Numa CHALLENGER 6 User manual

CARE & MAINTENANCE
INSTRUCTIONS
©2023 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
6

6
TABLE OF CONTENTS Page
Section I General Description ........................................... 1
Functional Description ............................................................. 2
1. Backhead ........................................................................ 2
2. Check Valve ................................................................... 2
3. Check Valve Spring........................................................ 2
4. Check Valve Housing..................................................... 2
5. Compression Rings ......................................................... 2
6. Feed Tube Retainer......................................................... 2
7. Feed Tube Housing ......................................................... 2
8. Feed Tube ........................................................................ 2
9. Choke .............................................................................. 3
10. Piston ................................................................................ 3
11. Case ................................................................................. 3
12. Bit Bearing........................................................................ 3
13. Wear Spacer.................................................................... 3
14. Disc Springs...................................................................... 3
15. Washer ............................................................................. 4
16. Retainer............................................................................ 4
17. Bit Retaining Rings........................................................... 4
18. Chuck............................................................................... 4
19. Thrust Washer................................................................... 4
Section II Maintenance................................................................. 5
Disassembly .............................................................................. 5
Inspection.................................................................................. 8
General Assembly.................................................................. 11
Feed Tube Assembly .............................................................. 11
Hammer Assembly ................................................................. 11
Section III Parts Identication ................................................... 13
Challenger 6 Exploded View................................................. 13
Challenger 6 Part Number Reference .................................. 13
Section IV Air Consumption Chart.......................................... 14
Section V Lubrication................................................................... 15
Section VI Storage......................................................................... 16
Short Term................................................................................ 16
Long Term ................................................................................ 16
Restarting................................................................................. 17
Section VII Button Bit Maintenance ....................................... 18
General.................................................................................... 18
Sharpening .............................................................................. 18
Section VIII Challenger 6 Recommended Spares........... 19

04/23/10
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 tness for a particular
purpose.
Any alteration or modication of the original product without the express written consent of
Numa will void this warranty.
REMEDY
If, during such warranty period, Buyer promptly noties 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 fulllment 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 prots 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 dened as follows:
WARNING A specic procedure or practice that must be strictly followed,
or a specic condition that must be met, to prevent possible
bodily harm.
CAUTION A specic procedure or practice that must be strictly followed,
or a specic condition that must be met, to prevent damage
to the equipment.
NOTE Important supplemental information.
Numa®,Champion, and Patriot
are registered trademarks of Numa.

03/09/23 Page 1
6
SECTION I
DESCRIPTION
GENERAL DESCRIPTION
The Challenger 6 is a valveless, pneumatically operated tool designed to utilize Numa 6" to
8-1/2" (152 mm to 216 mm) diameter bits in rock formations under a wide range of operating
conditions.
The Challenger 6 hammer design incorporates a hardened, reversible case. The simple
design of the Challenger 6 provides performance and dependability without sacricing tool
life.
The Challenger 6 is designed for universal applications using air pressure from 150 PSI
to 500 PSI (10.2 Bar to 34.5 Bar) with compressors ranging in size from 425 CFM (201 Litres/
Second) or more. When drilling conditions require supplementary hole cleaning, additional
hole cleaning air can be passed through the hammer by utilizing an interchangeable choke.
All standard hammers shipped from Numa have a blank choke installed. Refer to page 14
for correct choke selection and pages 7 & 11 to facilitate the removal and the installation of
the choke.
Challenger 6
Weight w/o Bit 258 lbs. (117 kg)
Outside Diameter 5-3/8" (137 mm)
Hammer Length:
Shoulder to Shoulder 52" (132 cm)
Shoulder to Bit Face 55" (140 cm)
Backhead API Thread 3-1/2 API REG
Table 1-1 General Hammer Specications
6" (152 mm) 52 lbs. (24 kg) 6-3/4" (172 mm) 55 lbs. (25 kg)
6-1/8" (156 mm) 52 lbs. (24 kg) 7" (178 mm) 63 lbs. (29 kg)
6-1/4" (159 mm) 53 lbs. (24 kg) * 8" (203 mm) 69 lbs. (31 kg)
6-1/2" (165 mm) 53 lbs. (24 kg) * 8-1/2" (216 mm) 72 lbs. (33 kg)
* Not for use in production drilling
Table 1-2 General Bit Specications
NOTE
NUMA 6" TO 8-1/2" (152 MM TO 216 MM) BITS ARE AVAILABLE IN CONCAVE,
CONVEX OR FLAT FACE DESIGNS WITH LARGE AIR FLUSHING HOLES AND CHIP
WAYS. OTHER SIZES MAY BE AVAILABLE UPON REQUEST.

Page 2 03/09/23
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FUNCTIONAL DESCRIPTION
1. BACKHEAD
The backhead connects the hammer to the drill rod. It is threaded into the top end of
the case with a large cross section thread form and into the drill rod with a standard
3-1/2 REG API thread. Other threads are available upon request. Wrench ats are
provided for disassembling.
2. CHECK VALVE
The check valve maintains pressure in the hammer when the air supply has been shut
off. The pressure in the hammer balances the hydrostatic pressure in the hole thereby
preventing contaminants from entering the hammer.
3. 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.
4. CHECK VALVE HOUSING
The check valve housing guides the check valve and the check valve spring. The
main air supply is directed to the feed tube through ports located in the check valve
housing.
5. COMPRESSION RINGS
Two compression rings, one between the check valve housing and the feed tube
housing and one between the feed tube and the feed tube housing, keep the internal
hammer parts tight.
6. FEED TUBE RETAINER
The feed tube retainer keeps the feed tube seated in the proper location. The feed
tube retainer also allows air to ow to the piston and feed tube.
7. FEED TUBE HOUSING
The feed tube housing is aligned in the main bore of the hammer. It is located by a
matching 45° angle in the case bore and is held in position by the backhead, check
valve housing and compression ring combination. The feed tube housing locates and
aligns the feed tube.

03/09/23 Page 3
6
8. FEED TUBE
The feed tube supplies the main air into the chambers located in the piston. The feed
tube collar seats against the feed tube compression ring which locates against a
shoulder in the feed tube housing. The feed tube is held in place by a feed tube snap
ring located above the feed tube collar. The long bearing surface design insures
alignment in the feed tube housing.
9. CHOKE
The interchangeable choke is located in the tip of the feed tube and is held in place
with a press t. A set of four chokes is supplied with each hammer. By installing the
correct choke, the hammer can be ne tuned to the compressor package.
10. 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.
11. CASE
The case is designed to contain the internal parts which make up the hammer assembly.
The case is reversible and is hardened to resist wear and to extend life in abrasive
conditions.
12. BIT BEARING
The bit bearing guides the bit to insure proper alignment between the piston and the
bit. The bit bearing is pressed into the chuck end of the case and locates against a
matching 45° angle in the case bore. The bit bearing provides a seal for the main air
supply.
13. WEAR SPACER
The wear spacer is not installed in a new hammer. It is located in the chuck end of the
case between the bit bearing and the disc springs. The wear spacer is used to take
up any space that can no longer be compensated for by the disc springs due to disc
spring compression fatigue in the bottom end of the hammer.
14. DISC SPRINGS
The four disc springs are located in the chuck end of the case. They are held in place
between the bit bearing and the washer. The disk springs are compressed as the chuck
is screwed into the case. They are designed to expand and maintain a tight assembly
as the internal hammer parts wear.

Page 4 03/09/23
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15. WASHER
The washer is located between the disc springs and the retainer. The washer is used
to provide an area to seat the disc springs.
16. RETAINER
The retainer is a hardened steel ring with a 3/4" (19mm) space to allow it to be compressed
when installing it in the case. The retainer is installed in the chuck end of the case and
prevents the disc springs and washer from falling out when the chuck, the bit retaining
rings and the bit are removed.
17. 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 an o-ring.
18. CHUCK
The chuck threads into the bottom of the case with a large cross section thread form.
It has internal splines that mesh with the splines on the bit body to transmit rotation.
19. 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.

03/09/23 Page 5
6
SECTION II
MAINTENANCE
DISASSEMBLY
•If at all possible, the backhead and chuck should be broken loose on the drill rig; this
is much easier than trying to do so after the drill has been removed from the drill rig.
CAUTION
USE CAUTION WHEN HANDLING DOWN 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
•Maintenance should be performed in a clean environment.
• Tools needed: hammer stand, chain vise, 2" (51mm) diameter brass rod, snap ring
pliers, press, a drift pin and a small screwdriver.
•Clean the outside of the hammer. This will insure a good surface to clamp on.
•Place the hammer horizontally on a hammer stand and secure the hammer with a
chain vise. Place the chain vise on the area of the case where the bit bearing is housed
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 check valve
housing is housed.
CAUTION
THE ACCEPTABLE CLAMPING AREAS START 5" (127MM) FROM EITHER CASE END,
TO AN ADDITIONAL 3" (76MM) BEYOND THIS POINT. PLACING THE CHAIN VISE
ON THE AREA OF THE CASE WHERE THE PISTON CYCLES CAN DISTORT THE CASE,
RESTRICT PISTON MOVEMENT AND VOID THE WARRANTY.
•Unscrew and remove the backhead from the case. Remove the backhead o-ring from
the backhead and thrust washer.
•Remove the check valve, the check valve spring and the check valve housing from
the backhead end of the case.
•Remove the compression ring from the base of the check valve housing.
•Remove the feed tube retainer.
•Unscrew and remove the chuck, bit and the bit retaining rings from the case.

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•Remove the thrust washer from the chuck.
•Remove the bit retaining rings o-ring from the bit retaining rings.
•Use the snap ring pliers to remove the retainer, then remove the washer and the four
disc springs.
•Using a 2" (51mm) diameter brass rod, slide the piston against the feed tube assembly
and push the feed tube assembly out the backhead end of the case.
•Slide the piston out the backhead end of the case.
•Removal of the bit bearing is not necessary for routine maintenance. If necessary,
insert the bit bearing press plate into the backhead end of the case, with the small
diameter toward the case bore. Using a 2" (51mm) diameter brass rod, slide the bit
bearing press plate to the chuck end of the case until it rests against the bit bearing.
Using a press, apply pressure to the 2" (51mm) diameter brass rod and force the bit
bearing press plate and the bit bearing out of the chuck end of the case. Refer to
gure 2-1 for bearing spacer dimensions.
N6 Bearing Spacer/Press Plate
Figure 2-1
3/64R3/64R
1/32 CHAMFER
1/32 CHAMFER
3 PLACES3 PLACES
3.235-3.250
3.235-3.250
2 1/2
2 1/2
1
1
4.200-4.215
4.200-4.215
7/8
7/8
45°
45°

03/09/23 Page 7
6
•Disassembly of the feed tube assembly is not necessary for routine maintenance. If
necessary, with the choke end of the feed tube against the work bench, apply down-
ward pressure toward the work bench. This will cause the feed tube to protrude from
the backhead end of the feed tube housing. Grasp the feed tube and slide it out of
the feed tube housing. Slide the feed tube compression ring off the choke end of the
feed tube. Place the feed tube collar toward the work bench. Using a drift pin, tap
the choke from the feed tube press diameter. The choke will fall out of the collar end
of the feed tube. Using a small screwdriver, pick the two feed tube o-rings from the
feed tube housing.

Page 8 03/09/23
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INSPECTION
•All parts should be washed in a clean solvent before they are inspected and
reassembled.
WARNING
USE CLEANING FLUIDS THAT ARE NONFLAMMABLE AND AVOID
BREATHING THE FLUID VAPORS.
•Handle all parts carefully, hardened parts may chip if dropped on a hard surface.
BACKHEAD
•Inspect the threads for cracks and burrs.
• Remove all burrs on the thread with a ne le.
•Replace if necessary.
CHECK VALVE
•The check valve should be smooth and free from abrasions.
•Replace if necessary.
•Replace the check valve spring if it is worn or broken.
FEED TUBE ASSEMBLY
•Inspect the outside diameter for nicks, burrs and scoring.
•Inspect all makeup surfaces for indentations or nicks caused by wear.
•Remove all minor irregularities with emery cloth.
•Replace if necessary.
PISTON
•Inspect the striking face, inside and outside diameters for nicks, scoring and cracks.
•Polish the piston with emery cloth to remove all minor irregularities, cracked pistons
should be replaced.
•Wash the piston thoroughly, inside and out, to remove all emery dust.

03/09/23 Page 9
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CASE
•Inspect the outside diameter for excessive wear or cracks. Inspect the internal case
bore for scoring.
• Remove all minor irregularities with ne honing stones.
•Clearance between the piston and the case should not exceed 0.015" (0.38 mm).
•Select the larger end of the case to be the chuck end. Replace if the outside diameter
is worn to 5" (127 mm) or less near the chuck end.
BIT BEARING
•Inspect the inside and outside for nicks and burrs.
• Remove all internal irregularities with a ne honing stone.
•Remove all external irregularities with an emery cloth.
•Clearance between the bit shank and bit bearing should not exceed 0.010" (0.25 mm).
•Replace if necessary.
BIT RETAINING RINGS
•Inspect for cracks or deformations.
• Remove all irregularities with a le or emery cloth.
•Replace if necessary.
CHUCK
•Inspect for cracks and burrs.
•For continued use, the outside diameter should be larger than the outside of the case
or the same. Collar length should not be less than 2.125" (54 mm).
CAUTION
IF THE COLLAR LENGTH IS LESS THAN 2.125" (54 MM) AND THE BIT IS
UNDER LOAD CONDITIONS, CONTACT BETWEEN THE SHOULDER OF
THE BIT RETAINING RINGS AND THE BOTTOM OF THE BIT RETAINING
RING AREA ON THE BIT, COULD CAUSE THE BIT TO FAIL IN THIS AREA.
•Torsional play in the splines should not exceed 0.125" (3.2 mm).

Page 10 03/09/23
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•Replace if necessary.
O-RINGS
•Inspect for damage such as cracks and deformations.
•Replace if necessary.
THRUST WASHERS
•Inspect for damage such as cracks.
•Replace if necessary.

03/09/23 Page 11
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GENERAL ASSEMBLY INSTRUCTIONS
•Assembly should be performed in a clean environment.
•All parts should be cleaned thoroughly and wiped dry before assembly.
•Oil all parts by hand using Rock Drill Oil to insure easy assembly.
•Coat all thread connections with a thread compound to allow joints to thread easily.
FEED TUBE ASSEMBLY
•Install the two feed tube o-rings in the two grooves located in the smallest inside
diameter of the feed tube housing.
•Place the feed tube compression ring over the choke end of the feed tube, then slide
it along the feed tube until it seats against the feed tube collar.
•Position the piston vertically on the work bench. Place the smallest outside diameter
of the feed tube housing on the piston so that the bores will align. Insert the choke
end of the feed tube into the feed tube housing. Slide the feed tube into the feed tube
housing until the feed tube compression ring is seated against the feed tube housing
shoulder. With the smaller diameter of the choke toward the collar end of the feed
tube bore, slide the choke all the way to the pressing diameter. Using a long drift pin,
tap the choke into the pressing diameter.
HAMMER ASSEMBLY
•Select the larger, outside diameter end of case to be the chuck end.
•Using the bit bearing press plate and a press, press the bit bearing into the chuck end
of the case. The larger inside diameter of the bit bearing should be facing toward the
chuck end of the case. Make sure the bit bearing is in contact with the shoulder of
the case.
•Place the four disc springs into the chuck end, being sure they are stacked correctly.
(See diagram page 13)
•Place the washer into the chuck end of the case.
•Using snap ring pliers, install the retainer into the chuck end of the case.
•Place the bit retaining rings o-ring around the bit retaining rings and place in the chuck
end of the case.

Page 12 03/09/23
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•Install the thrust washer installed against the shoulder of the chuck threads. Thread
the chuck into the case and hand tighten. Clearance between the case and chuck
should be a minimum of 0.050" (1.3mm) gap. If the gap is less than 0.050" (1.3mm), a
wear spacer must be installed between the bit bearing and the disc springs.
•Slide the piston in the backhead end of the case. Push the piston all the way to the
chuck end. The piston should ride in the case very smoothly. Stand the case up in a
vertical position, with the chuck end on the ground.
•Install the feed tube assembly into the backhead end of the case, be certain the feed
tube shoulders properly in the case. Due to close tolerances, caution is advised when
inserting the feed tube, it should not be forced into the case. Place the feed tube
retainer into the feed tube housing, resting it onto the feed tube collar.
Figure 2-2
Proper Feed Tube Shouldering in Wear Sleeve
•Install the compression ring.
•Install the check valve housing into the case, pushing it all the way to the compression
ring.
•Place the check valve spring into the check valve housing then insert the check valve
into the check valve housing.
•Place the thrust washer against the backhead thread shoulder. Install the backhead
o-ring into the groove on the backhead. Screw the backhead into the case and hand
tighten.
CAUTION
DUE TO THE CLOSE TOLERANCES BETWEEN THE CHALLENGER 6 INTERNAL PARTS
AND THE CASE, NUMA CAN NOT ACCEPT RESPONSIBILITY FOR DAMAGE CAUSED
BY WELDING ON THE CASE OD. WELDING ON THE CASE CAN CREATE DISTORTION,
CAUSE PREMATURE FAILURE AND VOID THE WARRANTY. CONTACT NUMA FOR
SPECIAL INSTRUCTIONS IF WELDING THE CASE BECOMES UNAVOIDABLE.

03/09/23 Page 13
6
Backhead 3-1/2 Reg. Pin
015357 (1)
Backhead O-Ring
005742 (1)
Thrust Washer - Brass
005478 (2)
Check Valve
011833 (1)
Check Valve Spring
011615 (1)
Check Valve Housing
005022 (1)
Compression Ring
005083 (1)
Feed Tube Assembly
005675 (1)
Feed Tube Retainer
011164 (1)
Choke
005559 (1)
Feed Tube
005431 (1)
Feed Tube
Compression Ring
005432 (1)
Feed Tube O-Ring
005680 (2)
Feed Tube Housing
005433 (1)
Piston
005003 (1)
Case
005268 (1)
Bit Bearing
005005 (1)
Wear Spacer
005026 (1)
Disc Springs
005028 (4)
Washer
005024 (1)
Retainer
005027 (1)
Bit Retaining Rings
005012 (1)
Bit Retaining Ring
O-Ring
005679 (1)
Thrust Washer - Brass
005478 (2)
Chuck
015358 (1)
016629 (1) - NTR
HAMMER ASSEMBLY #015356 / NTR #016628
Figure 3-1
SECTION III
PARTS IDENTIFICATION
EXPLODED VIEW
Exploded
view of disk
springs
Correct
Stacking

Page 14 03/09/23
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SECTION IV
AIR CONSUMPTION CHART
CHALLENGER 6
DRILL PRESSURE (PSI)
DRILL PRESSURE (BAR)
L/SEC
CFM
6.9 13.6 20.4 27.6 34.5
2000
1800
1600
1400
1200
1000
800
600
400
200
100 200 300 400 500
944
850
755
661
566
472
378
283
189
94.4
3/16 (4.8mm) CHOKE
1/4 (6.4mm) CHOKE
4
3
SOLID CHOKE
1/8 (3.2mm) CHOKE
1
2
1
2
3
4

03/09/23 Page 15
6
SECTION V
LUBRICATION
The Challenger 6 hammer requires a continuous supply of the correct type Rock Drill
Oil or an adequate application of Numa Enviro Lube. The Challenger 6 hammer consumes at
least two quarts (2 litres) of Rock Drill Oil per hour in order to maintain adequate lubrication.
See table 5-1 for recommended Rock Drill Oil.
As an alternative to Rock Drill Oil, Numa Enviro Lube provides continuous protection
for the Challenger 6 when 3 oz. (.09 litres) are used every 300' (92 m) or four hours of drilling,
whichever occurs rst. Numa Enviro Lube is utilized in 3-1/2" to 6" hammers only.
Medium SAE 30 Heavy SAE 50
Shell Air Tool Oil S2 A 150 Air Tool Oil S2 A 320
Texaco / Caltex Rock Drill Lube 100 Rock Drill Lube 320
Chevron Vistac 150 Vistac 320
Conoco Conoco 150 Conoco 320
Numa Bio Blend RDP 150 RDP 320
Table 5-1
Recommended Rock Drill Oil
CAUTION
ROCK DRILL OILS AND NUMA ENVIRO LUBE ARE THE ONLY ACCEPTABLE
LUBRICANTS. SAE 50 ROCK DRILL OIL SHOULD BE USED IN AMBIENT
TEMPERATURES OF 80° FAHRENHEIT (27° CELSIUS) OR HIGHER. CONTACT
NUMA FOR ACCEPTANCE OF ALTERNATIVE ROCK DRILL LUBRICANTS.
CAUTION
THE CHALLENGER 6 HAMMER, AS WITH ANY MACHINE, REQUIRES
CONTINUOUS LUBRICATION. THE FAILURE TO SUPPLY ADEQUATE
LUBRICATION TO THE HAMMER CAN CAUSE PREMATURE FAILURE AND MAY
VOID THE WARRANTY.

Page 16 03/09/23
6
SECTION VI
STORAGE
When storing a Challenger hammer, it is important to take the necessary steps in order
to insure a smooth operation after restarting.
When the hole is completed and the hammer is to be inactive for several weeks or
longer the following steps should be followed:
Each drill rod should be blown clear of all water. During this process, turn on the in
line lubricator and blow until the rock drill oil can be seen from the bottom end of each drill
rod. In addition, each rod (pin and box end) should be wiped clean and capped to prevent
foreign contaminants from sticking to the connector ends.
SHORT TERM STORAGE
When the Challenger hammer will be stored for only a short period of time the following
steps should be taken:
•Blow the hammer clear of all water.
•Pour 1 quart (1 liter) of Rock Drill Oil into the backhead.
•Turn the air on and cycle for 10 seconds. This will lubricate the internal parts.
•Cap the backhead and chuck end.
•Store the hammer horizontally in a dry environment.
LONG TERM STORAGE
When the Challenger hammer will be stored for only a long period of time the following
steps should be taken:
•Blow the hammer clear of all water.
•If at all possible, the backhead and chuck should be broken loose on the drill rig, this
is much easier than trying to do so in the shop.
•Disassemble the hammer.
•Inspect and wipe all the parts clean.