MX5456 Service Manual A4N
MX5456 Service Manual A4N
MX5456 Service Manual A4N
Table of Contents
1. INTRODUCTION ........................................................................................................................... 3
2.2.2 Commissioning........................................................................................................................................ 3
2.2.3 Lubrication............................................................................................................................................... 4
4. APPENDIX .................................................................................................................................... 9
4.1 REVERSE CIRCULATION HAMMER EXPLODED VIEW AND PARTS LIST AND TECHNICAL DATA................................ 9
5. WARRANTY ............................................................................................................................... 11
Please keep this instruction manual as a permanent record for your reverse circulation hammer.
The specifications and instructions contained in this manual are based on the up-to-date information as at publication date.
Be sure to work safely at all times. Wear protective clothing and safety equipment and observe all safety regulations as
prescribed by your employer, Government, or the site on which you work. Do not wear loose clothing that may get caught in
rotating parts and cause serious personal injury.
Remember that a “Reverse Circulation” percussive hammer emits noise and you should therefore take every precaution to
safeguard your hearing against damage by using proper ear protectors. Use eye protection at all times. Rock chips and dust
which may be discharged from the face of the bit or bore hole at high velocities and can cause severe injury.
Hammers can be heavy – Always use proper and approved lifting equipment and take every precaution to safeguard yourself
against injury. Keep hands clear at all times – Beware of getting fingers trapped between the chuck and bit and do not use
hands or feet to clear the top of the borehole at any time.
Other safety advice is given throughout this document which you are advised to read.
When the hole is completed and the hammer is to be inactive for some time the following steps should be taken.
Before restarting any hammer after prolonged periods of inactivity, disassemble and inspect all internal parts. Clean and
remove any oxidation with an emery cloth. Re-lubricate all internal components with rock drill oil and reassemble the hammer.
Full assembly and disassembly instructions can be found further on in this manual.
2.2.2 Commissioning
Always use drill bits in good condition (sharpened). Using overrun bits can affect the life of the bit, chuck/chuck sleeve and
reduce penetration rates which can damage internal components due to the non transference of energy in to the rock being
drilled.
Grease the threads on the back head and chuck and fit to the hammer complete with drill bit.
With the bit in the breakout pot, torque up the hammer until the standoff between the backhead and wear sleeve has
closed up.
Before adding the first drill rod pour 1 litre(2 pints) of rock drill oil in to the back head.
Ensure all drill rods are blown clean of any dirt and debris and that all threads are cleaned, greased and all o rings are
in good condition before coupling together.
Turn on air and blow until oil starts to run out of the bit shank.
Cycle the hammer on half air for the first few minutes to run in internal parts.
2.2.3 Lubrication
It is vital for DTH hammers to receive a constant supply of proper rock drill oil in to the air stream, to lubricate and protect the
internal components, and to provide a good air seal between the piston and its matching component parts for efficient drilling. It
is recommended that an automatic oiling system be used when operating your hammer. Too much oil can cause hydraulic
locking in the hammer. Drilling with insufficient lubrication will cause the hammer to run dry and cause premature wear or
failure. The correct consumption of oil/oil type is dependent upon the air volume and ambient conditions. Please refer to the
lubrication graph below for recommendations. There should be visual evidence of oil around the drill bit shank and within the
tube joints when changing tubes.
The recommended grade of oil is dependent on the ambient temperature in which drilling is taking place as well as the
operating pressure. As a rule of thumb, ISO320 grade rock drill oil should be used whenever possible as the hammer is a high
frequency tool, however, where the pump cannot pump the oil in colder conditions, a lower viscosity of oil can be used as per
the graph below.
Remember: Insufficient lubrication or incorrect lubrication grades may result in damage being caused to the hammer
and its components. Hydraulic oils, engine oils, gear oils and diesel are not recommended for lubricating DTH reverse
circulation hammers.
Litres/Hour Pressure - Bar
6.9 13.8 20.7 27.6 34.5
1 2 3 4 5
120 48.9
1500 42.0
100 37.8
Ambient Temperature ºF
Ambient Temperature ºC
1250 35.0
Air Volume – M3/MIN
Air Volume - CFM
80 ISO320 26.7
1000 28.0
000
60 15.6
750 21.0
40
500 14.0 4.4
20 -6.7
250 7.0 ISO150
0 -17.8
2 4 6 8 10 ISO40
-20 06 -28.9
US Pints/Hour
100 200 300 400 500
Pressure - PSI
At low temperatures of 5ºC (41ºF), and in hot humid conditions with higher air pressures, when hammers can freeze up. Anti-
freeze additive may be required at a rate of 1-2 litres (2-4 pints) per hour or more as necessary.
2.2.4 Operation
Be sure to familiarise yourself with the controls of the rig and work in accordance with the rig manufacturers recommendations.
The hammer begins to operate as the air supply is turned on and when the drill bit is pushed firmly into the hammer. Excessive
thrust pressures are not needed to make the piston cycle. The thrust controls on the drill should be adjusted to the correct
pressure and should be readjusted to take account of the weight of any extra drill rods added, so that the thrust pressure
remains constant and not excessive. Insufficient thrust pressure will make the hammer drill erratically and less efficiently and
cause premature wear to the bit and chuck splines with likely damage to the hammer components and threads.
When the hammer is lifted from the rock face, the drill bit extends from the chuck and the percussive action ceases. The air will
pass through the hammer, which can be used to flush the hole clean.
Rotation speeds should be selected to suit drilling conditions and drill bit diameters. High rotation speeds can cause premature
wear of drill bits, hammers and drill rods. Too slow a rotation speed can cause binding in the borehole and damage to drill bit
inserts through the snatching rotation action.
In hard and soft formations of rock, the aim of the hammer is to penetrate smoothly at the rate of 10mm (0.375”) per drill rod
revolution. Generally in softer geology, higher rotational speeds can give better results.
The controls of the drill should be adjusted in order to provide the largest drill chip size with the smoothest rotation and feed
characteristics. Rotation speeds should be set to suit the rock conditions being drilled.
It is recommended that you do not pour diesel into the hammer if it becomes bogged. However if this is done, there is the risk
an internal combustive effect if the hammer is fired while there is diesel in it. This will damage the hammer and its components.
Any heat induced failures are not covered by our terms of warranty.
Before adding drill rods make sure that the threads are clean, well greased and all O rings are in good condition. Ensure that
there are no contaminants likely to enter the hammer to cause damage and early wear.
It is recommended that proper drill guides and break out systems be used which suit the diameter of the hammer. All tools and
spanners used for the drill bit and break out flats should fit properly.
Make certain that the hammer is stationary when applying spanner or breakout tools. Do not rotate the hammer with a spanner
attached to the drill string unless it is safely captivated within the breakout clamp.
All internal hammer O Rings, check valve and check valve seal should be examined and replaced periodically, to ensure
optimum performance and effective sealing from borehole ingress.
2.3 Servicing
2.3.1 General
Dismantling the Hammer for servicing or to change the bit can be made easier if the chuck threads are regularly greased and
the backhead threads are well greased any time the hammer is opened for servicing. We recommend that a good quality
thread grease be used, and in acidic conditions, we do not recommend copper based greases as this can trigger a galvanic
reaction with corrosive effect to damage the root of the threads and cause failure.
2.3.5 Inspection
Prior to inspection, thoroughly clean all parts using a suitable cleaning agent. Diesel is not recommended for cleaning as it can
cause corrosion to components, and damage to health.
All parts should be visually inspected for any signs of damage, wear or cracking. The inner cylinder, wear sleeve and lock rings
can be checked for unseen cracking by suspending them and lightly tapping with a screw driver. If they emit a ringing tone then
they should be sound. However, a dull flat tone if emitted may indicate cracking, and the part should be replaced.
Take particular care to check the internal bore of the wearsleeve for pick-up marks and galling. If these are present, the barrel
of the wear sleeve should be honed out, using a hand hone to remove them. It is usual that if there are signs of damage or heat
checking on one part that there is also the same on mating parts.
Inspect surface of the piston for pick-up marks and galling (usually caused through poor lubrication or the presence of
contaminants) and smooth out with emery paper, making sure to clean thoroughly afterwards. Where galling of the piston has
occurred, substantial heat has been generated and quite often, micro cracking has occurred on the piston. In these cases, the
piston should be replaced if there is evidence of such cracking. Check the strike face of the piston for cracking or damage.
Inspect the Aligner for any galling or cracks. If either is present, then the aligner should be replaced.
All internal hammer O rings, check valve and check valve seal should be examined and replaced periodically, to ensure
optimum performance and effective sealing from borehole ingress.
2.3.7 Reassembly
The hammer can be reassembled in the following manner, referring to the exploded view of the hammer in the appendix.
Ensure all components, except for the sample tube, are liberally coated with good quality rock drill oil and threads with thread
grease. Replace all O rings and check valve seal before re assembly.
Identify the chuck end of the hammer and stand with the chuck end facing up. Insert the piston retaining ring in to the
groove provided. Ensure the extraction groove on the retaining ring is facing the chuck end of the hammer.
Insert the Aligner (with the smaller outside diameter facing the piston retaining ring) in to the wear sleeve. Using a soft
steel drift, tap the aligner in to place against the piston retaining ring.
Screw the chuck (and chuck sleeve on external flush models) in to the wear sleeve.
Seal up the chuck end of the hammer.
Turn the hammer over so the back head end is facing up.
Insert the Piston in to the wear sleeve (refer to the exploded view for orientation).
Insert the Sample tube mount in to the inner cylinder and fit the seating rings around the round holes on the inner
cylinder.
Insert the Inner cylinder assembly in to the wear sleeve. Tap the assembly in to place using a soft steel drift.
Fit the spacer on to the sample tube with the flat face facing down to the drill bit end of the sample tube. Place the lock
ring on top of the spacer. Place the steel make up ring on top of the lock ring. Place the check valve spring on to the
locating recess on the spacer and fit the check valve in to place.
Spray the area under the rings of the sample tube with penetrating oil (e.g. CRC / WD40). If hammer oil is used then
the sample tube will not go in to place properly because a hydraulic lock will occur between the sample tube shoulder
and the sample tube mount.
Insert the sample tube assembly in to the hammer.
Sudden loss of Over run/ blown out sample tube. Check sample tube wear regularly, and change before it is worn
pressure out.
PART FAILURE
Problem Possible cause Remedy
Cracked wear Abuse of wearsleeve Avoid welding, heating or torque wrenching in the wrong place
sleeve/ external as outlined in section 1.4. Note also section 1.6
part distortion.
Worn wearsleeve Outside diameter has worn beyond the discard point. Measure
casing O/D approx. 75mm (3”) from chuck end and backhead
end and replace if necessary.
Corrosion If drilling in a corrosive environment wash internal and external
parts regularly to avoid corrosive impact on the drill.
Bogged Drill can lead to reaming If such danger is imminent use a dig out sub.
and overheating distortion of the
drill.
Drill bogged can lead to chuck, Inspect all parts thoroughly if drill is recovered, and replace
wear sleeve and chuck sleeve to parts where necessary.
distort.
Piston cracked Lack of lubrication causes micro- Check lubricator and ensure oil film on the bit splines.
through large cracks leading to breakage
diameter
Feeding hard through voids on Use light feed and ensure the hole is kept clean and
broken ground can cause consolidated. Use foam or mud if necessary
wearsleeve to distort causing heat
cracks and galling on the piston
Using wrench over wrong area to Use wrench only in the
open drill can cause the wear Area indicated.
sleeve to distort.
Piston strike end Insufficient down-force Increase feed until rotation binds and pressure pulses and then
breaking back off until the rotation and pressure becomes smooth
Over running sample tubes will Replace sample tubes before they are worn out.
allow ingress between the two
striking faces and cause piston
nose to crack.
26 26 O Ring BS-243
27 Bit Retaining Pin MX5456BR01
28 Chuck MX5456CK01
27 Outside diameter 5.20” 132mm
Chuck end
C D
D C
D C
The warranty applies only to failures resulting from defects in the material or workmanship and does not apply to failures
occurring as a result of abuse, misuse, corrosion, erosion, negligent repairs and normal wear and tear. Failure to follow
recommended operating and maintenance procedures which result in component failure will not be considered for warranty.
This warranty is in lieu of all other warranties, other than title, expressed or implied.
Limitation of Liability
Mincon will not accept any remedies to the user other than those set out under the provisions of warranty above. The total
liability of Mincon or its distributors with respect to the sale of DTH Hammers or spare parts therefor, whether based on
contract, negligence, warranty, indemnity or otherwise shall not exceed the purchase price of the product upon which such
liability is based. Mincon and its distributors shall in no event be liable to any party relating to this sale for any consequential,
indirect, special or punitive damages arising out of this sale or any breach thereof, or any defects in or failure of or malfunction
of the Mincon DTH Hammer or spare parts.