BR SERIES MANUAL
Contents
1. BR1 BR2 BR3 BR33 BR4 Complete weight kg 8 13 22 25 34 6 without bit Ib 17 6 28 6 48 5 55 76 Length mm 709 838 768 768 913 without bit ins 27 9 33 30 2 30 2 35 9 Length mm 785 913 888 888 1090 bit extended ins 30 9 36 34 9 34 9 42 9 Length mm 760 889 830 830 1019 bit retracted ins 29 9 35 32 7 32 7 40 1 Outside diameter mm 51 62 78 82 95 of hammer ins 2 2 44 3 07 3 22 3 75 Bore mm 36 42 6 50 8 57 1 68 diameter ins 1 43 1 68 2 2 25 2 68 Piston mm 76 102 102 102 102 stroke ins 3 4 4 4 4 Piston kg 1 1 8 2 5 9 3 4 6 weight Ib 22 4 5 5 7 3 10 1 5 AIR CONSUMPTION FIGURES IN CFM 8 M min MODEL CHOKE 100 7 150 10 5 200 14 250 17 5 PSI BAR PSI BAR PSI BAR PSI BAR BRI ZAK 1 99 1 8 1 24 1 98 3 69 BLANK 1 39 2 98 uc 4 68 1 53 2 26 2 99 9 44 3 73 11 14 BR4 B 9 7 5 63 9 20 37 10 91 4 84 10 91 14 32 18 1 18 m 6 GENERAL MAINTENANCE In normal dry drilling conditions it is advisable to dismantle and check all hammer components every 250 hours of operation If a part is to be replaced because of irreparable damage or ultimate wear then that part must be scrapped to ensure it is not put back into further use This would seriously accelerate wear of certain other components 1 When new all BULROC Valved D T H hammers will have a gap between the Chuck and2. BR SERIE VALVED DTH HAMMERS Service Manual MADE IN BRITAIN N Certificate Number 2446 00 ISO9001 CONTENTS THE BR HAMMER SERIES ntroduction Hammer Components Hammer Parts List Hammer Specifications Air Consumption Figures BR HAMMER MAINTENANCE General Maintenance Wear Tolerances Selective Replacement Rebuilding Assembly Of A BR Hammer LUBRICATION Recommended Lubricants Rates TROUBLESHOOTING ALWAYS THINK SAFETY FIRST la This manual is published by and copyright O of Bulroc UK Ltd All Rights Reserved Always operate 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 enguiries call Bulroc on 44 0 1246 544700 or Skype BULROCUKSALES 1 INTRODUCTION BULROC Valved D T H hammers are robust tools of simple design to provide for maximum performance with the minimum of maintenance BULROC Valved hammers are designed to operate efficiently at air pressures between 100 psi 7 BAR and 250 psi 17 5 BAR using a wide range of Button Bit diameters from O60mm BR1 through to 4127mm BR4 BULROC Valved hammers are supplied with a Check Valve arrangement which maintains pressure in the hammer when the air has been shut off and so helps prevent contaminated water entering the hammer BULROC Va
3. ck the Non return Valve located underneath the Back head Depress it until it bottoms turning it slightly each time to ensure that it does not stick down It is advisable to change the Check valve if its sealing capacity is in doubt Check the Spring for breakage or weakness 8 SELECTIVE REPLACEMENT 1 Mount the Wearsleeve into the vice and nip gently 2 Push wad of clean rags through the bore 3 Check bore of Wearsleeve for cleanliness and identify the end of the bore with the two eccentric grooves machined internally The Split Spacer will be fitted to this the Chuck end ofthe Wearsleeve Im INTERGRAL BEARING 4 Stand the Wearsleeve Chuck end uppermost on a wooden block 5 Insert compression tool into the end of the Wearsleeve and place Split Spacer into the compression tool Z 6 Drive the Split Spacer through the compression tool the chamfered end goes in first O Y 7 When the Split Spacer is clear of compression tool remove tool and drive Split Spacer A into the Wearsleeve Distance from Wearsleeve end face is 3 1 4 BR1 3 1 4 BR2 4 3 BR3 3 BR33 3 3 4 BR4 8 Mountthe Wearsleeve in the vice with Chuck end to the left 9 Clean the Bearing and place wide end down on bench 10 Oil the shank of Piston and stand the Piston inside the Bearing 11 Clean the Cylinder Identify the correct way up i e radiused end to the Bearing Y Lu 12 Lower the Cylinder over the piston until it seats on the bea
4. e Backhead threads 21 Insert the Bit Retaining ring halves into the Chuck end of the Wearsleeve 22 Apply grease to threads of Chuck and screw Chuck into Wearsleeve 23 If a bit is to be fitted slip the Chuck over the Bit splines fit Retainers a 274 over plain portion of Bit Shank Offer the Bit assembly to the gt Wearsleeve and screw home WEARSLEEVE 24 Air Metering plug where fitted this is a steel Allen headed type plug e which is screwed into the bevelled valve housing 10 LUBRICATION Inadequate supply of the correct type of oil is a major contributor to excessive Component wear and consequently a rapid fall off in performance An air line lubrication should be installed preferably on the drill rig This should be of sufficient capacity to supply the required volume of oil for a full shift The lubrication must be adjustable and set to ensure the correct flow of oil required by the hammer The amount of lubricating oil will vary with the operating pressure and volume of air used by the hammer As a general guide any BULROC Valved D T H hammer will require 1 3rd of a pint per 100 CFM through the hammer 0 07 Itr per 1 0 M min per hour e g BR4 operating at 150 psi 300 cfm 1 pint per hour 10 5 Bar 8 5 M min 0 6 Itr per hour When drilling with foam or water the amount of lubricating oil should be increased by 50 When new drill tubes are put into use it is recommended that 2 a p
5. exceed the values shown either the Piston or the Inner Cylinder must be removed In this case do not scrap the replaced part as it can be returned to the hammer when the new partner is installed In this way itis possible to double the life of both the Piston and the Inner Cylinder e I T RS INNER CYLINDER BEARING PISTON BORE 0 010 ins 0 25mm 0 010 ins 0 25mm 0 012 ins 0 30mm BR33 0 010 ins 0 25mm 0 010 ins 0 25mm 0 012 ins 0 30mm 0 011 ins 0 28mm 0 010 ins 0 25mm 0 012 ins 0 30mm 4 Valves The hammer models BR1 through to BR4 use Disc Valves which are of even thickness Check the Valves for cracks or pitting marks By placing the Disc Valve on the bevelled valve housing and holding it in front of a light or daylight it is possible to conduct the light test That is if light is discernible between the Valve and Valve Seat turn it over and test the other side If light is still discernible scrap the Valve Assuming that the bevelled valve housing is not faulty 5 Check the Valve Guide for score marks If scored clean with fine emery cloth 6 Check the ends of the Cylinder for chipping also the shoulder of the Bearing Chipping in these areas indicates that the hammer has been run with the Chuck or Backhead or both in a loose condition Failure to maintain the gap between the Chuck and Wearsleeve will also result in chipping and ultimate failure in the aforementioned areas 7 Che
6. int of oil 0 25 Itrs be poured into each new tube to give them a good coating of oil and to preventthe hammer from running dry at any time Ambient temperatures will determine the grade of rock drill oil to be used Should the ambient temperature be between O C and 25 C use a 30 grade oil When the ambient temperature is over 25 C use a 50 grade Oil A selection of recommended rock drill oils suitable for BULROC Valved D T H hammers is given below MAKE TYPE 30 GRADE TYPE 50 GRADE BP ENERGOL RD E 100 ENERGOL RD E 300 VALVED HAMMER STORAGE PROCEDURE We recommend following the points listed below when removing a Down hole hammer from service This will ensure trouble free operation once the hammer starts work again Z The hammer should be stripped and cleaned and free of all water moisture as possible LZ Bulroc T220 or similar rock drill oil should be poured into backhead see chart below for quantity allowing all parts to be coated throughout the hammer LZ Both ends of the hammer should be then covered to prevent the ingress of dirt etc pa should be then laid horizontally in a dry environment ready for use next time Model Qty in UK Pints Qty in litre s BR1 amp 2 Va 0 14 BR3 33 Va 0 14 BR4 Y 0 28 If this procedure 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 Howeve
7. lved hammers are fitted with an Air Metering Plug This is supplied as a solid plug but can be drilled out to a selection of hole sizes in order to increase the volume of flushing air if excess compressed air is available This is to suit particular drilling conditions 2 HAMMER COMPONENTS 4 Piston Check Valve Spring Backhead 13 O Backhead Spacer Backhead O Ring Check Valve Wearsleeve Valve Chest Valve 8 e Centraliser Air Metering Plug Bevelled Valve Housing Split spacer hs Bit Retaining Chuck Seal Ring Inner Cylinder 3 HAMMER PARTS LIST RE DESCRIPTION BR1 BR2 BR3 BR33 BR4 F 6 BEVELLED VALVE HOUSING HSB1S04 HS82s04 HSB3S04 H sB3s04 HsB4s04 japo Discvave HsBiso6 Hs82so6 ircov ircov HsBasoe_ 2 valvecHesT HSB1s07 HsB2s07 H sB3s07_ HsSB3307 H sB4s0o7 HSB1S3810F HSB2S3811F HSB333801M HSB333801M HSB4S3811M RD40 PIN _HSB1S3810M PO Pp HsBisseie E E _HSB1S3816F HsB2as3816F HsB3s3816 o HSB2s8810F PO __HSB2S3816M__ HsBsss816M o REG 2 BOX ee HSB3S3801F HSB333801F HSB4S3801F lt EN HOLMAN 2 BOX HSB2S3813F HSB3S813F HSB333813F HSB4S3813F Due to continual product improvement specifications may be subject to change without notice RD40 BOX LTERNATIVE BACKEAD ONNECTIONS 4 HAMMER SPECIFICATIONS
8. r we strongly recommend that the hammer especially if stored for any long periods of time should be stripped cleaned inspected and re oiled 11 TROUBLESHOOTING PROBLEM PROBABLE CAUSE REMEDY INOPERATIVE DRILL increase to operational value SLOW PENETRATION lube needle value LOW RETURN AIR VELOCITY through metering plug or remove plug altogether SPASMODIC OPERATION A A For the full range of genuine Bulroc BR hammers button bits and parts contact Bulroc sales today on 44 0 1246 544700 or email info bulroc com Technical brochures and copies of this manual can be downloaded from our company website www bulroc com MADE IN BRITAIN This Page Left Intentionally Blank 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 BRSERIES 29 08 14
9. ring shoulder O ad i Lu Z 13 Valve Assembly The BR1 BR2 BR3 BR33 amp BR4 models employ Disc Valves Clean the Bevelled Valve Housing the Valve Chest and gt Centralising Plug Insert the Plug in its Mi a VALVE SEAT position in the Valve Chest Clean the Disc Valve and oil it with a light oil Locate a it on the Centralising Plug Join the Valve Chest and Valve Housing with the Disc Valve in place DISC VALVE AIR METERING O PLUG amp VALVE 2 CENTRALISER VALVE CHEST 9 REASSEMBLY PROCEDURE THREAD PROTECTOR BACKHEAD 14 Oil the guide on the bevelled valve housing and the smaller diameter of the Valve Seat itself Insert the beveled valve housing into the end of the Cylinder 15 Smear oil on all outside surfaces of Cylinder bevelled valve housing and bearing 16 Introduce the assembly to the wearsleeve The assemblies for BR1 to BRA will slide comfortably home with the Bearing butting upto the Split Spacer 17 If a Backhead Spacer is to be fitted it should be fitted at this i poi stage 2 18 Oil the Check Valve and fit into bore of Valve Chest Push the Check CHECK Valve home and check that it does not stick by rotating and fully depressing it to the bottom of the bore in the Valve Chest VALVE 19 Fita seal to the groove at the base of the Backhead threads grease the threads and screw the Backhead fully home 20 Fit the plastic thread protector over th
10. the Wearsleeve This is necessary to ensure that all the internal components are held securely in place This gap will gradually reduce during drilling and it is very important to check this gap approximately every 100 hours of operation When this gap reduces to 1 6mm 0 06 it is necessary to install the Backhead spacer This is to be positioned between the Valve Chest and the Backhead To install the Backhead spacer loosen off the Chuck then remove the Backhead and place the Spacer on the Valve Chest Now torque up the Backhead and tighten up the Chuck You should now find thatthe Chuck gap has been restored to its original width CHUCK WEARSLEEVE 3 2mm 0 125 BR BR2 BR3 BR33 BR4 2 Component checks on dismantled hammer With the hammer dismantled into its component parts check for lubrication starvation The Piston especially will show heat cracks and eventually larger cracks if the hammer has been under lubricated or used with an incorrect type of lubricating oil See page 11 for details 3 Selective replacement When the tolerance between the Piston Stem and the Bearing exceeds the values given in the table below it is necessary to replace the Bearing Similarly when the tolerance between the Piston bore and the Valve Seat probe this is the protuberance over which the Piston head operates exceeds the limit the Valve Seat should be replaced WEAR TOLERANCES When the Piston and the Inner Cylinder
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