Hyper 31/41/51/81 Hammer
Contents
1. Eg Hyper 41 operating at 300psi 427cfm 1 42 pints per hour 21bar 12 1 0 8 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 pint 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 a 30 grade oil should be used If the ambient temperature is greater than 25 degree centigrade use a 50 grade oil Bulroc supply their own recommended rock drill oil and this is detailed below together with other brands of suitable oils MAKE TYPE 30 GRADE TYPE 50 GRADE BULROC 1220 T320 12 HYPER HAMMER STORAGE 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 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 horizontally2. HYPER SERIES MAINTENANCE OPERATING AND SERVICE MANUAL HYPER 31 41 51 63 amp 81 MODELS Bulroc UK Limited All Rights Reserved Due to our policy of continued product development product specification may be subject to change E amp O E Congratulations On purchasing a Bulroc DTH Hyper Hammer Go drill it STRIPPING DISMANTLING HYPER HAMMERS CHECKING FOR WEAR amp DAMAGE 7 8 REBUILDING ASSEMBLY OF HYPER HAMMERS BUTTON BIT FOOT VALVES CORRECT DIAMETERS AND PROTRUSION HEIGHTS RECOMMENDED LUBRICANTS AND LUBRICATION RATES STORAGE PROCEDURES 004200 TROUBLESHOOTING BREAKOUT WASHERS 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 hammers 1 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 BULROC Hyper hammers are designed to give optimum performance with the minimum consumption of compressed air If however particular deep hole application require extra air flushing This can be achieved by drilling through the soft alloy plug in the piston ALWAYS
3. 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 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 end face from where they can be removed by hand COMPRESSION BACKHEAD 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
4. THINK SAFETY FIRST This manual is published by and copyright 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 enquiries call Bulroc 44 0 1246 544700 or Skype BULROCUKSALES HYPER HAMMERS BACKHEAD BACKHEAD BREAKOUT WASHER DIVERTOR PISTON RETAINING RING COMPRESSION BIT RETAINER O RING BIT RETAINING RING CONTROL TUBE nd 577 7757 UBE BUFFER G e BUTTON HOLDER k sss BIT s PART NUMBERS DESCRIPTION 31 41 HYPER51 63 81 1 7 138 6 4138 8 5138 7 HSH633803M__ HSH8138 2 BACKHEAD O RING IPBOROI 2 8 5114 1 6114 HSH8114 3 CHECK VALVE __ 0 1 __ 02 _ 0 IPRCV04 IPRCV05 4 CHECK VALVE SPRING 501 IPRCVS022 IPRCVSO3 IPRCVS04 IPRCVS05 5 DVERTER HSH320 6 4 202 HSH5120 HSHS6120 HSH8120 6 COMPRESSION RING 3128 5 4128 5 5128 5 6128 HSH8128 7 _JTUBEHOLDER 131 HSH4131_ HSH5131__ HSH6 131 HSH8131 8 TUBE BUFFERS 7 129 4
5. Wearsleeve Screw the Chuck fully in until there is no gap between the Wearsleeve and the Chuck Release Washer 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 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 the Backhead and coat the threads with a copper based thread grease Screw the Backhead into the Wearsleeve until it is hand tight then measure the gap between the Wearsleeve face and the lock up face on the Backhead This gap should be a minimum of 1 mm 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 using the appropriate Backhead spanner 10 BUTTON BIT FOOTVALVES FOOT VALVE Bulroc Hyper hammers designed to be used with Foot Valves that are to the following specifications INSERTION PROTRUSION FOOT VALVE SHANK TOOL No HEIGHT A DIAMETER B lt To guarantee the diameter and pr
6. amp 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 A 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 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 2 2 993 76 02mm 5 870 149 109mm 7 CHECKING FOR WEAR amp DAMAGE Fig 1 New Piston Face RADIUS A CHAMFER 9 Area to be machineq ig 2 Worn Piston Face During the working life of the hammer the Striking Face on the Piston may beco
7. 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 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 www bulroc com for button bits service kits repair kits and drilling accessories 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 30 04 14
8. 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 removalof the Chuck then it must be done with extreme care to avoid damage toeither 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 the hand grinder with a slitting wheel To remove the Chuck Release Washer a cutmust be made the centre of the washer all the way around it scircumference and completely through the Washer thus transforming the single 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 B CLAMP POSITIONS CLAMPING POSITION CLAMP POSITIONS HAMMER MODEL X DISTANCE FROM WEARSLEEVE END FACE Hype
9. hole flushing air passing through hammer Drill bit exhaust holes blocked SPASMODIC OPERATION Failed or damaged parts Lack of oil Drill bit broken Dirt in drill A CHUCK RELEASE WASHERS W oe oe ll D CHUCK RELEASE WASHERS HYPER 31 0 160 400mm 0 187 4 76mm HYPER 41 0 130 3 30mm 0 250 6 35mm HYPER 63 0 310 7 87mm 0 295 7 49mm HYPER 81 0 150 3 81mm 0 485 12 32mm HAMMER MODEL HYPER 51 0 160 400mm 0 280 7 11mm 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 fom 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 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
10. 129 8 5129 HSH6129 HSH8129 9 _ CONTROLTUBE HSH3130 4130 8 5130 HSH6330 HSH8130 40 PISTON HSH303 4103 8 5103 HSH6103 HSH8103 11 PISTONRETAINNGRING 5 1 HSH43 5 5132 HSH6132 HSH8132 12 RETAINING RING HSH337 HSH43 HSHi3 7 5 6337093 HSH8137 13 BITRETAINING O RING IPBOR01 HSH437A 5 51374 HSH6137A03 5 8137 44 CHUCK RELEASE WASHER HSH3126 HSH426G HSH5126 5 6326 HSH8126 15 CHUCK HSH3135 HSH4135 HSH5135 HSH6335093 HSH8135 16 WEARSLEEVE HSH3100 HSH4100 HSH5100 HSH6300 HSH8100 HEAVY DUTY WEARSLEEVES BACKHEADS AND CHUCKS ARE AVAILABLE ON ALL HYPER HAMMERS THESE ARE RECOMMENDED FOR USE IN PARTICULARLY ABRASIVE DRILLING CONDITIONS THE INTERNAL COMPONENTS ARE IDENTICAL BUT THE 0 D S OF THE WEARSLEEVE BACKHEAD AND CHUCK HAVE BEEN INCREASED NB HEAVY DUTY HYPER 41 MODELS DO NOT USE CHUCK RELEASE WASHERS L Y lt 44 lt L x LLI al gt L N B THE USE OF HEAVY DUTY PARTS LIMITS THE MINIMUM DIAMETER OF HOLE THAT CAN BE DRILLED BY THE HAMMER 4 HYPER HAMMER SPECIFICATIONS OUTSIDE DIAMETER LENGTH BIT EXTENDED LENGTH WITHOUT BIT LENGTH BIT RETRACTED 31 41 51 63 81 CONNECTIONS REG PIN REG PIN REG PIN REG PIN REG PIN STANDARDCHUCK WITHOUT BIT 878mm 990mm 1116mm 1232mm 1409mm B
11. IT EXTENDED 985mm 1109 1168mm 1404mm 1606mm LENGTH 37 55 42 27 47 75 53 54 61 07 954mm 1074mm 1213mm 1360mm 1551mm OF HAMMER 79 2mm 95 2mm 114 3mm 141mm 184 1mm _ 22mm 782mm 920mm 1163mm 1494mm BORE DIAMETER 2 2mm 76 2mm 92 0mm 116 3 149 4mm 4 00 4 25 4 25 4 25 4 00 102mm 108mm 108mm 102mm 11 0 Ib 17 9 Ib 26 8 lb 49 0 Ib 113 3 Ib WEIGHT WITHOUT BIT 24 0 kg 37 0 kg 60kg 96 0 kg 194 0 kg HYPER HAMMER CONVERSIONS Parts Required CONVERSION CHUCK BIT RETAINER PISTON COMPLETE HAMMER TO HYPER HYPER41 HYPER51 HYPER 63 j H 5 H 5 HYPER 81 S MISSION 508 HSH8135045 5 813704 5 810304 BR81H03 QL80 HSH8135108 HSH8137108 HSH8103108 BR81H05 9 AIR CONSUMPTION Air Consumption min 1400 1300 35cmm 1200 1100 30cmm 1000 900 25cmm 800 20cmm 700 600 15cmm 500 400 10cmm 300 200 5 100 Q Q Q Q OL O LO O LO O LO O LO O N LO N O N LO N CN NI NI NI 10bar 15bar 20bar Line Pressure 6 STRIPPING HYPER HAMMER 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 occurs the breakout washer can be ground or drilled out
12. ally 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 Pick up on the replaced Piston and will lead to early failure of this component 9 REBUILDING HYPER HAMMERS Backhead Check Valve Assembly Compression Ring 5 Control Tube Assembly Piston Retaining Ring Chuck Assembly 1 Ensure all the maintenance work outlined in the previous section has been completed 2 Stand the Wearsleeve on the floor Chuck end upwards Insert the Piston Retaining Ring into the bore hammer the ring down until it springs into the groove in 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 NOTE The Hyper 51 Wearsleeve has two piston retaining ring grooves and requires the ring to be fitted into the correct groove for the chuck bit configuration used 350R Bit 15 groove from end face at chuck end QL50 MACH 50 274 groove from end face at chuck end 3 Clamp the Wearsleeve horizontally in 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 Cover the threads with a copper based grease Then lift the whole assembly into the
13. in a dry environment ready for use next time Model Qty UK Pints _Qty in liter s Hyper 31 Ya 0 14 Hyper 41 amp 51 1 2 0 28 Hyper 63 amp 81 0 43 If this procedure is followed then apart from protecting the hammer from corrosion it will protect the parts from premature wear 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 PROBLEM PROBABLE CAUSE REMEDY INOPERATIVE DRILL Drill bit blowholes blocked Dirt inside drill Worn or damaged parts Insufficient lubrication Excessive lubrication Hanging Piston Insufficient air pressure Unblock holes Strip and clean drill Replace damaged parts Check oil level adjust lube needle value Adjust lube needle value Pistion stuck Polish out the score marks Check compressor discharge and increase to operational value Increase discharge pressure 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 Strip and clean Drill or increase hole size through the piston Clean out blockage Overhaul drill Check lubrication Replace bit Strip and clean SLOW PENETRATION Insufficient air pressure Dull drill bit Dirt in drill LOW RETURN AIR VELOCITY Insufficient
14. me 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 CHAMFER B HYPER 31 0 125 0 060 45 8 CHECKING FOR WEAR amp DAMAGE Hammer Minimum A 2 368 60 15mm 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 Hammer _ _ Minimum A Hyper 31 2 94 4 61mm Hyper 41 3 49 88 70mm Diameter A Hyper 51 14 22 107 25mm Hyper 63 5 25 133 54mm Hyper 81 6 76 171 89mm 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 periodic
15. otrusion height are correct it is recommended the correct insertion tool is used INSERTION TOOL PROTRUSION HEIGHT Using Foot Valves which are larger in diameter than the sizes shown will result in premature failure of the Foot Valve Foot Valves which are much smaller in diameter than the sizes shown will reduce the performance of the hammer 11 LUBRICATION The Hyper piston s oscillate at around 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 s whilst they are operating Failure to do so will quickly lead to excessive component wear and if the oil supply is cut of for any reason the pistons 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
16. r 31 4 000 102mm Hyper 41 4 750 121mm Hyper 63 7 750 197mm Hyper 51 5 375 137mm 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 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
Download Pdf Manuals
Related Search