Hyper 81/SD8
Contents
1. HYPER 81 MAINTENANCE OPERATING AND SERVICE MANUAL MADE IN N BRITAIN THE HYPER 81 HAMMER HAMMER COMPONENTS HAMMERPARTSLIST 3 HAMMER SPECIFICATIONS AIR CONSUMPTION MEE STRIPPING DISMANTLING THE HYPER 81 6 CHECKING FOR WEAR amp DAMAGE REBUILDING ASSEMBLY OF THE HYPER 81 9 BUTTON BIT FOOT VALVES CORRECT DIAMETERS AND PROTRUSION HEIGHTS 10 RECOMMENDED LUBRICANTS AND LUBRICATION RATES od STORAGE PROCEDURES 12 TROUBLESHOOTING 13 BREAKOUT WASHERS O A HAMMER CLAMPING POSITIONS B The BULROC range of Hyper down the hole hammers are strong and robust tools of a simple and straight forward design to provid maximum performance with a minimum of maintenance Please Note That contrary to other BULROC hammer models the Hyper series do use bits with Footvalves BULROC Hyper hammers are as standard with Check Valve aa m 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 BULROC Hyper hammers are designed to give optimum performance with the minimum consumption of compressed air If however particular d ep hole application require extra air flushing This can be achieved by drilling through the soft alloy plug in the piston ALWAYS THINK SAFETY FIRST 4 This manual is published by and copyright of Bulroc UK Ltd All Rights Reserved Always2. Pick up they should be removed by using emery cloth WEARSLEEVE MINIMUM A HYPER 81 6 76 171 89mm Using either a micrometer or a vemier 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 Pick 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 HYPER 81 8 Backhead 1 Ensure all the maintenance work outlined in the previous section has been completed 2 Stand the Wearsleeve on the floor Chuck end upwards Check Valve Insert the Piston Retaining Ring into the bore hammer the Assembly ring down until it springs into the groove the Wearsleeve bore It is important to make sure that the Piston Retaining Ring is positioned in the groove correctly Failure to do so will seriously effect hammer performance 3 Clamp the Wearsleeve horizontally a vice taking care not to overtighten the jaws Assemble the Chuck Chuck Release Washer and Bit Retainers around the Bit ensuring the Retainers are fitted with a new O Ring Gre
3. end face from where they can be removed by hand BACKHEAD COMPRESSION O RING CHECK VALVE BUFFER VALVE BACKHEAD 4 Lifting the Chuck end of the Wearsleeve again will allow the Piston to slide to the end face from where it can be removed by hand 5 Unless there is damage to the Piston Retaining Ring it should not be necessary to remove it from the Wearsleeve However if the Retainer is damaged it can be removed by dropping the inverted Piston onto the ring from the Backhead end of the Wearsleeve STRIKING FACE BACKEND END OF WEAKSLEEVE 7 CHECKING FOR WEAR AND DAMAGE Premature wear to internal parts is a result of either PISTON 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 burning both are signs of poor lubrication Using a micrometer measure the diameter and refer to the table below 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
4. examined 2 Secondly using a micrometer measure the diameter of the bore at both ends of the piston and refer to the maximum quoted sizes 3 Examine the striking face Distortion is acceptable proving there are no signs of cracking Burrs and dents can be removed with an emery stone HAMMER MINIMUM A HYPER 81 5 870 149 10mm 7 CHECKING FOR WEAR AND DAMAGE MAINTAINING THE PISTON Fig 1 New Piston Face RADIUS B Fig 3 Area to be machinec Fig 2 Worn Piston Face During the working life of the hammer the Striking Face 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 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 __ B __ 8 CHECKING FOR WEAR AND DAMAGE CONTROL TUBE Examine Control Tube using a micrometer check the diameter has not worn under the specified minimum If there are signs of
5. oil should be increased by 50 When new drill tubes are put into use it is recommended that 1 2 a pint of oil 0 25 be poured into each new tube to give them a good coating of oil and to prevent the 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 Hyper hammers is given below MAKE TYPE 30 GRADE TYPE 50 GRADE BULROC 220 1320 ENERGOL RD E 100 ENERGOL RD E 300 CHEVRON ARIES 100 ARIES 320 SHELL TORCULA 100 TORCULA 320 ESSO EXXON AROX EP 100 EP320 12 HYPER 81 STORAGE PROCEDURE We recommend following the points listed below when removing Down hole hammer from service This will ensure trouble free operation once the hammer starts work again The hammer should be stripped and cleaned and free of all water moisture as possible Bulroc 320 or similar rock drill oil should be poured into backhead see chart below for quantity allowing all parts to be coated throughout the hammer Both ends of the hammer should be then covered to prevent the ingress of dirt etc It should be then laid horizontally in a dry environment ready for use next time Model Qty in UK Pints in liter s Hyper 81 Ya 0 43 this procedure is followed then apart from
6. 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 enquiries call Bulroc on 44 0 1246 544700 or Skype BULROCUKSALES HYPER 81 2 508 Conversion BACKHEAD BACKHEAD PISTON RETAINING RING COMPRESSION RING CONTROL TUBE TUBE BUFFER RETAINING RING CHUCK RELEASE WASHER HOLDER BUTTON BIT 3 HYPER HAMMER 81 COMPONENTS Ref Description Backhead Backhead O Ring Check Valve Check Valve Spring Diverter Compression Ring Tube Holder Tube Buffer 2 Control Tube Piston Piston Retaining Ring Bit Retainer Ring Chuck Chuck Release Washer Wearsleeve Complete Hammer Part Number HSH813804M IPBORO1 05 IPRCVS04 HSH8120 HSH8128 HSH8131 HSH8129 HSH8130 HSH8103045 HSH8132 HSH8137045 HSH6 135045 HSH8126 HSH8100 BR81H03 MADE IN BRITAIN 4 HYPER 81 HAMMER SPECIFICATIONS OUTSIDE DIAMETER za fe 81 STANDARD BACKHEAD 4 1 2 CONNECTIONS CHUCK WITHOUT BIT 1380mm BIT EXTENDED 1550mm BIT RETRACTED 1490mm O OF HAMMER 184 1mm 2 lt BORE DIAMETER 149 4mm E a lt Y PIS
7. TON STROKE 102mm ci E E 113 3 lb 2 WEIGHT WITHOUT 194 0 x Y 5 AIR CONSUMPTION m min CFM 30 25 20 1200 1150 1100 1050 1000 100 150 10 200 15 5 Uy N Z 300 20 350 400 PSI 25 6 STRIPPING THE HYPER 81 HAMMER Brea kout Washer After extensive drilling the chuck might become to tight to loosen on a Bulroc Bench Splitter or the drill rig If this problem occurs the breakout washer can be ground or drilled out which will relieve the pressure and enable the chuck to be removed OO _ _ _ _ _ ______rrr 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 or a hammer splitter The stripping procedure is as follows 1 First remove the Chuck assembly This comprises the Button Bit Chuck Chuck Release Washer and the Bit Retainers 2 With the hammer laid horizontal unscrew the Backhead and remove it from the Wearsleeve The Diverter along with the Check Valve arrangement can now be pulled from the Backhead end 3 The remaining Compression Buffer and Control Tube assembly can best be removed by lifting the Chuck end of the Wearsleeve which will allow the Piston to push the parts up to the
8. ase the bit retainers well to ensure they don t slip Cover the threads with a copper based grease Then lift the whole assembly into the Wearsleeve Screw the Chuck fully in until there is no gap between the Wearsleeve and the Chuck Release Washer Compression Ring Assembly 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 O Piston 5 Assemble the two Control Tube Buffers around the Control Tube and then push the assembly into the Tube Holder Coat the outside of the assembly with rock drill oil and insert it into the Backhead end of the Wearsleeve 6 Slide the Compression Ring on to the Control Tube Assembly 7 Insert the Spring into the Check Valve and then slide the assembly into the Valve Chest Push the whole assembly down onto the Compression Ring 8 Fit a new O Ring to Backhead and coat the threads with a copper based thread grease Screw the Backhead Piston Retaining into the Wearsleeve until it is hand tight then measure the Ring gap between the Wearsleeve face and the lock up face on the Backhead This should be a minimum of 1 if the gap is smaller the ring should be removed and replaced with a new Compression Ring When the gap exceeds 1mm the Backhead should be fully tightened Chuck using the appropriate Backhead spanner Assembly 10 BUTTON BIT FOOT VALVES FOOT VALVE DB B
9. e 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 all other 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 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 the hand grinder with a slitting wheel To remove the Chuck Release Washer a cutmust be made in the centre of the washer all way around it scircumference and completely through the Washer thus transforming the single was
10. her 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 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 B CLAMPING POSITIONS HAMMER MODEL DISTANCE FROM WEARSLEEVE END FACE Hyper 81 7 000 178mm CLAMPING POSITION 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 threaded connec
11. protecting the hammer from corrosion it will protect the parts from premature wear and of course reduce down and eventual repair costs However we strongly recommend that the hammer especially if stored for any long periods of time should be stripped cleaned inspected and re oiled prior use to be sure of smooth drilling 13 TROUBLESHOOTING 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 A CHUCK RELEASE WASHERS AZ CHUCK RELEASE WASHERS HAMMER MODEL D HYPER 81 0 150 3 81mm 0 485 12 32mm 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 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 during th
12. tion 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 15 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 81 24 10 13
13. ulroc Hyper hammers are designed to be used with Foot Valves that are to the following specifications INSERTION PROTRUSION FOOTVALVE SHANK TYPE TOOL No HEIGHT A DIAMETER B HYPER 81 To guarantee the diameter and protrusion height are correct it is recommended the correct insertion tool is used INSERTION TOOL Using Foot Valves which are larger in diameter than the sizes shown will result in premature failure of the Foot Valve PROTRUSION HEIGHT A Foot Valves which are much smaller in diameter than the sizes shown will reduce the performance of the hammer 11 LUBRICATION Inadequate supply of the correct type of oil is a major contributor to excessive com ponent wear and consequently a rapid fall off in performance An air line lubricati on should be installed preferably on the drill rig This should be of suffi 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 Hyper hammer will require 1 3 rd of a pint per 100 CFM through the hammer 0 07 Itr per 1 0 M min per hour e g Hyper 81 operating at 250 psi 800 cfm 2 6 pints per hour Bar 22 7 M min 1 6 Itr per hour When drilling with foam or water the amount of lubricating
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