator s Routine Maintenance 23 4 Periodic Maintenance 24 5 Factors of Tool Life 24 6 N2 Gas Pressure Maintenance 26 7 Nitrogen Gas Charging Pressures Table 28 8 Maintenance of Oil Filter 29 9 Hydraulic Oil Grease 30 10 Maintenance Checking Schedule 31 Ⅵ TROUBLE SHOOTING 32 Ⅶ A...

Page 4: ...ary breaking and secondary breaking Ⅱ SAFETY PRECAUTION Please familiarize yourself with the operating instructions and appropriate regulations before starting to work with the hydraulic hammer Safety notices in Operation Manual follow ISO and ANSI standard for safety warning Notices indicate an imminently hazardous situation which if not avoided would result in death or serious injury Notices ind...

Page 5: ...wearing ear protection Use hearing protection 2 Operation Manual Service Manual Read the manual before use 3 Warn a danger nearby job sites Keep away the breaking area while the hammer works 4 Grease Injection Inject grease 5 Caution Gas Pressurized Container 6 Lifting Holder Position ...

Page 6: ...BHI Best Hammer Industries 3 ...

Page 7: ... Operation of the hydraulic hammer requires the installation of hydraulic pipe lines for exclusive use of the hydraulic hammer 7 The hydraulic system to the carrier must be checked by the authorized service engineer before first operation and after any modifications 8 After installation of hydraulic pipe lines check the pressure and oil capacity Check the relief valve on the hydraulic system which...

Page 8: ... 5 Warm up the engine of carrier for five and ten minutes before hammer operation especially in winter to reach the oil temperature to 30 40 68 F 104 F Optimum oil temperature is 50 80 59 F 176 F 4 Serial number marking position and Hose connection High Low pressure Left high pressure in let line Right low pressure out let line 5 Tool Replacement 1 Always wear the protective glasses and helmet whe...

Page 9: ... must be used 9 When operating the hammer ear eye and breast protection appliance must be used at all time 10 Do not operate the hammer in the underwater and mud without proper equipment 11 Stop the engine before attempting to make any repairs adjustment or servicing to either the carrier or the hammer 12 Do not operate the carrier if you are under the influence of drugs or alcohol 13 Remove hamme...

Page 10: ...Below parts are wear parts These parts are not covered by the warranty Wear parts Diaphragm backup ring buffer ring o ring round bushing stop pin spring pin tool holder bushing retainer pin tool and seal kit sets The warranty condition could be changed by individual contract but it should be confirmed in writing by BHI in advance 1 The followings are not covered by warranty Normal wear and tear of...

Page 11: ...d 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 3 During under warranty In case during under warranty you have problem with your hammer the claim application under warranty form should be filled out and mailed to BHI ...

Page 12: ...tion Oil leakage Rubber plugs 2 Bracket Frame Bolt looseness Pins lubrication 3 Piping Tightening of fittings Fully opened shut off valve Oil leakage Relief valve set pressure 4 Controls Adjustment of control cable Pins lubrication Engine throttle lever position Caution at operation sticker 5 Carrier pump Characteristics Performance 6 Hydraulic oil Quantity of oil Deterioration Contamination 7 Sta...

Page 13: ...pply this information or to use BHI parts and tools may result in forfeiture of warranty coverage IV TECHNICAL DATA 1 Manufacturer Model 2 Oil supply gpm 3 Working Pressure 4 Return Pressure 5 Relief setting Dealer name Address Customer s name and address Completed by Completed by Dealer Dealer s Signature Date Customer Customer s Signature Date Date of repair Parts used for repair Part No Part Na...

Page 14: ... Operating Pressure bar psi 160 180 2 320 6 610 Tool Diameter mm inch 155 6 1 Overall Length mm inch 3 289 129 4 Hose Diameter inch 1 85dB A Radius m 27 34 Specifications may be changed without prior notice Operating Weight Working Weight Including Tool and Mounting bracket When you want to install on the incorrect carrier which is beyond our recommended range you must consult it with an authorizi...

Page 15: ... it reaches to Cylinder Converting Port P2 While Piston E moves upward it is compressing the gas contained in the head cap chamber As high pressure applies to Valve High Pressure Port B1 B2 and Valve Converting Port B4 converts to low pressure Valve K remains in the down position 2 Valve Shift When the area A1 of the lower chamber of the Piston E reaches to the chamber of the Cylinder Converting P...

Page 16: ...etic energy obtained by the Piston during the power stroke is transmitted to the tool H and then impact energy required to break is transmitted to the rock After that Piston starts to move upward again B1 Valve High Pressure Port P1 Cylinder High Pressure Port B2 Valve High Pressure Chamber P2 Cylinder Converting Port B3 Valve Low Pressure Port P3 Cylinder Low Pressure Port B4 Valve Converting Por...

Page 17: ...BHI Best Hammer Industries 14 3 External Dimension Power cell and Silence Bracket ...

Page 18: ...BHI Best Hammer Industries 15 4 Construction Excavator Hammer Bracket Top mounted and silence mounted bracket on excavator must connect with hydraulic pipe lines ...

Page 19: ... is faster than required you have to turn the adjuster valve clockwise 1 4 turn slightly to reduce the speed Note Adjuster Valve should be adjusted less than 3 turns due to the change of working pressure 3 Adjustment of the Valves There are three valves in the cylinder as shown below 1 Blow Speed Control Adjuster Valve Initial standard turns 2 turns In case faster speed is needed B direction turn ...

Page 20: ... for one hour Also after 10 minutes working start is recommended During that time avoid Hammering in inclined condition If the frequency is fast the impact is low If the frequency is slow the impact is high 2 Applied Pressure All hammers must have sufficient pressure against the tool to allow the transmission of energy or the shock wave to flow through the tool to the material being broken As the ...

Page 21: ...rtant to proper size of the hammer to the carrier 3 Secondary Breakage of Boulders Short Bursts Better Production Long Tool Life When breaking large rocks do not attempt to break them from the center It is more efficient if breaking is done from the edge Take small bits and do not work on one spot for more than 30 seconds This method will increase your productivity and cause less wear and tear on ...

Page 22: ...olt is Loose Or Broken Tighten it properly or replace it You can tell if it is broken or loose by tapping on the bolt and listening for a distinctive high pitched sound 2 Rules to Remember 1 Avoid Blank Hammering At All Times If this happens the piston will strike the tool shank with full impact forcing the tool against the retainers and causing premature wear and failure to the tool tool retainer...

Page 23: ...or hammer space as a lifting device Not only this is dangerous but also it can cause damage to the hammer tool and bushings 4 Do Not Pry Under Any Circumstances Prying is the most common cause of tool breakage It also causes damage to other hammer components as well as reducing productivity Prying inhibits of the shock wave through the tool and creates heat buildup in the bushing area 5 In Cold We...

Page 24: ...e 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 6 Do Not Allow Cylinders To Reach The End Of Their Stroke They will not endure the hammer vibrations in this position ...

Page 25: ... and dampen the shock wave travelling through the tool and into the material Move the tool often to avoid this effect 9 Do not immerse the hammer into water or mud When components except tool are immersed in water and mud piston and other components may be rusted and become damaged at an early stage For under water operation please contact us option 10 Do not touch the tool and hammer body During ...

Page 26: ...n Points 1 Visual Inspection Check welds for possible cracks on the bracket cap rear tool and boom 2 Check for loose nuts and bolts 1 In the bracket cap 2 In the charging valve 3 In the accumulator 4 In the side plates 5 In the tool holder pin 3 The tool retainer pins When replacing tool retainer pins always replace them in sets and rotate then equally 4 Excessive oil leakage down the tool This is...

Page 27: ...ear exceeds 5mm Some Bushings are grooved to provide even grease distribution Replace the Bushings when the grooves are worn through Excess tool holder Bushing wear causes tool misalignment to the piston causing premature hammer failure 4 Replace damaged or worn parts Then wipe all components clean including the lubrication port Hand grease the tool shank and inside the chuck bushings before placi...

Page 28: ...ering Prying Drilling Tool deflection Replacement of Tool When a tool bit is worn out it is liable to slip Then sharpen the ti p But when grinding the tip many times to sharpen the edge the hardened surface layer wo uld cut off and it makes the rod to be worn out rapidly When the difference gap between t ool holder and tool holder bushing is over 6 mm then replace tool holder together with the too...

Page 29: ...s not optimum gas pressure it should be set according to the chart as below Head cap Accumulator Optimum Nitrogen Gas Pressure kg psi at20 68 F 2 Removal of gas charging adapter 1 Turn the handle of gas charging adapter counter clockwise until it stops 2 Unscrew the cap and release the gas inside the gas charging adapter 3 Remove the gas charging adapter from the gas valve and fit the cap of gas v...

Page 30: ...r 4 Turn the handle of gas charging adapter clockwise and stop when the pressure gauge indicator moves 6 When the optimum gas pressure is obtained close the main valve of gas charging cylinder by screwing clockwise Also turn the handle of gas charging adapter counterclockwise not to leak out Remove the gas charging adapter finally 5 Inspection of accumulator If there is a big tremor on the hose of...

Page 31: ...900 N2 GAS 3 WAY VALVE ASSEMBLY 1 2 16802000 N2 HOSE 1 3 13105910 N2 COUPLING KIT 1 4 13105920 N2 GAS CYLINDER 1 5 DF300520 EXTENSION STICK OPTION 1 2 Head Cap Part Low Pressure Model Temp HK300S C F PSI kg cm2 bar 20 68 242 256 17 5 0 5 3 Accumulator Part High Pressure Model Temp HK300S C F PSI kg cm2 bar 20 68 782 852 55 0 60 0 ...

Page 32: ...nd pipes Cleaning or replacing oil filter also requires check for oil contamination Replacement of filter first 50hours and every 100 hours thereafter Replacement of hydraulic oil every 500 hours An oil filter must be fitted in the return line of the hydraulic system with a mesh of no greater then 50 micrometers and a magnetic separator Preserve the environment from the ravages of pollution When d...

Page 33: ...r hammer operation Use of other hydraulic fluids is subject to approval Minimum viscosity 32 cSt Optimum viscosity 46 68 cSt Check the oil temperature constantly to ensure it does not exceed 80 176 F If higher temperatures are measured in the tank an oil cooler must be fitted 2 Grease NLGI No 2 Shell Alvania EP2 Lithan EP2 Mobilplex 48 When using oil at a extremely cold or hot weather it must be s...

Page 34: ...r wear Check spring pin rubber plug Check impact surface of working steel for chips Check tool for crack 4 Every 2 weeks Check pressure accumulator head cap Working steel for wear Check Tool Holder Bushing for wear Check Tool Holder Round Bushing for wear Check Bracket for wear Tighten screw Bracket Pin part Power cell Tension Bolt Hose Adapter part Bracket Set Bolt Mounting Bolt part 5 Every mont...

Page 35: ...Defective electric system for hammer operation Call authorized service man 6 Defective magnet of valve switch Replace magnet 7 Operating pressure too low Inspect the engine speed of carrier and readjust the operating pressure 8 Lack of hydraulic oil Fill hydraulic oil High frequency and low blow power Cause Required action 1 No gas in head cap Defective ring of the upper seal Replace seal ring 2 O...

Page 36: ...eck the pressure 10 Return line connects to control valve Return line must be connected directly to the oil tank or filter 11 Defective diaphragm of accumulator Lots of tremor of the hose can make damage at the entrance of hammer Replace the diaphragm 12 Hydraulic oil pressure is low Check the pressure and if it is red replace with new pressure relief cartridge Oil leakage Cause Required action 1 ...

Page 37: ... Hammer Industries 34 Ⅶ ACCESSORY PARTS LIST 1 Tool type and part list Tool Part Pode List Type A B C D E F G MOIL H WEDGE CONE BLUNT V WEDGE SPADE H SPADE V HK300S DC000050 DC000080 DC000060 DC000090 DC000070 ...

Page 38: ...mer Industries 35 2 Union cap parts list 3 Hose plug parts list 4 O ring adapter parts list HOSE SIZE O RING ADAPTER PF JIC 1 13009380 HOSE SIZE UNION CAP JIC TYPE 1 13007050 HOSE SIZE PLUG HOSE JIC TYPE 1 13008430 ...

Page 39: ...BHI Best Hammer Industries 36 5 Base cover plate dimension unit mm MODEL A B C D E F G H I DIA HK300S 704 810 40 235 260 235 40 200 220 39 ...

Page 40: ...raulic 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 ...

Page 41: ...BHI Best Hammer Industries 38 Ⅸ AUTO LUBE KIT OPTION ...

Page 42: ...ture of Retainer Pin 3 Free replacement can not be made when damage occurs below Retainer Pin which is below Tool Holder Bushing since it is considered user s fault such as prying 4 The manufacturing number of tool must be checked in order to make a claim 5 The manufacturing number is on the side of aperture for Retainer Pin 6 When problem occurs the damaged area as well as the manufacturing numbe...

Page 43: ... hitting part of tool in normal usage condition Damage to joint of Retainer Pin Vertical cuts in Tool 3 SEAL KIT Oil Leaks Tears Cuts Abrasion Scratches Hardening or Inverting of Seal Kit Charged Repair Oil leaks due to excessive use of Seals without replacement Hardening of Seals due to excessive rise of oil temperature over 80 Discoloration of Seals to dark brown Scratches on Seals due to inflow...

Page 44: ...BHI BHI HydroRam Hydraulic Hammer HK300S Parts List ...

Page 45: ...BHI Best Hammer Industries 2 HK300S POWER CELL PARTS LIST ...

Page 46: ...CKET PLUG 2 42 22402000 O RING 2 13 DK000400 IN OUT FLANGE 2 43 D9000050 PIN 4 14 20213620 HEX SOCKET HEAD BOLT 4 44 DL000030 TOOL HOLDEER 1 15 20211760 HEX SOCKET HEAD BOLT 12 45 DC000180 ROUND BUSHING 1 16 DL000200 CYLINDER 1 45 1 DC001210 ROUND BUSHING Oversized 0 08 0 1mm 17 DL000220 PISTON 1 46 DL000110 TOOL HOLDER BUSHING 1 18 DL000040 CYLINDER BUSHING 1 46 1 DL000310 TOOL HOLDER BUSHING Ove...

Page 47: ...HARGING KIT 1 58 2 DE000350 ORIFICE A 1 MEMO 58 3 DF000690 ORIFICE B 1 58 4 DF000700 ORIFICE C 1 58 5 DF000710 ORIFICE D 1 58 6 DE000360 HOLDER PIN 1 59 DE000320 DIAPHRAGM 1 60 DC000320 O RING PLUG 1 61 DC000330 CHARGING VALVE 1 62 DA000510 O RING CAP 1 63 22402040 O RING 2 64 22401930 O RING 1 65 20215040 HEX SOCKET BOLT 12 66 22402540 O RING 1 67 22409600 BACK UP RING 1 68 16804740 SPRING HOSE 2...

Page 48: ...EAL 1 7 22300260 STEP SEAL 2 8 22002730 DUST SEAL 1 9 22003980 U PACKING 1 10 22000250 BUFFER SEAL 1 11 22402260 O RING 4 12 22402020 O RING 2 13 22405610 BACK UP RING 2 14 22402060 O RING 2 15 22401440 O RING 1 16 22402000 O RING 2 17 22402040 O RING 2 18 22401930 O RING 1 19 22402540 O RING 1 20 22409600 BACK UP RING 1 21 22401410 O RING 1 22 22409410 BACK UP RING 2 23 22402110 O RING 4 24 22405...

Page 49: ...01160 L WRENCH 1 8mm 8 16501170 L WRENCH 1 10mm 9 16501190 L WRENCH 1 14mm 10 16501200 L WRENCH 1 17mm 11 16501210 L WRENCH 1 19mm 12 16503090 HAND RETAINER PIN 1 M12 13 16500770 HAMMER RING WRENCH 1 75mm 14 16500720 HAMMER RING WRENCH 1 55mm HK300S N2 GAS CHARGING KIT PARTS LIST No Part No Part Name Q ty MEMO No 5 DF300520 OPTION 0 DA698000 N2 GAS CHARGING KIT 1 1 13105900 N2 GAS 3 WAY VALVE ASSE...

Page 50: ...BHI Best Hammer Industries 7 HK300S BRACKET PARTS LIST ...

Page 51: ... MEMO 6 D9300070 RUBBER CAP S 6 7 DK300110 SIDE PAD 2 8 DL300120 SIDE CUSHION 2 9 DL301020 PREMIUM BRACKET 1 10 DL300080 BACK WEAR PLATE 1 11 DL300090 DOWN CUSHION 1 12 DL300130 DUST PROTECTION SEAL 1 13 DL300100 DOWN WEAR PLATE 3 14 DL300070 FRONT WEAR PLATE 1 15 20211760 HEX SOCKET HEAD BOLT 10 16 13000080 FLAT WASHER 10 17 DL300250 UPPER COVER 1 18 DL300030 DOWN COVER 1 19 20212470 HEX SOCKET H...

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