Numa Champion RC160 Maintenance manual

MANUFACTURER OF DOWN HOLE HAMMERS AND BITS
Champion
®®
®®
®
RC160
CARE & MAINTENANCECARE & MAINTENANCE
CARE & MAINTENANCECARE & MAINTENANCE
CARE & MAINTENANCE
INSTRINSTR
INSTRINSTR
INSTRUCTIONSUCTIONS
UCTIONSUCTIONS
UCTIONS
©2015 Numa All Rights Reserved
P.O. Box 348 ••
••
•646 Thompson Road ••
••
•Thompson, CT 06277 USA
US Toll Free: (800) 356-NUMA ••
••
•Tel: [phone] ••
••
•Fax: [phone]
E-mail: [email protected]
Website: www.numahammers.com
Patents 4,530,408 4,919,221 4,962,822 5,205,363 5,984,021 5,992,537 6,021,856 7,422,074

MANUFACTURER OF DOWN HOLE HAMMERS AND BITS
Champion
®®
®®
®
RC160
TABLE OF CONTENTS
Section I Description...............................................................1
Functional Description ................................................................... 2
1. Backhead.............................................................................. 2
2. Check Valve Seat................................................................. 2
3. Check Valve ......................................................................... 2
4. Check Valve Spring.............................................................. 2
5. Collection Tube..................................................................... 2
6. Collection Tube Housing ...................................................... 2
7. Belleville Washers ................................................................. 2
8. Feed Tube Housing ............................................................... 2
9. Feed Tube Compression Ring.............................................. 3
10. Feed Tube.............................................................................. 3
11. Piston...................................................................................... 3
12. Case....................................................................................... 3
13. Bit Bearing ............................................................................. 3
14. Snap Ring............................................................................... 3
15. Bit Retaining Rings................................................................. 3
16. Thrust Washers....................................................................... 3
17. Chuck .................................................................................... 4
18. Chuck Bushing ...................................................................... 4
19. Drive Plates............................................................................ 4
Section II Maintenance ...........................................................5
Disassembly .................................................................................... 5
Inspection ....................................................................................... 8
General Assembly........................................................................ 11
Feed Tube Assembly.................................................................... 11
Hammer Assembly....................................................................... 12
Section III Parts Identification................................................ 14
Champion RC160 Exploded View....................................... 14 & 15
Part Number Reference ....................................................... 14 & 15
Section IV Air Consumption Charts ...................................... 16
Section V Lubrication............................................................. 17
Section VI Storage ................................................................. 18
Short Term...................................................................................... 18
Long Term...................................................................................... 18
Restarting ...................................................................................... 19
Section VII Button Bit Maintenance...................................... 20
General ......................................................................................... 20
Sharpening.................................................................................... 20
Section VIII Champion RC160 Recommended Spares...... 21
Page

04/23/10
MANUFACTURER OF DOWN HOLE HAMMERS AND BITS
WARRANTIES AND REMEDIES
LIMITED WARRANTY
Numa warrants that the Product will be new and free from defects in material and
workmanship under normal use as contemplated by this Contract for a period of six (6) months from
the date of shipment.
Except for the foregoing warranty, Numa disclaims all warranties and representations wherever
made, including warranties of merchantability, durability, length of service, or fitness for a particular
purpose.
Any alteration or modification of the original product without the express written consent of
Numa will void this warranty.
REMEDY
If, during such warranty period, Buyer promptly notifies Numa in writing of any defect and
establishes that the above warranty is not met, Numa shall either repair or replace the Product or
credit the customer, as it deems necessary to meet the warranty.
Such repair, replacement, or credit of Product shall constitute complete fulfillment of Numa's
obligation under this warranty, and upon the expiration of the original warranty period, all of
Numa's obligations hereunder shall terminate.
LIMITATION OF LIABILITY
Numa shall not be liable to Buyer whether in contract, in tort (including negligence and
strict liability), under any warranty or otherwise, for any special, indirect, incidental or consequential
loss or damage whatsoever, including (without limitation) loss arising from delay, cost or capital
and loss of profits or revenues. The remedies set forth in this Contract are exclusive, and the total
cumulative liability of Numa under this Contract or for any act or omission in connection therewith
or related thereto, whether in contract, in tort (including negligence and strict liability), under any
warranty or otherwise, is limited to the price paid by Buyer for the Product.
The WARNINGS, CAUTIONS and NOTES used throughout the text of this
instruction book are defined as follows:
WARNING A specific procedure or practice that must be strictly followed,
or a specific condition that must be met, to prevent possible
bodily harm.
CAUTION A specific procedure or practice that must be strictly followed,
or a specific condition that must be met, to prevent damage to
the equipment.
NOTE Important supplemental information.
Numa®,Champion
®®
®®
®
, and Patriot
®®
®®
®
are registered trademarks of Numa.

Page 1
MANUFACTURER OF DOWN HOLE HAMMERS AND BITS
07/16/15
Champion
®®
®®
®
RC160
SECTION I
DESCRIPTION
GENERAL DESCRIPTION
The Champion RC160 is a valveless, pneumatically operated reverse circulation drill
designed to utilize Numa 16" to 20" (406 mm to 508 mm) diameter reverse circulation bits in
a wide range of drilling applications.
The Champion RC160 hammer design incorporates a hardened case and a large
diameter collection tube. The large bore design of the Champion RC160 provides high
performance levels as associated with other Numa down hole hammers.
The Champion RC160 was specifically designed to provide maximum performance
on the drill rigs that are most commonly used in large diameter drilling applications. The
Champion RC160 hammer is designed to operate using air pressure from 100 PSI to 200 PSI
(6.9 Bar to 13.8 Bar) with compressors having 2000 CFM (944 Litres/Second) or more.
Champion RC160
Weight w/o Bit 2875 lbs. (1304 kg)
Outside Diameter 15-1/2" (394 mm)
Hammer Length:
Shoulder to Shoulder 81-3/4" (208 cm)
Shoulder to Bit Face 91-3/4" (233 cm)
Table 1-1 General Hammer Specifications
16" (406 mm) * 950 lbs. (431 kg)
18" (457 mm) * 1100 lbs. (499 kg)
20" (508 mm) 1121 lbs. (510 kg)
Table 1-2 General Bit Specifications
* Bit weights are approximate
NOTE
NUMA 16" TO 20" (406 MM TO 508 MM) BITS ARE AVAILABLE IN A CONCAVE FACE
DESIGN WITH A LARGE CENTER COLLECTION TUBE TO TAKE ADVANTAGE OF THE
CHAMPION RC160 PERFORMANCE. OTHER SIZES MAY BE AVAILABLE UPON
REQUEST.

07/16/15Page 2
MANUFACTURER OF DOWN HOLE HAMMERS AND BITS
Champion
®®
®®
®
RC160
FUNCTIONAL DESCRIPTION
1. BACKHEAD
Thebackheadconnects the hammertothe drillrod.Backheads can bemanufactured
to be compatible with several reverse circulation drill rod designs. Please contact
your distributor or regional salesperson for more information. Wrench flats are
provided for disassembly.
2. CHECK VALVE SEAT
The check valve seat provides the sealing surface for the check valve and guides the
collection tube.
3. CHECK VALVE
The check valve maintains pressure in the hammer when the air supply has been
shut off. The check valve in the hammer balances the hydrostatic pressure in the
hole thereby preventing contaminants from entering the hammer.
4. CHECK VALVE SPRING
The check valve spring provides tension under the check valve to keep it closed. It
is compressed as the air is turned on.
5. COLLECTION TUBE
The collection tube extends from the backhead to the bit and transfers the collected
drill cuttings to the inner drill pipe of the reverse circulation drill rod. The collection
tube is designed to be easily replaced without removing the backhead from the drill.
6. COLLECTION TUBE HOUSING
The collection tube housing aligns the collection tube. Holes in the collection tube
housing allow the transfer of air to the feed tube assembly.
7. BELLEVILLE WASHERS
Two belleville washers sit between the collection tube housing and the feed tube
housing to keep the feed tube housing tight against the shoulder in the hammer.
8. FEED TUBE HOUSING
The feed tube housing is aligned in the main bore of the hammer. It sits against a
shoulder in the case and is held in position by the backhead, collection tube housing
and belleville washer combination. The feed tube housing locates and aligns the
feed tube.

Page 3
MANUFACTURER OF DOWN HOLE HAMMERS AND BITS
07/16/15
Champion
®®
®®
®
RC160
9. FEED TUBE COMPRESSION RING
A feed tube compression ring sits between the feed tube and the feed tube housing
and keeps the feed tube assembly tight.
10. FEED TUBE
The feed tube supplies the main air into the chambers located in the piston. It seats on
a shoulder in the feed tube housing and is designed with a long bearing surface to
maintain alignment in the feed tube housing.
11. PISTON
The piston functions as the only moving part in the hammer, controlling the operational
air cycle. The percussive action of the piston striking the bit transfers the energy
through the bit in order to fracture rock formations.
12. CASE
The case is designed to contain the internal parts which make up the hammer
assembly. The case is hardened to resist wear and to extend life in abrasive conditions.
13. BIT BEARING
The bit bearing guides the top end of the bit to insure proper alignment between the
piston and the bit. The bit bearing is positioned in the chuck end of the case and is
held in place by the snap ring.
14. SNAP RING
The snap ring sits in a groove in the case and retains the bit bearing.
15. BIT RETAINING RINGS
The bit retaining rings are designed to allow the bit to move between the drilling and
cleaning positions and prevent the bit from coming completely out of the hammer.
The bit retaining rings consist of two matched halves and are held together with the
bit retaining ring o-ring.
16. THRUST WASHERS
Two brass thrust washers, one located between the backhead and the case and one
between the chuck and the case, provide for easy disassembly.

07/16/15Page 4
MANUFACTURER OF DOWN HOLE HAMMERS AND BITS
Champion
®®
®®
®
RC160
17. CHUCK
Thechuckthreadsintothebottomendofthecasewithalargecrosssectionthreadform.
It has internal splines that transmit rotation to the bit through a set of delrin drive plates.
18. CHUCK BUSHING
The chuck bushing is a nylon insert located in the bottom end of the chuck to provide
a bearing surface between the lower bit shank and the chuck.
19. DRIVE PLATES
The plastic drive plates provide wear protection for the splines. They are inserted
between the chuck and the bit. A complete drive plate set (12) is sent with each bit.

Page 5
MANUFACTURER OF DOWN HOLE HAMMERS AND BITS
07/16/15
Champion
®®
®®
®
RC160
SECTION II
MAINTENANCE
DISASSEMBLY
••
••
•Maintenance should be performed in a clean environment.
CAUTION
USE CAUTION WHEN HANDLING DOWN THE HOLE HAMMER PARTS. NUMA HAMMER
PARTS ARE MANUFACTURED FROM HARDENED, HEAT TREATED MATERIALS.
DROPPING OR STRIKING THESE PARTS MAY CAUSE SEVERE DAMAGE. STRIKING THE
HAMMER PARTS WITH HAMMERS, CROWBARS OR LIKE INSTRUMENTS WILL VOID THE
WARRANTY.
••
••
•Toolsneeded:hammerstand,14-1/2"(368mm)"J"orforkwrench(possiblyincorporated
in the hammer stand), overhead crane or lift truck, pulldown visetong with a 15-1/2"
(394 mm) diameter capacity or a self contained power wrench capable of 150,000
foot pounds (20,700 KGM) of torque, lifting eyes, 2" (51 mm) diameter brass rod or mild
steel rod 3 to 5 feet (1 m to 1.5 m) long, snap ring pliers, chains, lifting slings, a drift pin
and several different sized screwdrivers.
••
••
•Clean the outside of the hammer. This will insure a good surface to clamp on.
••
••
•The collection tube can be replaced without disassembly of the hammer. Prior to
removal of the collection tube, pressure wash the inside diameter of the collection
tube to remove any cuttings or debris. The collection tube is equipped with two 3/4"
(19 mm) holes to facilitate removal. With the hammer in a vertical position, use an
overhead crane or lift truck of appropriate capacity to remove the collection tube.
Thoroughly lubricate the collection tube O.D. and reverse the process to install the
new collection tube.
CAUTION
FAILURE TO THOROUGHLY CLEAN THE COLLECTION TUBE BEFORE REMOVAL MAY
ALLOW FOREIGN MATERIAL TO CONTAMINATE THE HAMMER.
••
••
•Using an overhead crane or lift truck of appropriate capacity, place the hammer on
a hammer stand and secure it in the wrench. The chuck end can be held in the
wrench by the 14-1/2" (368 mm) flats. The backhead is also held in the 14-1/2" (368
mm) wrench except with the addition of flat stock between the wrench and the
backhead flats (as the backhead flats are 12-1/2" (318 mm) across). Place the
visetongs on the area of the case where the bit bearing is located when working on
the chuck end of the hammer. When working on the backhead end of the hammer,
place the chain vise on the area of the case where the feed tube housing in located.

07/16/15Page 6
MANUFACTURER OF DOWN HOLE HAMMERS AND BITS
Champion
®®
®®
®
RC160
CAUTION
THE ACCEPTABLE CLAMPING AREAS START 8" (203 MM) FROM EITHER CASE END, TO
AN ADDITIONAL 10" (254 MM) BEYOND THIS POINT. PLACING THE VISETONG ON THE
AREA OF THE CASE WHERE THE PISTON CYCLES CAN DISTORT THE CASE, RESTRICT
PISTON MOVEMENT AND VOID THE WARRANTY.
••
••
•With the chuck secured in the fork wrench, (see figure 2-1) loosen the joint by turning
the case with the visetongs. Remove the hammer from the wrench and reverse the
hammer end to end in the hammer stand / wrench. With the backhead flats secured
in the fork wrench (see figure 2-1), loosen the joint by turning the case with the
visetongs.
••
••
•With the crane or lift truck, move the hammer into an upright position with the chuck
end down. With an adequate lifting device, lift and support the hammer while
unscrewing the chuck. After setting the hammer down, and while lifting and
supporting the backhead, unscrew and remove the backhead from the case.
••
••
•Remove the backhead o-ring and thrust washer from the backhead.
••
••
•Remove the collection tube o-ring from the backhead I.D. on the drill rod mating
end.
••
••
•Remove the check valve seat, the check valve and the check valve spring from the
backhead end of the case. The check valve seat is equipped with two 1/2" (13 mm)
UNC tapped holes for lifting eyes to facilitate removal.
••
••
•Using a small screwdriver, pick the check valve seat o-ring from the outside diameter
of the check valve seat.
Hammer Stand/Wrench Diagram
Figure 2-1
Pulldown Visetongs
Petol No. VTDA120
Force Direction Required:
15,000 - 25,000 lbs.
(6,800 - 11,400 Kg.)
Blocking to
height of stand
Hammer stand and wrench
combination, structural steel,
I-Beam, weld construction
bracing to suit.
Champion
RC160