KING Portable Brinell User Manual

“The Name Behind the Standard”

King Tester Corporation

King Portable Brinell
Hardness Tester

User’s Manual

Website: www.kingtester.com

Email: [e-mail]

Phone: [phone]

Address: 308 Schell Lane

Phoenixville PA 19460

King Portable Brinell Hardness Tester

1. Introduction ..................................................................................................................................... 1

2. Features ........................................................................................................................................... 1

2.1 Portable Testing ......................................................................................................................... 1

2.2 Permanent Indentation & Easy Inspection ................................................................................ 1

2.3 Accurately Testing Real Results ................................................................................................. 1

2.4 Optional Test Conditions with Wide Testing Range .................................................................. 1

3. Technical Parameters ...................................................................................................................... 3

4. Principle & Components ................................................................................................................. 3

5. Operations ....................................................................................................................................... 4

5.1 Preparation ................................................................................................................................ 4

5.2 Operation .................................................................................................................................. 4

6. Introduction of Main Parts ............................................................................................................. 5

6.1 Indenter ..................................................................................................................................... 5

6.2 Gauge ......................................................................................................................................... 5

6.3 Pump Handle ............................................................................................................................. 5

6.4 Pressure Release Lever .............................................................................................................. 5

6.5 Calibration Valve ........................................................................................................................ 5

6.6 Oil Cylinder ................................................................................................................................ 6

6.7 Test Head Carriage ..................................................................................................................... 6

7. Standard Package ............................................................................................................................ 7

8. Optional Accessories ....................................................................................................................... 7

9. Maintenance ................................................................................................................................... 8

10. Packing & Transportation ............................................................................................................. 11

11. Warranty ....................................................................................................................................... 13

12. Repairs ........................................................................................................................................... 13

Appendix:

Table 1: Brinell Hardness Table ..................................................................................................... 14

Table 2: Testing Accuracy of Brinell Hardness Testers .................................................................. 23

Table 3: Testing Conditions for Brinell Hardness Testers .............................................................. 23

Table 4: Selection of Testing Conditions for Brinell Hardness Testers .......................................... 23

Table 5: Conversion of Brinell Hardness and Tensile Strength ...................................................... 24

King Portable Brinell Hardness Tester

1

Rev. March 2017

www.Kingtester.com

©Copyright King Tester Corporation 2017. All Rights Reserved

1. Introduction

King Portable Brinell Hardness Tester is the finest portable hardness tester in the world. It tests up to
3000kg of test force using a 10mm carbide ball indenter. The indentation results reflect the hardness of
the material. The tester may be used on most metals and is particularly suitable for testing nonuniform
materials. The testing results are accurate with excellent repeatability and correlate with tensile strength.
The test conditions and accuracy meet the requirements of ISO 6056 and ASTM E110 and can be used
to test rough castings, forgings, nonferrous metals and semi-finished products after heat treatment.

2. Features

2.1 Portable Testing

The King Portable Tester is suitable for use in the lab or in the plant. It is easy to operate and
convenient to carry. It can be used to test all sizes of parts and parts in any direction (like upside down,
underside, or side face). When the part cannot be moved easily, the King Tester is the answer.

2.2 Permanent indentation & easy inspection

By applying 3000kg test force and 10mm ball indenter, the permanent indentation can be inspected at
any time after testing, and the existence of the indentation shows that the part has been tested.

2.3 Accurately testing real results

The King Tester applies the same principle as a bench type Brinell hardness tester. The result is far
more accurate and repeatable than other portable Brinell hardness testers. The calibrated accuracy of the
test force is 1% which confirms to ASTM E10.

2.4 Optional test conditions with wide testing range

You are not limited to a 10mm ball and 3000kg test force. You have options of a 2.5mm, or 5mm ball
and different test loads from 187.5kg-3000kg. The tester has multiple testing forces and indenters so
that the King Tester can test all kinds of material and its testing range is 16-650 HBW.

King

Portable

Bri

nell Hardness T

ester

2

©Copyright King Tester Corporation 2017. All Rights Reserved

www.Kingtester.com

Rev. March 2017

Fig. 1 King Tester Components (with part #’s)

1. Pressure Release Valve (43-26)

2. Cylinder Cap (14)

3. Calibration Valve

4. Pump Segment (43-7)

5. Gears

6. Crank (SB-16C)

11. Pump

Handle (8)

12. Standard

Base (C1)

7. Carrying Handle (15)

8. Elevating Screws (SB-

21, SB-22)

9. Handle (15)

10. Gauge (9)

13. Test Head (B1)

14. Ball Retainer (10mm,

5mm, 10-2.5mm)

15. Ball (10mm, 5mm, 2.5mm)

16. Anvil (SB-25,SB-26,SB-27)

17. Basket

King

Portable

Bri

nell Hardness T

ester

3

©Copyright King Tester Corporation 2017. All Rights Reserved

www.Kingtester.com

Rev. March 2017

3. Technical Parameters

Test Force:

3000kg (500kg, 750kg, 1000kg, and 1500kg are
optional)

Accuracy of Test Force:

1%

Indenter:

10 mm carbide ball indenter (2.5mm & 5mm ball
optional)

Testing Range:

16-650 HBW

Max. Specimen Height:

13” or 20”

Throat Depth:

4” or 6” (unlimited with Chain Adapter)

Repeatability:

ISO 6506/ASTM E110

Error:

ISO 6506/ASTM E110

Net Weight:

34 lbs.

4. Principle & Components

The King Tester uses a hydraulic principle with hand-operation to apply the 3000kg test force. The
central part of King Tester is a small hydraulic system in which a release valve is used to control the
test force. When the force reaches 3000kg, the release valve will open and the pressure will begin to
drop. The tester should be pumped an additional 3 times after reaching 3000kg. The components of the
tester are shown as Fig. 1.

The tester consists of a base and a test head.

The base is composed of carriage, anvil, anvil holder, throat, handle, and elevating system. The base
with anvil is easy to use to clamp parts or to test piping. The test head is installed between the side
plates which hold the tester. The screw elevating system is controlled by the hand crank which can be
moved up and down to select the proper height for the test head. The base is constructed and designed
to eliminate deflection.

The test head is comprised of a gauge, pump handle, indenter, oil cylinder, pressure release lever, pump
handle, and calibrating valve.

The test head is a sophisticated hydraulic system. By pumping a small number of times, the cylinder
(indenter) will produce a large force. The function of the dial gauge is to indicate the approximate test
force. The pump handle is used to create the test force; and the indenter applies the force onto the
workpiece and result is a standard Brinell indentation. The cylinder stores the oil; the pressure release
lever is similar to an on/off switch used to initiate the creation of the test force. The calibrating
assembly controls how much pressure is created.

King

Portable

Bri

nell Hardness T

ester

4

©Copyright King Tester Corporation 2017. All Rights Reserved

www.Kingtester.com

Rev. March 2017

5. Operations

5.1 Preparation

5.1.1 Prepare the part

Choose an appropriate part to test and clean any rust, scale or dirt from around the test point before
testing. If the surface of the sample is rough or has a coating, hardened layer, or decarbonized layer, the
operator needs to grind the surface of the workpiece properly until the substrate part of the workpiece is
exposed.

5.1.2 Calibration of the tester

The King Tester is calibrated before leaving the factory. A calibration certificate is attached to the
tester. Before using the tester, verify the accuracy of the tester with a test block.

5.1.3 Select and Install the Anvil

The standard tester package includes 3 anvils:

a) The flat anvil fits most parts and test blocks;
b) The V anvil is used to test cylinder and convex specimens;
c) The dome anvil is used to test concave surfaces and tubes.

Selecting the correct anvil is important to avoid unstable loading and assure the accuracy and reliability
of the test.

5.1.4 Check the Indenter

Check the indenter before testing and make sure the indenter holder is fastened tightly; otherwise it may
damage the indenter ball.

a) Install the pump handle;
b) Open the pressure release valve;
c) Raise the test head to appropriate height.

Check the ram before testing to make sure the ram is retracted. If not, turn the crank, lower the test head
until it is pressing on the workpiece then apply a test force. The length of the exposed part of the
indenter cannot be more than 3/8 inches.

5.2 Operation

Put the part in the throat of the tester; turn the crank in order to make the test head move down and
clamp the specimen between the test head and the anvil. Now close the pressure release lever and load
the test force on the specimen and watch the gauge. Continue to move the pump handle. When the
gauge indicates 3000kg, the calibrating valve will work and the pressure will begin to fall. Make 3 more
pumps using the pump handle. Open the pressure release lever, raise the test head and move the tester
away from the part. Use a KingScope™ or KingScan® to measure the diameter of the indentation.
Check the tables in the appendix for Brinell hardness test results.

King

Portable

Bri

nell Hardness T

ester

5

©Copyright King Tester Corporation 2017. All Rights Reserved

www.Kingtester.com

Rev. March 2017

6. Introduction of Main Parts

6.1 Indenter

The indenter is composed of indenter body, indenter ball and indenter holder.
The ram body is the hydraulic system which transfers the test force onto the part.
Make sure the indenter is not extended more than 10mm before loading test force. If the indenter is
extended more than 10mm, it will not create a valid indentation because the test force is not able to
reach 3000kg.
Don’t use the pump handle until the indenter is in contact with the part.
The instrument uses the carbide ball for testing. The advantage of the carbide ball is it is hard, durable,
and highly accuracy. However it will not test the steel harder than 60 HRC.
The carbide ball replacements can be purchased from King Tester.

6.2 Gauge

The gauge is an indicator of the test force and lets the operators see the test force as it increases and
decreases. However, the gauge does not control the test force and while it is representative of the load it
does not fully capture the dynamic of the test.
Make sure to protect the gauge.

6.3 Pump Handle

The function of the pump handle is to make the hydraulic system produce a test force.
The reciprocating motion of the pump handle forces a small piston in the hydraulic system to press oil
into the cylinder, and the pressure transfers to the indenter. The indenter will respond to this process by
moving and increasing the test force.

6.4 Pressure Release Lever

The pressure release lever is the on/off switch of the hydraulic system. When the pressure release lever
is open and the pressure will decrease to 0. Close the pressure release lever and the hydraulic cylinder
will hold pressure. As the operator moves the pump handle, the hydraulic cylinder will place force on
the indenter.
Required procedures:

a) When not using the tester, keep the pressure release lever open.
b) Do not pump the handle unless the indenter is in contact with a part or test block.
c) After testing, open the pressure release lever and raise the test head immediately.

6.5 Calibration Valve

The calibration valve is the auto control pressure switch of the hydraulic system. Before leaving the
factory, the calibration valve is calibrated accurately to 3000kg, with a tolerance of less than 1%. When
the pressure in the cylinder reaches 3000kg, the calibration valve will instantly open releasing the
pressure. Once pressure drops below 3000kg, the calibration valve closes.
Do not remove the calibration screw or the tester will lose accuracy.

King

Portable

Bri

nell Hardness T

ester

6

©Copyright King Tester Corporation 2017. All Rights Reserved

www.Kingtester.com

Rev. March 2017

6.6 Oil Cylinder

The oil cylinder contains a cover, locking nut for the oil sac, oil sac, and sump.
If the cylinder does not have adequate oil the tester will not achieve pressure. If the test force does not
reach 3000kg, you need oil. (Refer to Maintenance Section)
The process of replacing the oil in sump is complicated; any carelessness will result in the tester
needing to be returned to the manufacturer for service and repair. Adding or changing the oil should be
done by either the manufacturer or a properly trained and King certified technician.

6.7 Test Head Carriage

The test head carriage is composed of the base, carrying handle, elevating system, and crank.
The tester can test most parts. If the part can be clamped between the indenter and the anvil, it can be
tested, and even when the tester is upside down, it will give you accurate results.
The tester is made of high grade alloy steel making sure not to deform or bend under 3000kg test force.
The elevating screw system consists of a crank, gear seat and multiple gears. Turning the crank will
move the side mounts up and down.