Hyper 63/DHD360
Contents
1. 63 Maintenance Operating Service Manual Certificate Number 2446 00 DHD360 m THE BULROC HYPER 63 HAMMER AIRCONSUMPTION 4 STRIPPING THE CHUCK ASSEMBLY STRIPPING THE BACKHEAD ASSEMBLY REBUILDING ASSEMBLY OF HYPER 63 9 BUTTON BIT FOOT VALVES CORRECT DIAMETERS AND PROTRUSION HEIGHTS 10 __ RECOMMENDED LUBRICANTS AND LUBRICATION RATES STORAGE PROCEDURES TROUBLESHOOTING CHUCK RELEASE WASHERS The Bulroc Hyper 63 down the hole hammer is a strong and robust tool of a simple and straight forward design to provide maximum performance with a minimum of maintenance Please Note The Hyper 63 series use bits that have footvalves BULROC Hyper 63 hammers are supplied as standard with a check valve arrangement which is designed to maintain the pressure inside the hammer when the air is switched off and so help prevent contaminated water from entering the hammer ALWAYS THINK SAFETY FIRST This manual is published by and copyright of Bulroc UK Ltd All Rights Reserved Always your Bulroc drilling equipment according to the instructions contained within this operating manual Further copies of this manual can be downloaded from the Bulroc website www bulroc com For urgent support or sales enquiries call Bulroc on 44 0 1246 544700 or Skype BULROCUKSALES BACKHEAD PISTON RETAINING RING BEARING O RING BEARING2. FOOTVALVE SHANK TOOL HEIGHT A DIA B TYPE HYPER63 FVITO93 1 940 49 3mm 1 500 38 1mm DHD360 m The Hyper 63 piston oscillates at 1000 bpm at 150 psi 10bar It is therefore extremely important that an adequate supply of the correct type of rock drill oil is constantly fed to the hammer whilst it is operating Failure to do so will quickly lead to excessive component wear and if the oil supply is cut of for any reason the piston will quickly seize inside the wearsleeve resulting in irreparable damage to both components An air line lubrication system should be installed preferably on the drill rig The lubricator reservoir should be of sufficient capacity to supply the required volume of rock drill oil for a full shift With larger hammers this may be impractical but the capacity should be sufficient for at least half a shift This is equally important that the lubricator system must be adjustable and have a visual check to ensure the lubricator does not run out of oil As a good general guide all Bulroc Hyper hammers require a third of a pint of oil per hour per 100cfm of air through the hammer 0 07 litre per metre cubed Eg Hyper 63 operating at 150psi 328cfm 1 27 pints per hour 10 3bar 9 31cmm 0 72 litre per hour The amount of lubricating oil should be increased by 50 when drilling with water or foam When new drill pipes are added to the drill string it is recommended that a half pin
3. BIT RETAINING RING O RING CONTROL TUBE TUBE P BIT RETAINING BUFFER RING RQ N CHUCK RELEASE WASHER TUBE IN HOLDER M v BUTTON BIT 3 HAMMER PARTS W C Soper Hyper 63 Valveless Hammer Ref Description art Number CO NO GO R ON Backhead Backhead O Ring Check Valve Check Valve Spring Diverter Compression Ring Tube Holder Tube Buffer 2 Control Tube Piston Piston Retaining Ring Bit Retaining Ring Bit Retaining O Ring Chuck Chuck Release Washer Wearsleeve Guide Bush Guide Bush O Rings 2 Complete Hammer HSH633803M HSH61 14 IPRCV04 IPRCVS04 HSH6120 HSH6128 HSH6131 HSH6129 HSH6330 HSH6103 HSH6132 HSH6337093 HSH6137A093 HSH6335093 HSH6326 HSH6300 HSH6386 HSH6386A BR63H01 4 HAMMER SPECIFICATIONS OUTSIDE H63 HAMMER SPECIFICATIONS DIAMETER English Metric Weight less bit 216 Ibs 98 1 kgs Length less bit 48 6 1235 Outside Diameter 5 62 142 8 mm Piston Weight 49 0 Ibs 22 3 kgs otroke 4 25 108mm CONSUMPTION P S I BAR Cu Mtr min 350 20 7 958 27 1 ea D O L T 2 ul l 5 O E _ Line Pressure 5 SIRIPPING THE CHUCK ASSEMBLY Breakout Washer After extensive drilling the chuck might become to tight to loosen on a Bulroc Bench Splitter or the drill rig If this problem
4. RADIUS on the Piston may become dented or deformed see fig 2 To prevent this face from cracking or chipping the Piston should be returned to a lathe where the strking face can be re machined flat and then have B the outer radius and inner chamfer reformed see fig 3 Care should be taken to remove the minimum amout of material during this re machining process and at no point should more than 2mm be removed from the face Pistons with wear patterns or indentations deeper than 2mm should be replaced The table below contains useful machine information for reforming the piston face MACHINE DETAIL HAMMER RADIUS A CHAMFER 9 Area to 8 CHECKING FOR WEAR AND DAMAGE CONTROL TUBE Diameter JA HAMMER MINIMUM DIA HYPER63 1 875 47 62mm Examine the control tube dia A using a micrometer check the diameter has not worn under the specified minimum If there are signs of pick up they should be removed by using emery cloth WEARSLEEVE x HAMMER MINIMUM DIA A HYPER63 5 25 133 35mm Using either a micrometer or a vernier measure the outer diameter A of the Wearsleeve If it is below the minimum it must be replaced The wear rate of the Wearsleeve can be slowed by replacing the Chuck before the wear area reaches the Wearsleeve The bore of the Wearsleeve should be periodically checked for any signs of Pi
5. occurs the breakout washer can be ground or drilled out which will relieve the pressure and enable the chuck to be removed NB On no account should the wearsleeve be impacted by a hand hammer Splitting should not be assisted by the use of localised heat i e Blow torch Assuming now both the Chuck and Backhead threads have been loosened either on the drilling rig ora hammer splitter The stripping procedure is as follows 1 Remove the chuck assembly 2 The bearing can now be removed Inspect both O rings for damage 3 Removing the O Ring from the bit retaining ring will allow this to be removed Alternatively pulling the two pieces apart will allow the O ring to stretch enough to fit over the end of the bit shank 4 The bit can now be removed quite easily 6 STRIPPING THE BACKHEAD ASSEMBLY d 1 With the hammer laid horizontal unscrew the backhead and remove it from the wearsleeve A 2 The remaining assembly can best be removed by lifting the chuck end of the wearsleeve which will allow the piston to push the other parts up to the end face From where they can be removed by hand CHECK COMPRESSION TUBE SPRING RING HOLDER CONTROL TUBE 4 CHECK VALVE DIVERTER 3 he backhead assembly can now be split quite easily TUBE BUFFER WEARSLEEVE CHUCK END PISTON RETAINING RING 4 Unless there is damage to the pi
6. washer into two thinner washers that will then spin freely Great care must be taken especially if the Washer is cut with a slitting wheel to ensure that the cut only penetrates the Washer and does not pass through into the body of the Chuck The size shown as D in the above table should be your MAXIMUM depth of cut and itis recommended that either the saw blade orthe slitting wheel are marked in some way so as to indicate when they have achieved this depth CLAMPING POSITIONS CLAMPING POSITION CLAMP POSITIONS HAMMER MODEL X DISTANCE FROM WEARSLEEVE END FACE Hyper 63 7 750 197mm There are many different Splitting Machines available for unscrewing the threaded connections on Bulroc Hyper Hammer some are attachments to the Drill Rig others are independent hydraulic units or purpose made Bench arrangements Regardless of which machine is chosen they all require some method of securing the Wearsleeve whilst applying a torque to either the Chuck or Backhead The most common machines use either Clamps or Chains around the O D of the Wearsleeve and the positioning of these is very important if they are placed too close to the joint being Split they will in effect increase the frictional forces on the threaded connection making it impossible to unscrew the component from the Wearsleeve The above table shows the correct position for the clamping mechanism to ensure no additional load will be applied to the t
7. cedure is followed then apart from protecting the hammer from corrosion it will protect the parts from premature wear and of course reduce down time and eventual repair costs However we strongly recommend that the hammer especially if stored for any long period of time should be stripped cleaned inspected and re oiled prior to use to be sure of smooth drilling 13 TROUBLESHOOTING PROBLEM PROBABLE CAUSE REMEDY INOPERATIVE DRILL Insufficient air pressure Check compressor discharge and increase to operational value SLOW PENETRATION Insufficient air pressure Increase discharge pressure Dull drill bit Re grind or change bit Worn drill parts Replace worn parts Too much or too little lubrication Check oil level and if necessary adjust lube needle value Dirt in drill Strip and clean LOW RETURN AIR VELOCITY Insufficient hole flushing air passing Drill or increase hole size through the through hammer piston SPASMODIC OPERATION CHUCK RELEASE WASHERS W 22 22 22 CHUCK RELEASE WASHERS MODEL HYPER 63 0 310 7 87 0 295 7 49mm Chuck Release Washers are fitted to the Bulroc Range of Hyper Hammers to assist the removal of the Chuck from the Wearsleeve after drilling The Chuck Release Washer is manufactured from a composite material that reduces the friction between the lock up faces on the Chuck and Wearsleeve making it easier to overcome the tensional loading applied to these parts durin
8. ck up If a Piston has broken within the Wearsleeve it is imperative that the bore is honed to remove any Burrs or Pick up Failure to do so will result in Pick up on the replaced Piston and will lead to early failure of this component 9 REBUILDING THE HAMMER 8 Backhead T Checkvalve Assembly 6 Compression Ring D Control Tube Assembly 4 Piston 2 Piston Retaining Ring 3 Chuck Assembly 1 Ensure all maintenance work outlined in the previous sections have been carried out 2 Stand the wearsleeve on the floor with the chuck end upwards Insert the piston retaining ring into the bore and hammer the ring down until it springs into the groove in the wearsleeve 3 Clamp the wearsleeve horizontally in a vice taking care not to overtighten the jaws Assemble the chuck chuck release washer and bit retainers ensure you fit a new O ring Slide the bearing over the shank ensuring the correct orientation see diagram on the left ensure you again fit new O rings Cover the threads with a copper based grease 4 Coat the piston with rock drill oil and slide it into the backhead end of the wearsleeve Ensure the piston striking face enters first 5 Assemble the two control tube buffers around the control tube and the push the assembly into the tube holder Coat the ouside of the assembly with rock drill oil and i
9. g the drilling process Due to the forces applied to the Chuck Release Washer you may find that its thickness W is reduced during the drilling cycle and it is therefore recommended that a new Washer be fitted each time the Chuck is removed It is possible thaton some of the larger Hammers in the Bulroc range when drilling with large diameter Button Bits or Overburden Systems certain conditions can generate higher torques than normally expected resulting in difficulties when trying to remove the Chuck from the Wearsleeve Should this occur then the removal of the Chuck can be achieved by cutting away the Chuck Release Washer We do however stress at this point that cutting away the Chuck Release Washer is a final option and should not be done until allother options have proved unsuccessful If the cutting away of the Chuck Release Washer is necessary for the removal of the Chuck then it must be done with extreme care to avoid damage to either the Chuck or the Wearsleeve The composition of the Chuck Release Washer allows for itto be cut with either a hacksaw or a small hand grinder equipped with a slitting wheel The hacksaw method is much safer and less likely to damage the Chuck or Wearsleeve but obviously much slower than thehand grinder with a slitting wheel To remove the Chuck Release Washer cutmust be made in the centre of the washer the way around it s circumference and completely through the Washer thus transforming the single
10. hreaded connection thus making the joint easier to split Due to the high torque loads applied to a Hammer during its drilling cycle equally high loads are required to Split the Chuck and Backhead away from the Wearsleeve and because of this the clamping arrangement around the Wearsleeve must generate enough friction to prevent it from spinning during the process However great care must be taken to make sure the clamps or chains are not over tightened as this can cause deformation to the Wearsleeve that can result in both Wearsleeve failure and Piston seizure once the Hammer is returned to service To help increase the Wearsleeve s resistance to deformation it is recommended that the Hammer Piston is first slid to the end of the Hammer being split before clamps of chains are attached By doing this the Piston O D will limit the amount of deformation in the Wearsleeve bore if too much clamping pressure is applied NOTE The use of Chain type Hydraulic Breakers can leave deep intrusions in the O D of the Wearsleeve which may result in stress concentrations that could lead to premature failure of the Wearsleeve Turnoaks Business Park Burley Close Chesterfield Derbyshire S40 2UB Tel 44 0 1246 544700 Fax 44 0 1246 544701 E mail info bulroc com website bulroc com HYPER 63DHD360 16 01 15
11. nsert it into the backhead end of the wearsleeve 6 Slide the compression ring on to the control tube assembly 7 Insert the spring and the check valve into the diverter and push the whole assembly into the wearsleeve Until it reaches the compression ring 8 Fit a new O ring to the backhead and coat the threads in copper based thread grease Screw the backhead into the wearsleeve until it is fingertight Then measure the gap between the wearsleeve face and the lock up face on the backhead This gap should be a minimum of 1mm If the gap is smaller the assembly should be removed and a new compression ring should be fitted If the gap is greater than 1mm the back head should be fully tightened using an appropriate backhead spanner 10 BUTTON FOOTVALVES Bulroc Hyper Hammers are designed to be used with footvalves FOOT VALVE OB The correct footvalve must be fitted otherwise the performance of the hammer will be seriously affected Using a footvalve which is larger in diameter than specified will result in the rapid failure of the footvalve Using a footvalve which is smaller in diameter than the size shown will greatly reduce the performance of the hammer r 2 5 gt The protrusion height is also important and to ensure the correct height prevent damage when replacing the footvalve it is recommended U that the correct insertion tool r INSERTION
12. ston retaining ring there should be no need to remove it However if this should need replacing dropping an inverted piston down the upright wearsleeve from the backhead end should remove it 7 CHECKING FOR WEAR DAMAGE Premature wear to internal parts is a result of either 1 Incorrect or insufficient lubrication 2 The ingress of debris into the hammer 3 Incorrect service and storage The maximum wear allowances shown in this section are a guide as to when to replace parts In certain conditions parts may need to be replaced before they reach the sizes shown STRIKING FACE BODY DIA 1 There are two main areas to examine on a used Piston Check the Body diameter A for signs of Pick up and heat caused discolouring both are signs of poor lubrication Using a micrometer measure the diameter and refer to the table for the minimum size Any light Pick up marks can be removed by using emery cloth however if there are signs of overheating and cracking the Piston should be replaced and the lubrication system examined HAMMER MINIMUM DIA HYPER63 4 575 116 21mm 2 Secondly examine the Striking Face Distortion is acceptable providing there are no signs of cracking Burrs and dents can be removed with an emery stone 7 CHECKING FOR WEAR OR DAMAGE MAINTAINING THE PISTON Fig 1 New Piston Face Fig 2 Worn Piston Face During the working life of the hammer the Striking Face
13. t a quarter of a litre of rock drill oil is poured into the pipe to provide a good internal coating and helps prevent the hammer from running dry at any time The grade of rock drill oil will be determined by the ambient temperature at the drilling site If the ambient temperature is between 0 and 25 degree centigrade then 30 grade oil should be used If the ambient temperature is greater than 25 degree centigrade use a 50 grade oll Bulroc supply their own recommended rock drill oil and this is detailed below together with other brands of suitable oils MAKE MEDIUM SAE 30 HEAVY SAE 50 ISO VG 100 ISO VG 220 T220 T320 ENGERGOL RD E 100 ENERGOL RD E 300 CHEVRON ARIES 100 ARIES 320 SHELL TORCULA 100 TORCULA 320 ESSO EXXON AROX EP100 AROX EP320 12 HAMMERS STORAGE We recommend following these points listed below when removing Down the Hole Hammer from service This will ensure trouble free operation once the hammer starts work again The hammer should be stripped and cleaned and freed of as much water moisture as possible Bulroc T220 or similar rock drill oil should be poured into the backhead allowing all parts to be coated throughout the hammer Amount required for a Hyper 63 is 74 of a pint or 0 43 litre Both ends of the hammer should be then covered to prevent the ingress of dirt etc It should then be laid horizontally in a dry environment ready for use next time If this pro
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