Alldrill Drilling Manual PDF

60 Paramount Drive, Wangara,
Western Australia, 6065

Phone: +61 8 9302 5317
Fax: +61 8 9302 3715
Email: sales@airdrillhammersandbits.com.au
2
Section 1 Page Number
ADHB Reverse Circulation Hammers
AD108RC 4
AD116RC 5
AD117RC 6
AD124RC 7
Section 2
ADHB Reverse Circulation Percussion Bits
AD108RC 8
AD116RC 8
AD117RC 8
AD124RC 8
Section 3
Reverse Circulation Hammer operation and Maintenance Information
Preface 11
Safety 12
Hammer Operation and Maintenance
Lubrication 13
Drilling Operation 14
Drilling in Water 15
Bit Rotation 16
Percussion Drill Bit 16
Breaking Threads 17
Air Consumption 18
Elevation Chart 18
Hammer Disassemble 19
Hammer Re assemble 20 - 24
Hammer Storage 25
Thread Make Up Torque 25
Hammer Trouble Shooting 27 - 28
Understanding Reverse Circulation Hammers 29 - 30
Reverse Circulation Hammer Operating Cycles 31
Reverse Circulation Schematic 32
3
Phone: +61 8 9302 5317
Fax: +61 8 9302 3715
Email: hammers&bits@airdrill.com.au
Document Type: Spare Parts List for AD108RC

Hammer Model: AD108RC (Hammer OD 108mm) Metzke 4‖ Box
Will suit TRC 542 Reverse Circulation DTH Hammer
Item No Description Part No Weight (kg) Qty
1 CIRCLIP 5108110 0.03 1
2 AIR SCREEN 5108620 0.02 1

3 ADAPTOR NOZZLE 5108600 0.60 1
4 ADAPTOR NOZZLE Ó RING 5108610 0.02 1
5 CHECK VALVE SEAL 5108915 0.02 1
6 CHECKVALVE 5108900 0.40 1

7 C/VALVE SPRING 5108910 0.10 1
8 I/TUBE Ó RINGS 542/3 0.02 5
9 INNER TUBE 5108505 HT 3.50 1

10 TOP CYLINDER TOP ****
5108700 7.50 1
11 TOP CYLINDER BOTTOM ****
12 TOP CYLINDER ÓRING 5108710 0.02 1
13 PISTON 5108200 12.00 1
14 PISTON CASE 5108100 18.50 1
15 BEARING BUSH 5108300 2.50 1
16 BEARING BUSH Ó‘RING 5108310 0.02 2
17 PISTON RETAINER RING 5108201 0.02 1
18 BIT RINGS 5108800 0.30 1

19 BIT RING Ó RING 5108810 0.02 1
20 DRIVE SUB 5108400 3.0 1

‗O‘ RING KIT 5108120
Complete Hammer 5108000 56.00
Percussion Bits
**** Top Cylinder Comes Assembled
121mm (4-3/4‖) - 130mm (5-1/8‖)
Hammer Information
Thread Make Up Torque Thrust on Hammer Tolerances Spanner Flats
1406 - 1632 kg force Minimum 1056 kg Piston to Piston Case Clearance 0.3mm 98.5mm
Maximum 2794 kg Drill Bit Collar & Drive Sub I.D 0.5 mm
Percussion Bit Sizes
Diameter Weight Face Design Buttons
121mm 9kg Concave Hemi
4
Phone: +61 8 9302 5317
Fax: +61 8 9302 3715

Hammer Model: AD116RC (Hammer OD 116mm) Metzke 4‖Box
Will Suit TRC 543 Reverse Circulation DTH Hammer
1 CIRCLIP 5108110 0.03 1
2 AIR SCREEN 5108620 0.02 1
6 CHECKVALVE 5108900 0.40 1
7 C/VALVE SPRING 5108910 0.10 1
8 I/TUBE Ó RINGS 542/3 0.02 5
9 INNER TUBE 5108505 HT 2.50 1

5116700 8.00 1
13 PISTON 5108200 12.00 1
14 PISTON CASE 5116100 20.00 1
15 BEARING BUSH 5108300 2.50 1
18 BIT RINGS 5108800 0.30 1

19 BIT RING Ó RING 5108810 0.02 1
20 DRIVE SUB 5108400 3.00 1
Complete Hammer 5108000 58.00
Percussion Bits
121mm (4-3/4‖) - 130mm (5-1/8‖)
Hammer Information
1406 - 1632 kg force Minimum 1056 kg Piston to Piston Case Clearance 0.3mm 98.5mm
5
Phone: +61 8 9302 5317
Fax: +61 8 9302 3715

Hammer Model: AD117RC (Hammer OD 117mm) Metzke 4-1/2‖ Box
1 CIRCLIP 5117110 0.05 1
2 AIR SCREEN 5117620 0.02 1
6 CHECKVALVE 5117900 0.60 1

7 C/VALVE SPRING 5117910 0.10 1
8 I/TUBE Ó RINGS 545/7 0.02 4
9 INNER TUBE 5117505 HT 5.00 1

5117700 8.00 1
13 PISTON 5117200 14.00 1
14 PISTON CASE 5117100 18.00 1
15 BEARING BUSH 5117300 2.500 1

18 BIT RINGS 5117800 0.22 1

19 BIT RING Ó RING 5108810 0.02 1
20 DRIVE SUB 5117400 3.00 1

Complete Hammer 5117000 62
Percussion Bits
127mm (5‖) - 140mm (5-1/2‖)
Hammer Information
2267 - 2449 kg force Minimum 1329 kg Piston to Piston Case Clearance 0.3mm 101.6 mm
127mm 9.5kg Concave Hemi
6
Phone: +61 8 9302 5317
Fax: +61 8 9302 3715

Hammer Model: AD124RC (Hammer OD 124mm) Metzke 4-1/2‖ Box
1 CIRCLIP 5117110 0.05 1
2 AIR SCREEN 5117620 0.02 1
6 CHECKVALVE 5117900 0.60 1
7 C/VALVE SPRING 5117910 0.10 1
8 I/TUBE Ó RINGS 545/7 0.01 4
9 INNER TUBE 5117505 HT 5.00 1

5124700 11.00 1
13 PISTON 5124200 16.00 1
14 PISTON CASE 5124100 19.00 1
15 BEARING BUSH 5124300 3.00 1
18 BIT RINGS 5124800 0.25 1
19 BIT RING Ó RING 5108810 0.01 1
20 DRIVE SUB 5124400 3.50 1
Complete Hammer 5124000 67
Percussion Bits **** Top Cylinder Comes Assembled

133mm(5-1/4‖) - 146mm (5-3/4‖)
Hammer Information
2267 - 2449 kg force Minimum 1329 kg Piston to Piston Case Clearance 0.3mm 101.6 mm
127mm 9.5kg Concave Hemi
7
REVERSE CIRCULATION PERCUSSION BIT
Hammer Model Size Part Number Gauge Carbides Face Carbides Weight
mm Inches Kg Lbs
5108/5116 RC Reverse Circulation
120 4-3/4" B5108-120RC 8 x 9/16" 8 x 1/2" 11.3 25

124 4-7/8" B5108-124RC 8 x 9/16" 8 x 1/2" 11.5 25.4
127 5" B5108-127RC 8 x 9/16" 8 x 9/16" 11.8 26.1
130 5-1/8" B5108-130RC 8 x 5/8" 8 x 9/16" 12 26.5
133 5-1/4" B5108-133RC 8 x 5/8" 8 x 9/16" 12.2 26.9
137 5-3/8" B5108-133RC 8 x 5/8" 8 x 9/16" 12.4 27.4
Collaring Bit
152 6" B5108-152RC 8 x 5/8" 9 x 5/8" 16.5 36.5
165 6-1/2" B5108-165RC 8 x 5/8" 10 x 5/8" 17.4 38.5
178 7" B5108-178RC 8 x 5/8" 10 x 5/8" 18.4 40.7
191 7-1/2" B5108-191RC 8 x 5/8" 10 x 5/8" 19 42
5117 RC Reverse Circulation
124 4-7/8" B5117-124RC 8 x 9/16" 8 x 1/2" 11.8 26.1

127 5" B5117-127RC 8 x 9/16" 8 x 9/16" 12 26.5
130 5-1/8" B5117-130RC 8 x 9/16" 8 x 9/16" 12.2 26.9
133 5-1/4" B5117-133RC 8 x 5/8" 8 x 9/16" 12.2 26.9
4 x 5/8" & 4 x
137 5-3/8" B5117-137RC 8 x 5/8" 9/16" 12.4 27.4
4 x 5/8" & 4 x
140 5-1/2" B5117-140RC 8 x 5/8" 9/16" 12.5 27.6
Collaring Bit
152 6" B5117-152RC 8 x 5/8" 9 x 5/8" 16.6 36.7
165 6-1/2" B5117-165RC 8 x 5/8" 10 x 5/8" 17.7 39.1
171 6-3/4" B5117-171RC 8 x 5/8" 10 x 5/8" 18.2 40.2
178 7" B5117-178RC 8 x 5/8" 10 x 5/8" 18.6 41.1
191 7-1/2" B5117-191RC 8 x 5/8" 10 x 5/8" 19.3 42.7
5124 RC Reverse Circulation
4 x 5/8" & 4 x
137 5-3/8" B5124-137RC 8 x 5/8" 9/16" 15 33.2
4 x 5/8" & 5 x
140 5-1/2" B5124-140RC 8 x 5/8" 9/16" 15.3 33.8
4 x 5/8" & 5 x
143 5-5/8‖ B5124-143RC 8 x 5/8" 9/16" 15.3 33.8
4 x 5/8" & 6 x
146 5-3/4" B5124-146RC 8 x 5/8" 9/16" 15.7 34.7
Collaring Bit
178 7" B5124-178RC 8 x 5/8" 10 x 5/8" 21.9 48.4
191 7-1/2‖ B5124-191RC 8 x 5/8" 10 x 5/8" 23 50.6

8
Reverse Circulation Hammer Operation
&
Maintenance Information
9
10
Preface
The Airdrill Hammers & Bits (ADHB) Reverse Circulation Down the Hole (DTH)
Hammers are a precision machine, with very close tolerances designed to provide
optimum Drilling results with minimal air wastage. As such these precision ma-
chines require proper maintenance and correct operation to achieve the performance
and expectations demanded by drillers worldwide.
The following pages contain information for safe drilling operations and correct
maintenance and storage for ADHB Reverse Circulation DTH Hammers and Percus-
sion Bits.
Please read this information before use, to ensure correct and safe operation. With
correct use and care your Airdrill Hammers & Bits Reverse Circulation Hammer
will provide you a long service life and exceptional performance.
11
Safety
As with all mechanical machines the safe operation of the Reverse Circulation DTH
Hammer is the first priority in ensuring efficient drilling. All local government and
Site regulations should be followed in conjunction with your employees Occupa-
tional Health and Safety procedures and policies.
 DTH Hammers are heavy and as such approved lifting equipment and proce-
dures should always be followed when moving hammers.
 Due to the design of the DTH Hammer drilling is very noisy and all safeguards
should be taken to protect against hearing damage. Approved Earmuffs and or
earplugs should always be worn during the operation of DTH Hammers.
 Eye protection should also be employed throughout the Drilling Operation
 Approved Safety Helmets should also be worn at all times when on a Drilling
Site.
 As DTH Drilling uses the rapid rotation of Drill Strings all clothing should be
tucked in and kept well clear of rotating parts.
 Keep hands and fingers well clear at all times, with special care taken when re-
moving and installing Percussion Bits.
12
Hammer Operation and Maintenance
Lubrication.
Lubrication is the single most important operation to achieve maximum hammer

performance and life. Lubrication is vital to minimize part wear, corrosion and pre-
mature failure of your DTH Hammer. Airdrill Hammers and bits recommends the
use of a reputable Rock Drill Oil. The following chart shows different brands and
specifications of Rock Drill Oil. Airdrill Hammers and Bits recommends the use of
environmentally safe Rock Drill oils and greases such as Matex Drilling RDO 302
ES (Rock Oil) and Thread Compound (ES Thread Compound). Rock Drill Oils
are designed to provide extreme pressure capabilities, rust and corrosion protection,
antifoam properties, adherence to internal tool surfaces, and good emulsion charac-
teristics.
Oil Grease
Manufacturer Product Name Product Name Thread ‗O‘ Ring
Operating Temp up Operating Temp
to 32° above 32°
Matex RDO 302 ES RDO 302 ES ES Thread Com-
pound
Valvoline ROCK DRILL OIL Rock Drill Oil
Shell TORCULA 100 Tonna T220 HP Thread Grease
ExxonMobile APOX EP100 EP320 Mobile Temp
SHC460
Chevron VISTAC ISO100 ISO 320
Caltex ARIES 100 ARIES 320 Threadtex
Castrol RD OIL 100 Magna CF220 Castrol Lyt Red Rubber Grease
As with all lubrication too much or not enough lubrication will both affect the opera-
tion of your DTH Hammer. The following chart shows the recommended Litres per
hour at selected CFM. Pouring oil down the rod line when each new rod is added
may cause the hammer to hydraulically lock causing drilling down Time. ADHB
recommends the use of a Hammer lubricator.
13
Effects of incorrect Hammer Lubrication
The major source of damage to DTH hammers (Excluding wear and tear) is incor-
rect lubrication. DTH hammers operate in some of the worst environmental condi-
tions encountering extreme heat, pH levels, salinity and a wide variety of rock for-
mations containing acidic and basic chemical compositions.
All of the above conditions can lead to pitting and hydrogen embrittlement of the
metal components causing premature failure of the hammer components.
Correct water injection utilizing clean water and correct oil injection rates will help
to minimize the corrosive effects of the chemicals encountered.
To minimize damage and premature wear, it is highly recommended that drillers

should service the hammer immediately before reusing or storing the hammer.
Drilling Operation
Before commencing drilling ensure all the hammer threads are correctly tightened.
The following table shows the correct torque that should be applied when tightening
the hammer. Incorrect make up torque can result in thread damage. When threads are
not tightened prior to drilling the percussion of the hammer combined with the rota-
tion of the drill string results in over tightening of the DTH hammer. This can dam-
age the threads and also lock the hammer preventing bit change and hammer mainte-
nance.
Thread Torque
Hammer AD108RC AD116RC AD117 AD124
AD131
Torque 3100-2600 ft-lbs 5000-5400 ft-lbs 8100-8500 ft-lbs
The Reverse Circulation DTH Hammer will begin to operate as soon as the air sup-
ply is turned on and the percussion bit is firmly pressed into the rock face. The
weight or thrust required to efficiently operate the hammer can be obtained from the
weight on hammer chart (Page 15). The effect of the drill rods weight on the ham-
mer should also be taken into account when drilling. Insufficient thrust pressure will
make the hammer drill erratically resulting in premature wear to the percussion bit
and drive sub splines with damage to threads also likely to occur.
Sufficient thrust must be applied to the hammer to achieve optimum drilling rates.
ADHB Reverse Circulation hammers produce significant energy which needs to be
accommodated for when applying thrust to the hammer. The following table shows
the required thrust.
14
As the hole gets deeper less thrust will be required as the drill string gets heavier.
Eventually hold back will be required to prevent excessive weight on the percussion
bit.
Minimum Total Thrust on Hammer
Hammer Model 10.5kg/cm2 14.1 kg/cm2 17.5 kg/cm2 21.1 kg/cm2 24.6 kg/cm2
150 psi 200 psi 250 psi 300 psi 350 psi
AD108RC 566kg 754kg 1023kg 1226kg 1430kg
AD116RC 1245 lbs 1658lbs 2250lbs 2698lbs 3146lbs
AD117RC 869kg 1155kg 1452kg 1732kg 2024kg
1912lbs 2541lbs 3194lbs 3811lbs 4452lbs
AD124RC 1270kg 1694kg 2134kg 2431kg 2970kg
Lifting the hammer off the rock face will result in the percussion bit sliding out of
the hammer and the percussive action of the hammer will cease. During drilling this
can be used to introduce extra air to the hole to help flush the hole of cutting or flu-
ids. For efficient hole clearing adequate air velocity must be obtained. An annular
velocity of 3000 feet-per-minute (fpm) is required. Use the following formula to
check the velocity.
(183) x (supply CFM)
Velocity (fpm) = ———————————–——
(bit size)2 - (drill pipe size)2
The above formula is in imperial.
Drilling in Water
DTH hammers are equipped with a check valve to assist when drilling under water.
The check valve closes when the air supply is turned off, this maintains the air pres-
sure in the hammer and prevents water from entering the hammer. Drilling under
water increase the back pressure which decreases the efficiency of the hammer thus
slowing the penetration rate. A point can be reached when the up hole velocity of
the air is insufficient to overcome the water head and piston will stop, to overcome
this extra air must be utilized.
Back pressure in water is determined by the amount of head of water above the ham-
mer. The back pressure can be calculated by using the following.
1 metre Head = 0.1kg/cm2

1 kg/cm2 = 10 metres of Head
1 ft head = 0.434 psi
1 psi = 2.3ft of Head
After a pipe change in a hole with 200m of water the operator will need 200m x 0.1
kg/cm2 (20 kg/cm2 ) of air supply to unload the water from the hole. Once the water
starts to flow from the hole the pressure required will drop.
15
The hammer will commence to operate as sufficient pressure drop is obtained across
the hammer. Efficient hammer operation will not commence until the pressure drop
across the hammer equals 150psi.
Salt water
During many drilling operations salt water is encountered, this can cause premature
corrosion and wear. When drilling in high salinity levels extra oil should be added to
the drill string between shifts, with the hammer being left under the water level to
avoid exposure to air between shifts.
Bit Rotation
The ―RPM‖ of the drill string is important to achieve good percussion bit life and
good penetration rates, over rotating can cause significant percussion bit damage
whilst under rotation will affect the chip size of the sample and also penetration
rates. When initially collaring a bit hole a rotation speed of between 40-50 rpm is
recommended. Upon reaching the bed rock the following formula can be used as a
starting point to determine the rpm required.
RPM = 154
bit size (in inches)
Percussion Drill Bit
The Percussion Drill Bit is what carries the piston energy to the rock face, therefore
the condition of the bit cutting face should be well maintained. As the bit accumu-
lates drill time the buttons and the steel will start to show a wear pattern. The pattern
and rate of wear will depend greatly on the geological formation being drilled.
In soft formations the buttons on the drill bit may form a ―snakeskin‖ effect on
the surface, these surface cracks must be ground off to prevent bit failure. In hard
formations where the bit wears quickly ―flats‖ will be formed on the buttons. These
flats should be ground away before they reach half the diameter of the button. Some
formations wear away the steel of the percussion bit leaving the button exposed. The
button must be ground down to prevent button failure. The following table indicates
the recommended height of button bit exposed above the steel of the percussion bit.
Percussion Bit Face Holes and Face Relief Slots
As percussion bits wear the relief slots can be worn away and the face holes can be-
come restricted. Both of these should be ground to ensure efficient bottom hole
clearing and prevent excessive back pressure across the hammer.
16
Button Diameter Height of exposure
mm Inches mm Inches
11 7/16 6 1/4
12.5 1/2 7 9/32
14.5 9/16 8 5/16
15.8 5/8 9 3/8
19 3/7 13 1/2
When changing Percussion Bits before the hole is completed ensure the diameter of
the new percussion bit is less than that of the original to prevent probable loss of
Gauge buttons when going back down the hole.
Breaking threads loose to change Percussion Bits
When breaking the Drive Sub loose to change Percussion bits follow these guide-
lines.
 Keep hands well clear of the bottom of the hammer. Only grip the Drive
Sub and the Percussion Bit from the sides as fingers can be jammed if
anything falls.
 Always use the hydraulic breakout on the Drill Rig. If this is not available
use a wrap around wrench to prevent crushing of the Piston Case
 Always use good sharp jaws in the breakout as the Piston Case is hard-
ened and only good quality jaws will be able to grip the Piston Case.
 Do not heat the hammer, this may cause cracking of the piston case.
Air Consumption
Air Pressure, volume and hole cleaning
ADHB Reverse Circulation Hammers require adequate high pressure air to perform
correctly. Check the Air pressure chart for your hammer on each Hammer page.
17
Effect of Elevation
Elevation above sea level affects the compressor output. As elevation increases the
compressors volume output decreases. Use the table below to determine the volu-
metric loss.
Elevation Correction Factor

Metre Elevation Feet Elevation Correction Factor
1219 4000 0.86
1524 5000 0.82
1828 6000 0.79
2133 7000 0.76
2438 8000 0.73
2743 9000 0.70
3048 10000 0.68
3352 11000 0.65
3657 12000 0.63
3962 13000 0.61
4266 14000 0.59
4571 15000 0.57
18
Hammer Disassembly
If possible, break the thread joints on the Drill Rig, otherwise use a hydraulic break-
out bench.
Disassemble the hammer with the hammer lying horizontal if possible
1. Remove the Circlip that holds the Adaptor Nozzle.
2. Remove the Adaptor Nozzle and the Inner Tube Together.
3. Remove the Drive Sub, Percussion Bit and Bit Retainer Rings.
4. Push the Piston Bearing Bush up the hammer to clear the Piston Retainer Ring.
5. Remove the Piston Retaining Ring. A small tool with a pointed end can be used
to pry the retaining ring from the groove. Slide the tool into the relief groove
and flick the retainer ring into the piston case. Care should be taken not to
scratch the piston Case.
6. Slide the Piston Bearing Bush out of the hammer.
7. Slide the Piston out of the bottom end of the hammer.
8. Unscrew the Top Cylinder from the Piston case.
9. By turning the Top Cylinder upside down the Check Valve and spring should
fall out.
Wash all of the components with a cleaning solvent and immediately dry with high
pressure air. Immediately coat all components with lubricant to prevent oxidization
as surface damage may have occurred during drilling allowing oxidization to occur
quickly.
19
Hammer Re-assembly
To ensure optimum performance of your Reverse Circulation DTH Hammer it is es-

sential to service the hammer regularly.
Routinely replacing ‘O‘Rings, check valve seals and springs and bearing bush seals
is good practice and will ensure your hammer does not lose air unnecessarily.
When re-assembling your hammer ensure all of the components are coated with
Rock Drill Oil. Take particular care to adequately lubricate the internal diameter of
the piston case and the piston.
For safety and ease of installation the piston case should be horizontal when install-
ing the piston. Once the Piston, piston retainer ring bearing bush and drive sub are
correctly installed the hammer can be stood vertically for the installation of the re-
maining components
Piston Case
Ensure the internal diameter of the piston case is kept well lubricated. Remove any
pick up marks or burrs with light hand sanding. These imperfections mainly occur
due to the introduction of foreign material during the drilling process.
The piston case is heat treated and as such never apply heat as this may cause crack-
ing or distortion. When tightening the piston case do not put the chain wrench over
the threaded area as this may cause distortion or cracking.
Piston
Install the piston into the hammer with the smaller diameter facing the drive sub end
of the piston case. Before installation lubricate the piston internally and externally
with Rock Drill Oil. Top Cylinder End
Once installed ensure the piston Figure 1
slides freely in the bore of the pis-

ton case. Strike Face
Bearing Bush.
Prior to installation locate the

‗O‘Rings onto the bearing bush ensuring that rock drill oil is adequately coated ex-
ternally and internally.
20
Install the bearing bush with the larger di- Top Cylinder End
ameter facing the drive sub end of the pis- Figure 2
ton case. Push the bearing bush up to the
piston retainer ring.
Please note the bearing bush can only be installed in one di-
rection for the hammer to operate. The Top Cylinder must be
towards the Top Cylinder
‗O‘Rings Drive Sub End

Piston retainer Ring.
Slide the piston past the retainer groove and install the piston retainer Ring. It is
easiest to insert the retainer ring with the split facing towards the bottom of the pis-
ton case. A thin steel rod with a 90° hook at one end will assist in the locating of the
retainer into the groove
Bit Retainer Rings
If the hammer is to be stored locate the ‗O‘Ring onto the 2 piece Bit retainer rings
and slid into the piston case until bedded up against the bottom of the bearing bush.
If the hammer is going into service then slide the drive sub onto the Percussion bit
with the bit retainer rings fitted on top of the drive sub. (See Figure 4)
Drive Sub Thread
Drive Sub
Coat the Drive Sub threads with no-gall tool joint lubri-
cant, zinc based or equivalent. If hammer is going into
service then install drive sub with percussion bit. If the
Figure 3
hammer is to be stored, seal the drive sub on the bottom
end and thread into piston case.
Figure 4
Assembled Reverse Circulation Per-

cussion Bit with Bit Retainer
1
Rings and Drive Sub.
1. Percussion Bit 2
2. Bit Retainer Rings 3

3. Drive Sub
1
21
Top Sub
Coat the Top sub threads with no-gall tool joint lubricant, zinc based or equivalent.
Avoid excess grease as this can be introduced into the hammer and block airways or
internal air ports..
Prior to installation lightly coat the internal diameter and ported section of the Top
Cylinder with Rock Drill Oil.
Slowly slide the Top cylinder into the piston case being careful not to damage the
piston or piston case during installation. Hand Tighten the thread.
Top Chamber Ports
Top Cylinder ‗O‘Ring
Figure 5
Check Valve
Lubricate the check valve and the spring with rock drill oil. Ensure the
Check Valve seal is installed on the internal diameter of the check
valve. Drop the check valve spring into the Top cylinder ensuring it is
sitting squarely. Drop the Check valve down onto the spring ensuring it
also sits squarely. Figure 6
Adaptor Nozzle.
Apply a light coating of Rock drill oil to the Adaptor Nozzle.

Add the ‗O‘ Ring to the external diameter of the adaptor Noz-
zle. Push the adaptor nozzle down onto the check valve push-
ing the check valve down. Continue to push until the Circlip
groove in the Top cylinder is exposed. While holding down the
adaptor nozzle install the circlip with circlip pliers. Figure 7
22
Order of Assembly of Check Valve Assembly.
1. Check Valve Spring
2. Check Valve
3. Check Valve Seal (Install into check valve first)
4. Adaptor Nozzle
5. Adaptor Nozzle ‗O‘Ring (Installed prior to Assembly)
6. Air Screen
7. Circlip
7
6
5
4 Figure 8
3
2
Inner tube.
Apply a light coating of Rock Drill oil to the entire length of the externall diameter
of the inner tube. The internal diameter does not require any lubrication. Install the
‘O‘Rings on the Inner Tube. Push the Inner tube down into the Hammer through the
Adaptor nozzle. Continue to push the inner tube until the inner tube sits flush with
the adaptor Nozzle.
During Drilling the Inner tube should be checked regularly for wear to prevent inter-
nal contamination of the hammer with Rock Sample. The wear indicator is the short-
est length the inner tube should wear to.
‗O‘Rings
Wear Indicator
Piston Seal Diameter
Figure 9
23
Hammer Storage
Short term Storage (1 or 2 weeks)
1. Blow the hammer clear of all water while still on the Drill Rig
2. Pour 1 litre of Rock Drill Oil into the Hammer
3. Turn the Air on and cycle the hammer against a block of wood for 10 seconds.
This will lubricate the internal components.
4. Remove the hammer from the Drill Rig and cap the Top Sub end of the Ham-
mer
Long term Storage (more than 3 weeks)
Completely dismantle the hammer and follow the hammer reassembly direction of
this manual. Store the hammer with both ends capped in a dry place, with the ham-
mer in a horizontal position.
Before re-starting after long periods of inactivity, disassemble the hammer and in-
spect all internal components for rust. Use a light emery to remove any oxidization ,
completely wash and dry the hammer and re-assemble following the directions in
this manual.
Thread Make Up Torque
Correct thread Make up torque is essential to prevent over tightening of the hammer.
Over tightening the threads can cause the threads to crack or make it impossible to
undo the threads to replace the percussion bit or service the hammer.
The following table has the correct Torque that should be applied to the hammer
threads.
Hammer Model Ft-lb

AD108RC 3100-3600
AD116RC 3100-3600
AD117RC 5000-5400
AD124RC 6500-7000
24
Hammer Trouble Shooting
Problem Probable Fault Corrective Action
Hammer will not start Low Pressure Increase Compressor discharge pressure, use
Booster Compressor
Incorrect Hammer Assembly Check Hammer Assembly
Dirty Hammer Clean Hammer
Damaged Components Overhaul Hammer
Intermittent Operation Worn Components, faulty Valve, Overhaul Hammer
Damaged Drill Bit or Drive Sub
Dirty Hammer Clean Hammer
Too much down pressure Set the down pressure until the rotation starts to
bind, then back off the down pressure until the
hammer rotates smoothly
Rotation speed too slow Percussion Drill bit rotational speed of between
300mm and 400mm per second. Place chalk mark
on drill string and check the advance vs the rota-
tion. If the Drill string advance more than 12mm
per rotation increase the rotation until the advance
is 10mm per rotation.
DTH Hammer will not Plugged Bit or Inner Tube Lift hammer off bottom and blow air down. If
stop Hammering still continuous hammer inspect inner tube and
Percussion bit for blockages.
Worn Piston Measure the Large diameter of the piston, if air
leaks past this it can cause the hammer to fire.
Too much water injection Reduce water injection
Check Valve not sealing Broken Check valve spring Replace check valve spring
Damaged check valve Check urethane face and internal seal, replace if
worn or damaged
Low penetration/ Low Worn internal components Inspect piston, piston case and inner tube. Meas-
Pressure ure diameters and replace if clearance is greater
than 1/2mm between bearing surfaces.
Lack of lubrication Ensure an oil film is coming from bit splines.
(place cardboard under hammer to check)
Thread Damage to Top Hammer not correctly torque up prior Refer Make up torque table (Page 24)
Cylinder or Drive Sub to Drilling
Incorrect breakout location. Refer breakout location.
Piston Galling Lack of lubrication Ensure an oil film is coming from bit splines.
Piston Cracked Lack of lubrication Ensure an oil film is coming from bit splines.
DTH Hammer badly bogged which Flood tool with water when badly bogged
can cause piston case to distort causing
heat checks and cracks
Using breakout wrench over wrong Use breakout wrench in the approved areas only
areas can cause piston case to distort
which can initiate heat checks in pis-
ton
25
Problem Probable Fault Corrective Action
Piston strike face cracking Not enough down force Increase down pressure until rotation
binds and then back off until rotation
and pressure become smooth.
Contamination from excess or acidic Avoid excessive water during Drilling

water causes pitting in the piston face operation. Only use pH neutral water
free from contamination.
Damaged Percussion bit Ensure strike face of percussion bit is
not damaged.
Crack in Piston Case Excessive external wear Measure diameter of piston case.
Heat or weld applied to piston case Replace—never use heat on piston

case.
Drive Sub cracked down spline Incorrect down pressure Increase down pressure until rotation
Damaged Percussion Bit Splines Check percussion bit splines for dam-
age; repair or replace
Tapered wear on Drive Sub Splines Not enough down force Increase down pressure until rotation
Percussion Bit splines burred Check percussion bit splines for dam-
age; repair or replace
Understanding Reverse Circulation DTH Hammers
This brief summary is designed to give geologists and drillers knowledge of the RC
system they use, as background information to relate to when analyzing the systems
overall performance.
Hammer Principles: Conventional and Reverse Circulation (RC) hammers are sim-
ple air motors that are powered by high pressure air. This is feed via an intake/
valving/timing system that controls the piston that delivers the energy to the percus-
sion bit. The air exhaust system is controlled by the percussion bit and the air pas-
sages to the surface. As with any non-electrical motor, any exhaust restriction will
reduce the motors power. In the case of a DTH Hammers air exhausting from the
hammer is also used to carry the rock cuttings to the surface. Any restrictions that
limit the flow of exhaust air and cuttings to the surface restricts the power of the
hammer.
Conventional Hammers vs Reverse Circulation Hammers: Conventional Ham-

mers exhaust the high pressure air through the holes in the percussion bit into the
drill hole and to the surface up the outside of the hammer. Reverse Circulation Ham-
mers exhaust the air down the outside splines of the percussion bit and then up the
26
holes of the percussion bit and the internal diameter of the hammer and the drill
string to the surface.
RC Drill Rods: RC drill rods are essentially two drill rods of different diameter
with the smaller drill rod contained inside the large one. The high pressure air is
passed down the ID of the larger Rod past the OD of the smaller rod with the sample
and exhaust air going up the ID of the smaller Rod. Drilling with incorrect drill Rod
sizes will restrict the exhaust air and thus reduce the power output of the hammer.
Piston cycle rates: At boosted pressures of up to 1000psi the cycle rate of the piston
can be up to 2400 cycles per minute which equates to the piston striking the percus-
sion bit 30-40 times per second.
Bit Interaction with Sample: The oscillating, cutting action of the rotating percus-
sion bit occurs at a rate of up to 40 times per second creating a crushing, grinding
rotary action on any chips at the face of the percussion bit. This grinds the sample
into a fine dust which can reduce the energy of the piston. The aim is to effectively
clear the sample chips from the face of the bit quickly thus reducing the chance of
hammer power loss. To achieve this the driller must maintain correct down pressure
and not flood the hole with water.
Limitations on Reverse Circulation Drilling: With the advent of higher pressure

boosters in the drilling industry other components have not kept pace with the
changing technology. Drill Rods today are basically the same as was used 25 years
ago with Rotary Mud Drilling. These aged designs have small annuluses designed to
accept 500cfm-900cfm but are used with large 1200cfm-220cfm compressors ex-
hausting air at 150psi to 200psi pressures into a small chamber created by the annu-
lar restriction. The higher exhaust pressure created helps the mass flow of air up the
smaller inner tube, this also creates very high turbulent back pressures in the cham-
ber around the percussion bit. Hammer drilling performance is reduced as air and
trapped particles swirl around trying to find their way to the face holes.
27
Reverse Circulation Hammer Operating Cycles
High Pressure
Air
Low Pressure
Air
Exhaust Air
Piston
1. With the piston resting on the percussion bit and the hammer closed up in the drilling posi-
tion, high pressure air is directed into the bottom chamber of the Hammer and the piston
lifts. This commences the piston cycle.
2. As the piston travels upwards it forms the top chamber by forming a seal with the inner tube
and the ID the piston. Further movement seals the port that feeds the bottom chamber and
also simultaneously releases the seal on the bottom chamber allowing the air to expand and
exhaust down the splines of the percussion bit. At the same time the Top chamber port is
opened which feeds the high pressure air into the previously formed top chamber thus in-
creasing the pressure above the piston and forcing it back down.
3. During the down cycle or power stroke the piston reseals the bottom chamber on the piston
bearing bush thus stopping the exhaust air and creating a chamber of high pressure air below
the piston which forces the piston back up the hammer.
4. Lifting the hammer of the bottom of the hole allows the percussion bit to slide down the
drive sub also allowing the piston to slide down the hammer and rest on the piston bearing
bush. The piston strike face and the strike face of the percussion bit can now not come into
contact thus allowing the free flow of high pressure air directly through the hammer without
the hammer cycling.
28
Schematic—Reverse Circulation System with Blow Down Valve.
Deflector Box
Low Pressure
Sample Return
Saver
Sub
Reverse
Circulation
DTH Hammer
Dual Wall Rotation Head

Drill String
High Pressure Air

Inlet
Air Swivel
Caution
The Reverse Circulation system requires a continuous Air Flow into the inner tube to maintain
continuous suspension of sample flow in the Inner Tube.
Operators must ensure that all the sample is delivered before turning the air off.
Any interruption of Air Flow at or to the bit face holes will result in in sample blockages in the
inner tube and return lines. If partial blockage of sample occurs, or if drill pipes commence to stick
in the hole, operators should utilize the dual blow down or blow back features of the Blow Down
Valve to clean blockages or increase outside circulation to free up the drill pipe.
Failure to monitor Sample flows to the cyclone will interrupt drilling operations.
29

Alldrill Drilling Manual PDF

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Alldrill Drilling Manual PDF

Transféré par

Droits d'auteur :

Formats disponibles

60 Paramount Drive, Wangara,

Western Australia, 6065

Document Type: Spare Parts List for AD108RC

2 AIR SCREEN 5108620 0.02 1

4 ADAPTOR NOZZLE Ó RING 5108610 0.02 1

5 CHECK VALVE SEAL 5108915 0.02 1

6 CHECKVALVE 5108900 0.40 1

8 I/TUBE Ó RINGS 542/3 0.02 5

9 INNER TUBE 5108505 HT 3.50 1

16 BEARING BUSH Ó‘RING 5108310 0.02 2

17 PISTON RETAINER RING 5108201 0.02 1

18 BIT RINGS 5108800 0.30 1

20 DRIVE SUB 5108400 3.0 1

Thread Make Up Torque Thrust on Hammer Tolerances Spanner Flats

Percussion Bit Sizes

Diameter Weight Face Design Buttons

121mm 9kg Concave Hemi

124mm 9kg Concave Hemi

127mm 9kg Concave Hemi

Document Type: Spare Parts List for AD116RC

3 ADAPTOR NOZZLE 5108600 0.60 1

4 ADAPTOR NOZZLE Ó RING 5108610 0.02 1

5 CHECK VALVE SEAL 5108915 0.02 1

6 CHECKVALVE 5108900 0.40 1

7 C/VALVE SPRING 5108910 0.10 1

8 I/TUBE Ó RINGS 542/3 0.02 5

9 INNER TUBE 5108505 HT 2.50 1

15 BEARING BUSH 5108300 2.50 1

16 BEARING BUSH Ó‘RING 5108310 0.02 2

17 PISTON RETAINER RING 5108201 0.02 1

18 BIT RINGS 5108800 0.30 1

20 DRIVE SUB 5108400 3.00 1

‗O‘ RING KIT 5108120

Complete Hammer 5108000 58.00

Thread Make Up Torque Thrust on Hammer Tolerances Spanner Flats

Percussion Bit Sizes

Diameter Weight Face Design Buttons

121mm 9kg Concave Hemi

124mm 9kg Concave Hemi

127mm 9kg Concave Hemi

Document Type: Spare Parts List for AD117RC

4 ADAPTOR NOZZLE Ó RING 5117610 0.02 2

5 CHECK VALVE SEAL 5117915 0.02 1

6 CHECKVALVE 5117900 0.60 1

8 I/TUBE Ó RINGS 545/7 0.02 4

9 INNER TUBE 5117505 HT 5.00 1

16 BEARING BUSH Ó‘RING 5117310 0.02 2

18 BIT RINGS 5117800 0.22 1

20 DRIVE SUB 5117400 3.00 1

Thread Make Up Torque Thrust on Hammer Tolerances Spanner Flats

Percussion Bit Sizes

Diameter Weight Face Design Buttons

124mm 9kg Concave Hemi

127mm 9.5kg Concave Hemi

136mm 11kg Concave Hemi

140mm 13kg Concave Hemi

Document Type: Spare Parts List for AD124RC

1 CIRCLIP 5117110 0.05 1

2 AIR SCREEN 5117620 0.02 1

3 ADAPTOR NOZZLE 5117600 0.50 1

4 ADAPTOR NOZZLE Ó RING 5117610 0.01 2

5 CHECK VALVE SEAL 5117915 0.01 1

6 CHECKVALVE 5117900 0.60 1