BHI HydroRam HK230S User manual

BHI
HydroRam
Hydraulic Hammer
HK230S
Operation Manual
& Parts List

FOREWORD
We thank you very much for your purchasing of our BHI HydroRam Hydraulic hammer.
To obtain the best performance of your hammer under any working conditions, you need to
do proper handling, regular inspection and maintenance. Otherwise the hammer may fail to
display its full capacity or result in various troubles of the certain parts.
This Operation Manual and Parts List provide you with all the information you need to
correctly use for maintenance. Please read carefully this publications prior to the installation
and operation in order to prevent any possible mishandling of the hammer and minimize the
down time of the equipment. Any inquiry related to the maintenance and service through
your local dealer will be highly appreciated.
BHI dealers and 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 instructions or not using the genuine
parts.
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.
Note! The descriptions in this book do not apply to any particular specification. Both
standard and optional equipment are covered, and each hammer is equipped and set in
accordance with each specific order. Consequently, standard and optional equipment are not
marked in the text of this book.
Best Hammer Industries
Technical Information

BHI
Best Hammer Industries
INDEX
Ⅰ. INTRODUCTION ----------------------------------------------------------
1
Ⅱ. SAFETY PRECAUTION -----------------------------------------------------
1
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. WARRANTY --------------------------------------------------------------
7
1. Delivery record -----------------------------------------------------------------
9
2. Claim application under warranty ------------------------------------------
10
Ⅳ. TECHNICAL DATA --------------------------------------------------------
11
1. Standard Specifications --------------------------------------------------------
11
2. Principles of Operation ---------------------------------------------------------
12
3. External Dimension - Power cell and Bracket ------------------------------
14
4. Construction - Excavator & Hammer Bracket -------------------------------
15
5. Torque Chart ---------------------------------------------------------------------
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. ACCESSORY PARTS LIST -------------------------------------------------
34
1. Tool type and parts list --------------------------------------------------------
34
2. Union cap parts list --------------------------------------------------------------
35
3. Hose plug parts list --------------------------------------------------------------
35
4. O-ring adapter part list ----------------------------------------------------------
35
5. Base cover plate dimension --------------------------------------------------
36
Ⅷ. UNDERWATER KIT(OPTION) ------------------------------------------------
37
Ⅸ. AUTOLUBE KIT(OPTION) ------------------------------------------------
38
Ⅹ. WEAR PARTS AND JUDGMENT TOOL -------------------------------------
39
Ⅺ. PARTS LIST-----------------------------------------------------------------------
41

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Best Hammer Industries
- 1 -
Ⅰ. INTRODUCTION
BHI HydroRam Hydraulic Hammer, designed and built to provide durable operation under
any working conditions, has been developed by BHI's excellent engineers with accumulated
technology and experiences for many years.
This Manual contains safety, operation and routine maintenance instruction. It does not
contain disassembly for service.
Do not operate the hammer unless the following safety instructions have been thoroughly
read and understood. Read this Manual before installing, operating or maintaining the
equipment.
Job applications are as below.
Construction sites:
Concrete demolition, general construction, rock breaking including trenching.
Mines & quarries:
Primary 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 indicate a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
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.
WARNING and BASIC OPERATION INSTRUCTIONS decals are included with each BHI
hammer and operation kit. Decals must be installed on the hammer bracket.

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Best Hammer Industries - 2 -
1. Safety Decals
Sticker
Description
Instruction
1
Head 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

BHI
Best Hammer Industries
- 3 -

BHI
Best Hammer Industries - 4 -
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. If the carrier is too light, it may become unstable and fall over.
4) Keep linkage and pin holes clear when installing the hydraulic hammer. Do not touch
any parts when the boom is moving. Never use your fingers to check the alignment of
the linkage.
5) Collect any oil which leaks out and dispose of it correctly.
6) 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 secures high pressurized accumulator. It
must have been approved by the relevant authority. Make sure that the pressure of
relief valve has been set correctly, i.e. to the maximum permissible operating pressure
of the hydraulic hammer.
Model
Unit
HK230S
Relief Setting
Pressure
Kg/cm2 / [psi]
210 / [2985]
* The above relief setting pressures are subject to change - efficiency of the pump.
9) Check the connections of the hydraulic hammer and the hammer hoses.
10) The connecting threads must be undamaged and free of sand or similar foreign
body.

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Best Hammer Industries
- 5 -
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.
3) Check for looseness of threads of hose, all kinds of bolts and nuts and re-tighten
securely.
4) Grease the shank bore 5 - 6 times by the hand grease pump.
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 when fitting/removing the tool since
metal chips may fly off when the retaining bar is hammered out.
2) Never use your fingers to check the alignment of the recession in the tool to the
oblong holes for the locking bars.
6. Hammer Operation
1) Close the front screen and splinter protection apparatus on the cab to prevent

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Best Hammer Industries - 6 -
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.
3) The hydraulic hammer should be operated only from the driver's seat and should not be
put into operation until both carrier and hammer are in the correct position.
4) Shut off the hydraulic hammer immediately if anyone moves in the danger area, which
is much larger for hammer operation than for carrier operation due to the risk of flying
debris.
5) When working with a hydraulic hammer, operation of the carrier is governed by carrier
manufacturer's safety regulations.
6) The hydraulic hammer is only suitable for the applications described. Never pry with
the tools.
7) Check the oil temperature constantly to ensure it does not exceed 80℃. If higher
temperatures are measured in the tank, an oil cooler must be fitted.
8) Flying debris from the hammer, tool, rock or other material may cause serious or fatal
injury to the operator, personal protection equipment 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 hammer from carrier before the transport.
14) Before leaving the carrier, always lower the boom and insure the carrier is stable.
15) Never leave the carrier with the engine running.
Danger of Explosion
․ N₂ gas cylinder should be used for charging gas into the accumulator and head cap.
․ Release all pressure prior to servicing or disassembly.
. Do not open without reading the Manual or consulting the authorized service man!
Unauthorized repair work on the accumulator is forbidden. Defective accumulators must be
replaced.
․ All accumulators are subjected to recurring tests by experts, at the latest after 5 years.
All hydraulic oil brands used in the carrier units are suitable for operating. The use of
other hydraulic fluids is only permissible after consulting with our service station. In summer
and in regions with high temperatures, it is recommended that oils with a viscosity of
category H-LP 36 or higher be used. At temperature lower than -20℃(4°F), the hydraulic

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Best Hammer Industries
- 7 -
hammer should not be put into operation.
Apply grease at least once a day. Grease the tool bit at least every 2 or 3 hours more
often if the tool becomes dry or material is extremely dusty or abrasive, using hand grease
pump. Pump 5 - 10 times. When changing tool, clean and grease the shank bore. Insufficient
greasing may cause abnormal wear of the tool holder bushing and tool, and tool breakage.
Injury or death can result from improper operation or maintenance.
Please read and understand this Operation Manual!!!
Preserve the environment !!!
When dispose of the waste Hydraulic Hammers, obey all local, state of federal regulation
for the industrial waste.
Ⅲ. WARRANTY
Warranty period is six(6) month. 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 the hammer and any part thereof
․ 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.
- use of unauthorized parts, fluids or tools.
- corrosion or failure to protect from adverse environmental conditions.
- faulty or improper condition of the carrier on which the hydraulic hammer was installed.

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Best Hammer Industries - 8 -
2. After installation of the Hydraulic Hammer
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.
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.

BHI
Best Hammer Industries
- 9 -
Website : www.bhice.com
Best Hammer Industries
5-91, Daepoong-ri, Daeso-myun, Eumsung-kun
Choongbook-do, Korea
Tel: [phone] - 1370~1, Fax:[phone]
E MAIL: [e-mail]
DELIVERY RECORD
To: ______________________________
Owner: _____________________________________ Address: ______________________________________
Distributor: _______________________________ Address: ______________________________________
Service Shop: ______________________________ Address: ______________________________________
Model of Hammer: _____________________Serial No.: _______________ Delivery Date: ___________
Model of Carrier: __________________________________________________________________________
A. Checked on the following items: Symbol for inspection
Normal :V, Clean :C, Adjust :A, Disassembly :D, Refill gas :G
Lubricate :L, Repair :M, Replace :R, Tighten :T, Not remedied :X
1. Hammer body: ☐ Accumulator gas pressure ☐ Operating pressure
☐ Head cap gas pressure ☐ Operating sound
☐ tool Holder lubrication ☐ 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. Standard tools: ☐ Quantity
8. Manuals: ☐ Operation manual & Parts list
B. Instructed proper operation and maintenance procedures.
The owner's signature below acknowledges that the hammer above mentioned was delivered to him in a
satisfactory condition and he has received proper instruction about the operation and maintenance.
Purchaser signature: ______________________Date: ____________________
Distributor: _____________________Serviceman: _______________________

BHI
Best Hammer Industries - 10 -
Website : www.bhice.com
Best Hammer Industries
5-91, Daepoong-ri, Daeso-myun, Eumsung-kun
Choongbook-do, Korea
Tel: [phone] - 1370~1, Fax:[phone]
E MAIL: [e-mail]
CLAIM APPLICATION UNDER WARRANTY
1. Model & Serial No.:
2. Date of Installation :
1) Manufacturer & Model
2) Oil supply(gpm)
3) Working Pressure
4) Return Pressure
5) Relief setting
3.
Carrier:
To insure efficient operation, it is essential that complete and proper hydraulic adjustments have been
verified at the time of the installation. 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.
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 Name
Q'ty
1
Details of Failure:
2
3

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Best Hammer Industries
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IV. TECHNICAL DATA
1. Standard Specifications
Model
Unit
HK230S
Recommended Carrier
Tons
20-28
US Tons
22-31
Impact Energy Class
ft.lbs
6,000
Impact Frequency
bpm
370-750
Working Weight
kg
[lbs]
1,950
[4,300]
Oil Flow
lpm
[gpm]
120-180
[31.7-47.6]
Operating Pressure
bar
[psi]
160-180
[2,320-2,610]
Tool Diameter
mm
[inch]
138
[5.43]
Overall Length
mm
[inch]
2,850
[112.3]
Hose Diameter
inch
1
85dB(A) Radius
m
14-18
* 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 authorizied technical staff. If not, the hammer may have major problems.

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Best Hammer Industries - 12 -
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. Inside of head cap is charged with the
high pressure N2 gas and gas energy stored in the upstroke of the piston (E)
effectively acts on the piston (E) during the impact.
1) Upstroke of Piston
As high pressure always applies to A1 and
A2 changes to low pressure, the force affects
the Piston(E) upward until 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 Port(P2), the chamber of
the Cylinder Converting Port becomes and
remains high pressure. Cylinder Converting
Port(P2) communicates with Valve Converting
Port(B4) and delivers the high pressure oil.
When the area(V1) of the Valve Converting
Port(B4) applies to high pressure, Valve(K)
moves upward and shifts. Then Valve High
Pressure Port(B2) communicates with Upper
Port(P4) of the Piston and oil being pressurized
is admitted to Upper Chamber of the Piston.

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Best Hammer Industries
- 13 -
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, its descending speed is
accelerated by the pressure of gas in the Upper
Chamber of the Piston.
4) Impact
Kinetic 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 Port P4: Upper Port of the Piston
V1 : Valve Converting Area H: Tool
Gas : N2 gas Chamber E: Piston
K : Valve

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

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

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Best Hammer Industries - 16 -
5. Torque Chart [ Units: kg․m / N.m] / lb-ft ]
Item
Torque
Tension Bolt
280kg.m / 2746N.m / 2025 lb-ft
Accumulator Cover Bolt
35kg.m / 343N.m / 253 lb-ft
Accumulator Assembly Bolt
100kg.m / 980N.m / 723 lb-ft
Mounting Bolt
130kg.m / 1274N.m / 940 lb-ft
6. Blow Speed & Power Control
1) Blow Speed Control (Adjuster Valve)
(1) Standard turn initially set at the factory means
turning the adjuster counterclockwise after
being completely locked.
(2) Initial (standard) turn [Initial turn/(Total turn)]
Model
HK230S
Turn
1 (10)
In case faster speed is needed than basic turn,
B direction => turn it counterclockwise
In case of slower speed is needed,
A direction => turn it clockwise
2) Blow(Striking) Frequency & Power control ( Cylinder Adjuster Valve )
(1) Initial (standard) turn [Initial turn/(Total turn)] : 0 Turn
In case faster speed is needed than basic turn,
B direction =>Max. 1.5 turn it counterclockwise
In case of slower speed is needed,
A direction => turn it clockwise
DO NOT TURN THE CYLINDER ADJUSTER MORE THAN TWO(2) FULL TURNS FROM ITS
SEATED POSITION OR IT MAY BLOW OUT OF THE HAMMER CAUSING INJURY OR DEATH TO
ANYONE IN THE VICINITY!
3) Blank Firing Prevention system
(1) Initial (standard) turn [Initial turn/(Total turn)] : 0 Turn
(2) In case of Blank Firing Prevention system :
B direction => Max. 1.5 turn it counterclockwise

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Best Hammer Industries
- 17 -
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. If it is improperly aligned, it could
respond as though it was working in light
material and remain in a high frequency, low
impact mode. When it is properly aligned, it selects best frequency impact combination for
maximum performance with that material at that particular time. When installing a new
Hammer, it is recommended that the Hammer is run in vertical position at about 250~300
blow per minute 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 tool
moves through the material, applied pressure is
continuously adjusted by using a combination of
the boom, dipper and attachment controls so
that the hammer follows the tool.
Applied Pressure Must be Correct
If applied pressure is insufficient, the tool will
dance around on the material rather than
sending energy into the rock. When this happens,
impact created by the piston is not transmitted
to the rock as a shock wave but is absorbed by
the hammer and excavator causing abnormal
structural fatigue.