DKI DK 60 Series User manual

DK 60 Hammer Series
820 South Sixth Ave
Manseld, Tx 76063, USA.
Web: drillking.com / Email: [email protected]
Technical Manual

Page 1
Introduction ............................................................................................................. 2
DK 60 Hammer Introduction ................................................................................... 3
Safety Recommendation & Precautions ................................................................ 4
Hammer View and Parts List ................................................................................... 6
Bit Shank DHD360 ......................................................................................................... 6
Bit Shank QL60 ............................................................................................................... 7
Bit Shank SD6 ................................................................................................................. 8
Clamping Locations ...................................................................................................... 9
DK 60 Hammer Air Consumption at Dierent Working Pressure ................... 10
DK 60 Hammer Assembly ....................................................................................... 10
Assembly with Shank type QL60 & DHD360 ......................................................... 11
Assembly with Bit .......................................................................................................... 15
Assembly with Shank type SD6 .............................................................................. 16
Assembly with Bit .......................................................................................................... 17
Lubrication .............................................................................................................. 18
Storage .................................................................................................................... 18
Warranty .................................................................................................................. 19
Table of Content

Page 2
Introduction
Drill King International was founded back in 2004 by Randy Broseh in Arlington, Texas. A
year later, the business turned into a real family aair when brother Larry Broseh acquired
the business. The brothers used their extensive industry knowledge to create a unique
company with the best customer service in mind.
Continued growth and customer demand saw Drill King in 2008 decide to build a 60,000
sq.ft (5,575 sq.m) facility in Manseld Texas. From this point the company has gone
from strength to strength creating innovative drilling tolls and solutions for a variety of
customer projects around the globe.

Page 3
DK 60 Hammer Introduction
The DK Hammer Series is designed to operate eciently on air pressure. Compressed
air is directed to the hammer via the rotation spindle and drill pipe. Exhaust air from the
hammer is passed through blowholes in the drill bit and is used to ush clean the drilled
hole. Rotation is provided by a rotation unit on the drill rig and transferred to the hammer
via the drill pipe.
The drill pipe is threaded so that the drill string can be extended as drilling advances
and the hole becomes deeper. Feed force is also transmitted to the hammer via the hole
down unit and the weight of the drill pipe.
The DK Hammer Series was developed after much research by utilizing the newest tech-
nologies available. The DK Hammer Series is designed to be used in a wide range of ap-
plication in rock conditions.
- Innovative & simple design for easy eco kit maintenance
- High frequency design for fastest penetration rates
- Available for common bits shanks IR/QL/SD
- Customizable options for open hole or cased hole projects
- Premium alloys & treatment used for longer lasting tools

Page 4
Safety Recommendation & Precautions
The safety Recommendations listed below are intended to alert the hammer operators
and maintenance personnel to the possible physical dangers inherent in the various
phases of operating and maintaining equipment of this kind.
We recommend that all operators and maintenance personnel read and thoroughly un-
derstand the safety precautions before attempting to operate or perform maintenance
on the drilling equipment. We put “SAFETY FIRST” and suggest this must always be the
primary consideration of all personnel while operating or maintaining the equipment.
Since the Safety Recommendations can’t cover every potential situation, it is suggested
that everyone exercises good judgernent and common sense while operating, servicing,
or working near the equipment.
NOTE:
SAFETY STATEMENTS ARE INCLUDED THROUGHOUT THE MANUAL WHERE IT MAY
APPLY SPECIFICALLY TO INDIVIDUAL COMPONENTS OR ASSEMBLIES. FAILURE TO
COMPLY WITH SAFETY WARNING CAN RESULT IN SERIOUS OR FATAL INJURY. IM-
PROPER OPERATION AND MAINTENANCE CAN CASUE SEVERE EQUIPMENT DAMAGE
OR EXCESSIVE WEAR ON THE HAMMER AND HAMMER BIT.
☑Be equipped with appropriate attire, hard hat, gloves, safety shoes, eye and ear pro-
tection. Don’t wear loose clothing that could get caught in the equipment.
☑Safety goggles or safety glasses are required. Rocks, dust, and loose particles from
drilling may be blown into the as during drilling. Also, use safety glasses when
sharpening bits.
☑Handle all equipment with care.
☑Operating the hammer at extreme pressures or speeds may cause failure or exces-
sive wear. Please follow the instructions in the technical manual and use the recom-
mended procedures for operation and maintenance of the hammer.

Page 5
☑Compressed air or uid used for cleaning purposes should be utilized with extreme
caution:
• Do not apply directly to your skin
• Do not use for cleaning directly from your clothing
• Do not direct it at another person
• Be careful not to blow directly into the equipment
• Wear safety glasses AT ALL TIMES of the operation
☑Check the drill rod to power head spindle joint and make sure it is securely tight-
ened before running the rotary head in reverse rotation. If you have a loose con-
nection, it could result in the drill rod becoming disconnected cornpletely. If the
drilling rod becomes disconnected, it could strike personnel.
☑Be cautious about getting under the downhole hammer for inspedion. The down-
hole hammer could unexpectedly cycle, forcing the piston to drop out of the down-
hole hammer. This could cause bodily injury to anyone under the downhole ham-
mer.
☑When using solvents to clean parts, make sure that they are nonammable, and
that it meets current OSHA and International Standards; be sure to use the solvent
in a well-ventilated area.
☑Be sure all downhole hammer components are properly lubricated and maintained,
while in storage. Failure to follow lubrication recommendations could cause dam-
age and wear to the downhole hammer, its components, and /or personnel injury.
☑Never heat up any parts of the hammer or weld on it. Use extreme care when break-
ing loose the top and bottom connections, using either a spanner wrench or a at
wrench that properly ts the driver and top sub.

Page 6
Hammer View and Parts List
Bit Shank DHD360
NO Part Name Qty Part Number
1 Top Sub 1 HPDK-A6002
2 Top Sub O-Ring 1 HPDK-A6003
3 Choke Set 1 HPDK-A6008
4Check Valve 1 HPDK-A6007
5 C.V. Spring 1 HPDK-A6009
6 Press Ring 1 HPDK-A6005
7 Make Up Ring 1 HPDK-A6006
8 Air Distributor 1 HPDK-A6010-LYT-WGT
9 Air Dis. O-Ring 1 HPDK-A6011
10 Cylinder 1 HPDK-A6012-LYT-WGT
11 Piston 1 HPDK-A6014-LYT-WGT
12 Wear Sleeve 1 HPDK-A6001
13 Snap Ring 2HPDK-A6021
14 Bit Bearing 1 HPDK-A6020
15 Bit Ret. Ring 1 HPDK-A6018
16 Bit Ret. Ring O-Ring 1 HPDK-A6019
17 Drive Sub 1 HPDK-A6022
Complete Hammer HADK-A600I
Sealkit (Items 2, 9 ,16) HPDK-A60SEALKIT
Dimensions & Weights
Top Sub 3 ½” API REG PIN
E. Length (in / mm) 44.24 / 1123.6
OD Range (in / mm) 5.59 / 142
Weight w/o bit (lbs / Kg) 198 / 89.8
Piston Weight (lbs / Kg) 41.6 / 18.7

Page 7
Bit Shank QL60
NO Part Name Qty Part Number
1 Top Sub 1 HPDK-A6002
2 Top Sub O-Ring 1 HPDK-A6003
3 Choke Set 1 HPDK-A6008
4Check Valve 1 HPDK-A6007
5 C.V. Spring 1 HPDK-A6009
6 Press Ring 1 HPDK-A6005
7 Make Up Ring 1 HPDK-A6006
8 Air Distributor 1 HPDK-A6010-LYT-WGT
9 Air Dis. O-Ring 1 HPDK-A6011
10 Cylinder 1 HPDK-A6012-LYT-WGT
11 Piston 1 HPDK-A6014-Q-LYT-WGT
12 Wear Sleeve 1 HPDK-A6001-Q
13 Snap Ring 2HPDK-A6021
14 Bit Bearing 1 HPDK-A6020-Q
15 Bit Ret. Ring 1 HPDK-A6018-Q
16 Bit Ret. Ring O-Ring 1 HPDK-A6019
17 Drive Sub 1 HPDK-A6022-Q
Complete Hammer HADK-A600Q
Sealkit (Items 2, 9 ,16) HPDK-A60SEALKIT
Dimensions & Weights
Top Sub 3 ½” API REG PIN
E. Length (in / mm) 42.16 / 1070.8
OD Range (in / mm) 5.59 / 142
Weight w/o bit (lbs / Kg) 198 / 89.8
Piston Weight (lbs / Kg) 41.6 / 18.7

Page 8
Bit Shank SD6
NO Part Name Qty Part Number
1 Top Sub 1 HPDK-A6002
2 Top Sub O-Ring 1 HPDK-A6003
3 Choke Set 1 HPDK-A6008
4Check Valve 1 HPDK-A6007
5 C.V. Spring 1 HPDK-A6009
6Spring Washer 1 HPDK-A6005
7 Make Up Ring 1 HPDK-A6006
8 Air Distributor 1 HPDK-A6010-LYT-WGT
9 Air Dis. O-Ring 1 HPDK-A6011
10 Cylinder 1 HPDK-A6012-LYT-WGT
11 Piston 1 HPDK-A6014-S-LYT-WGT
12 Wear Sleeve 1 HPDK-A6001
13 Snap Ring 1HPDK-A6021
14 Bit Ret. Ring 1 HPDK-A6018-S
15 Bit Ret. O-Ring 1 HPDK-A5019
16 Bit Bearing 1 HPDK-A6020-S
17 Drive Sub 1 HPDK-A6022-S
Complete Hammer HADK-A600S
Sealkit (Items 2, 9 ,16) HPDK-A60SEALKIT
Dimensions & Weights
Top Sub 3 ½” API REG PIN
E. Length (in / mm) 44.84 / 1138.9
OD Range (in / mm) 5.59 / 142
Weight w/o bit (lbs / Kg) 198 / 89.8
Piston Weight (lbs / Kg) 41.6 / 18.7

Page 9
Clamping Locations
A
BED
C
DO NOT USE TONGS
IN AREAS A, C AND E
HAMMER
LOCATION
FROM TOP SUB
END OF WEAR
SLEEVE "A"
LENGTH OF
GRIP AREA "B"
LOCATION
FROM DRIVER
SUB END OF
WEAR SLEEVE
"C"
LENGTH OF
GRIP AREA "D"
IR3.5 3 4 3 4
IR340 4 4 4 4
QL40 4 4 4 4
SD4 4 4 4 4
IR350 6 4 5 4
QL50 6 4 5 4
SD5 6 4 5 4
IR360 4.5 4 5 4
QL60 4.5 4 4.5 4
SD6 4.5 4 5.5 4
IR380 6.5 4 6 4
QL80 6.5 4 6 4
SD8 6.5 4 6 4
SD10 8 6 6.5 6
IR112 9.5 6 7 6
QL120 9.5 6 7.5 6
SD12 9.5 6 8 6
SD15 9.5 6 8.5 6

Page 10
DK 60 Hammer Air Consumption at Dierent Working
Pressure
In dicult drilling conditions, extra ushing can be obtained by changing the choke in
the check valve. This might be desirable, e.g. when there is a large inux of water into the
hole, when there is a big dierence between the diameter of the drill bit and the diame-
ter of the drill pipes, or when penetration rates are abnormally high.
Friction between the drill pipes and the hole wall can sometimes reduce the penetration
rate. Increasing the air pressure to give more impact power and faster penetration can
often counteract this.
DK 60 Hammer Assembly
The DK 60 Hammer assembly process is identical to the disassembly process yet in re-
verse.
The following guideline should be used;
• Assembly process is identical on dierent shanks except the SD5, which has a slight
distinction.
• All parts should be clean and free of grit, dirt, and other foreign material.
• All nicks and burrs on parts should be removed.
• All parts should be coated with rock drill oil & threads with thread grease and pref-
erably the same type to be used on the drilling rig.
• All damaged 0-rings' should be replaced. All seals should be oiled or greased to
avoid cutting or tearing.
• Make sure the threads are clean and dry, and that sucient drying time is allowed.
PSI BAR CFM CuMtr/Min
150 10.3 390 11
250 17.2 590 16.7
350 24.1 800 22.6

Page 11
Assembly with Shank type QL60 & DHD360
*The bottom portion of the Case with Shank type QL 60 & DHD 360
1. Insert Retainer Ring (Part No. 21) at the rst groove into the Case (Part No.1)
2. Slide the Bearing (Part No. 20) into the Case (Part No. 1). The bearing may need to be
tapped from side to side to t well.
3. Insert Retainer Ring (Part No. 21) at the second groove into the Case (Part No. 1).
Retainer Ring
Bearing
Retaining Ring

Page 12
4. Insert the O-ring (Part No. 19) at the center groove of the Bit Retainer Ring (Part No. 18).
And then insert the Bit Retainer Ring (Part No. 18) with O-ring into the Case (Part No. 1).
5. Screw the Chuck (Part No. 22) into the Case (Part No. 1) Matching screw line tightly.
6. Install the Piston (Part No. 14) into the Case (Part No. 1).
7. Insert the O-Ring (Part No. 11) at the groove of the Air Distributor (Part No. 10) and then
put the Air Distributor (Part No. 10) with the O-ring above into the Cylinder (Part No. 12).
O-Ring Bit Retainer
* The Upper Portion of the Case.
Piston
Air
Distributor
O-Ring
Cylinder

Page 13
8. Put the assembled Cylinder (Part No. 12) into the Case (Part No. 1).
9. First put Urethane Make-Up ring (Part No. 6) and then the Spacer Ring (Part No. 5) into
case tightly.
10. Insert the Spring (Part No. 9) into the Check Valve (Part No. 7) with Choke (Part No. 8)
and put them into the center of the hole in the case
Urethane
Make-Up Ring
Spacer Ring
Spring Check Valve Choke

Page 14
11. Insert the O-Ring (Part No. 3) on the groove of the Top Sub (Part No. 2). And then screw
the Top Sub (Part No. 2) with the O-Ring into the top end of the Case (Part No. 1).
12. The Completed Assembly of the DK 60 Hammer.
Top Sub
O-Ring

Page 15
Assembly with Bit
1. Loosen & Screw out the Chuck (Part No. 22) from the bottom end of the Case. (Part No. 1)
2. Pull out the Bit Retainer Ring (Part No. 18) with O-Ring (Part No. 19) from the Case (Part No.1)
3. Fit down the Chuck (Part No. 22) around the bit as shown in the pictures.
4. Put the Bit Retainer Ring (Part No. 18) with the O-Ring around the bit as shown in the pic-
tures.
5. Screw the assembled Chuck with the Bit into the Case.
Bit Chuck
Bit
Bit Retainer
Ring

Page 16
Assembly with Shank type SD6
*The bottom portion of the Case with the Shank type SD6 (Refer to SD6 View & Parts List)
1. Put the Retainer Ring (Part No. 21) at the rst groove into the Case (Part No. 1).
2. Put the O-Ring (Part No. 19) at the center groove of the Bit Retainer Ring (Part No. 18).
And then put the Bit Retainer Ring (Part No. 18) with O-Ring into the Case (Part No. 1).
3. Slide the Bearing (Part No. 20) into the Case (Part No. 1)
The bearing may need to be tapped from the side to side to t well.
4. Screw the Chuck (Part No. 22) into the Case (Part No. 1) matching screw line tightly.
*Assembly processing of the upper Case with Shank Type SD6 is the same assembly with
Shank Type DHD360 and QL60.
Retainer Ring
O-Ring Bit Retainer
Chuck
Bearing

Page 17
Assembly with Bit
1. Loosen & screw out the Chuck (Part No. 22) from the bottom end of the Case. (Part No.1).
2. Slide the Bearing (Part No. 20) Out of the Case (Part No. 1).
3. Pull out the Bit Retainer Ring (Part No. 18) with O-ring (Part No. 19).
4. Fit down the Chuck (Part No. 22) around the Bit (Refer to below picture).
5. Fit down Bearing (Part No. 20) around the Bit.
6. Put Bit Retainer Ring (Part No. 18) with O-ring around the Bit.
7. Screw the assembled Chuck with the Bit into the Case (Part No. 1).
Chuck
Bearing
Bit Retaining Ring

Page 18
Lubrication
In order to maintain satisfactory operation of the Drill King Hammers, you must lubricate
the hammer properly. The recommended lubricant to use with Drill King Hammers is the
Biodegradable and Environmentally Friendly Rock Drill Oil (Part Number DKRDO-5G).
- Check the oil level in the lubricating tank
- Check for oil in the compressed air.
- Mineral oils have the best lubricating properties
- Lubricating out used in water well drilling should be non-toxic.
You can make sure the lubricant is being carried to the hammer via the compressed at
by placing a plank over the drill steel support and letting the operating air blow over the
plank. If you see that it is oily then the oil should be getting to the hammer. It is also es-
sential to the life of the hammer components.
Proper thread lubricants are also critical to the life of the hammer components. Thread
lubrication applied to the stress relief grooves at the base pin will help ght the eects of
corrosive drilling uids.
It is a necessary procedure to reapply thread lubricant (Drill King Copper Cote Part No.
630010 1-gal) to the driver sub threads when changing bits. It is also important that the
drive sub and the top sub threads be recoated with thread lubricant often in order to
assure the maximum protection from corrosion pitting.
Corrosion failures in percussion hammers and hammers bits can be controlled by main-
taining a protective barrier between the bit and hammer parts and the environment
through proper application of readily available rock drill oils and thread lubricants.
The best method for preventing failures due to corrosion fatigue is to be sure the surface
of the bits and components of the hammer is coated with rock drill oil. Threaded connec-
tions and thread run out grooves should be protected by coating with thread lubricant.
When using water injection, solvable rock drill oil with a higher viscosity rating should
utilized.
Storage
When storing Drill Hammers, it is important to blow the hammer clear of all water. After
disassembling the hammer, all internal parts are liberally coated with rock drill oil. Store
the hammer horizontally in a clean dry place.