4” MODEL R PROSPECTOR...

TECHNICAL MANUAL

3” MODEL R PROSPECTOR HAMMER &

4” MODEL R PROSPECTOR HAMMER

HAMMER MODEL AND SERIAL NUMBER ____________________

SUPPORT PACK/HAMMER OILER SERIAL NUMBER ________

Contact Us 11140 N. State Road 67, Mooresville, Indiana 46158 US

Website: www.PioneerOneHDDP.com + 1-317-831-2081

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PIONEER ONE INC 3”R AND 4”R SERIES PROSPECTOR HAMMER TECHNICAL MANUAL

TABLE OF CONTENTS:

DESCRIPTION ..............................................................................................................................................................3 SAFETY CONSIDERATIONS. ..........................................................................................................................................3 WARRANTY….……………………………………..………………………………………….………………………………………………………….…………..4 HAMMER SETUP AND OPERATION:..............................................................................................................................5 Choke Selection / Jet sub Backhead Orifice Setup ...............................................................................................5 Bit Installation .................... .................................................................................................................................6 Makeup Torque ................................................................................................................................................... 6 Lubrication Guidelines .........................................................................................................................................6 Rotation Speed .................................................................................................................................................... 8 Hole Collaring ...................................................................................................................................................... 8 Thrust Force ........................................................................................................................................................ 9 Hole Cleaning and Dust Suppression ...................................................................................................................9 Bit Selection .........................................................................................................................................................9 HAMMER TROUBLESHOOTING:.................................................................................................................................10 Building too much pressure ...............................................................................................................................10 Building too little pressure along with poor performance .................................................................................10 Fouling from water and cuttings ........................................................................................................................11 Breaking or loose exhaust tubes ........................................................................................................................11 Broken casings and pistons ................................................................................................................................11 STEERING PATTERNS……….…………………….………………………………………………….……………………………………..…………..………12 TORQUE SPECIFICATIONS AND TONG JAW PLACEMENT……….…………………………………………………………………………..….13 REMOVING DRILL BIT………………………………………………………………………………..………………………………………………………….14 CLEANING DEBRIS FROM INSIDE OF HAMMER…..………..……………………………………………..………………………………….…….15 REMOVAL OF TORQUED PARTS…………………………………………………………………………………..…….………………………………….15 BLOW TUBE REPLACEMENT AND INSTALLATION…..………………………………………………………………………………………..…..16 LOADING SONDE AND SONDE TUBE ASSEMBLY………………………………………………………………….…………………………………17 DISASSEMBLY……………………………………………………………………………………….……………………….…………………………….……….20 ASSEMBLY………………………………………………………………………………………….…………………………………………………….………..…21 STARTUP REFERENCE GUIDE AND PROCEDURES………………………………………………………..…………………………………………24 3” HAMMER WEAR LIMITS…………………………………………..………………………………………………………………..……………………..31 4” HAMMER WEAR LIMITS………………………………………………………………..………………………………………………………………….32 3”R HAMMER EXPLODED VIEW..………………………………….…..…………………………………………………………..………………………33 3”R SONDE HOUSING………………………………………………….…….…………………………………………………………………..……………..34 4”R HAMMER EXPLODED VIEW…..…………………………….….…………………………………………………………….……………..........…35 4”R SONDE HOUSING………………………………………………..………………………………………………………………………………...……….36 19” SONDE HOUSING…………………….…………………………………………………..…………………………..…………………………….………37 SUPPORT PACK EXPLODED VIEW ………..…………………………………………………………………..…………………………………………..38 OILER EXPLODED VIEW………………………………………………………………………………………..……………………………………………….39 DRILLING FLUIDS AND EPOXY MSDS ……………………………………………………….………………..……………….…………………..40-46 WARRANTY CARD….………………………………..…………………………………………………………….……………………………………………..47

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DESCRIPTION:

Pioneer One's 3 & 4 inch Model R Prospector Hammers are percussion rock drills designed for use on HDD rigs.

The drill rig must be capable of delivering sufficient hold down, hold back, oil injection, torque, rpm, air pressure

and volume.

Pioneer One's 3 & 4 inch Model R Prospector Hammers are recommended for all hard rock applications.

SAFETY CONSIDERATIONS:

Read and understand this manual before using or servicing your downhole/HDD

hammer. If you need technical assistance, contact your Pioneer One salesman

or dealer immediately.

Keep your downhole/HDD drill in proper working condition. Replace and/or repair any worn or broken parts.

Wear the proper approved safety equipment when operating or maintaining the downhole/HDD drill. These include, but are not limited to: safety glasses, hard hat, ear protection, gloves, steel toe boots, and respirator.

Beware of live air. Inspect all air lines and connections before operating your downhole/HDD drill. Never get under a downhole/HDD drill for any reason-exhausting high pressure air is dangerous. Remember: Part breakage or failure could cause hammer parts or the drill bit to fall out of the hammer casing.

Never impact a carbide insert or other heat treated steel hammer component with a hammer or other hardened steel member for any reason. Always use a brass (or soft steel) bar to tap hammer parts as you service your downhole/HDD drill.

Ensure that chain wrenches or tongs are rated for the torque applied. Breakout tooling can be dangerous.

Serial Number __________________ Model Number ____________________

Please take the time to record the serial number assigned to your hammer and record it on the front-page of this

manual. This information is required to ensure the correct service parts are supplied when needed. This number is

also stamped on the backhead flats.

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Warranty

The Prospector Drilling System comes with a 6 (six) month limited warranty. Pioneer One, Inc. warrants materials

and workmanship. If failure occurs, Pioneer One, Inc. will replace or repair failed part or parts at Pioneer One,

Inc.'s discretion with no cost to the customer for parts or labor. This warranty applies only to failed parts. If a part

fails, the Prospector hammer must be taken out of service, "red tagged" or " locked out", until repairs are made.

Continued use could cause severe property damage and/or serious injury, including death. All operators must be

properly trained and certified in the correct assembly and operation of the Prospector HDD air hammer system,

failure to do so voids warranty.

This warranty shall not apply to the following conditions:

1. Any failure or breakage caused by improper operating procedures.

2. Lack of proper maintenance

3. Improper repairs or parts installation not performed by a Pioneer One, Inc. representative.

4. Improper storage procedures.

5. Damage caused by accidents, misuse, negligence, vandalism, natural disasters, or parts or accessories installed

which are not manufactured and/or installed by Pioneer One, Inc..

6. Pioneer One, Inc. shall not be held liable for any damage including, but not limited to, loss of profits, downtime,

or penalties due to loss of time.

7. Depreciation

8. Normal wear items such as, but not limited to, bit, wear sleeve, piston, outer case housing and torqued parts.

Pioneer One, Inc. makes no other warranties other than the ones listed above.

WARRANTY WILL BE VOIDED BY:

WELDING ON CASING WILL DESTROY HEAT TREATMENT AND CAUSE CRACKS IN THE CASING

HEATING CASING ABOVE 400F (204C) WILL DISTORT BORE AND RUIN HEAT TREATMENT

GRIPPING WITH WRENCH ACROSS THREADS CAN DISTORT BORE AND START CRACKS

HAMMERING ON CASING CAN FORM CRACKS ON OUTSIDE OF CASING

Before any P1 Series HDD hammer is operated, it should be set up for the proper air consumption, and both

joints (chuck and backhead) should be torqued to Pioneer Ones specifications using chain tongs and/or

mechanical breakout/makeup wrenches approved for the required toque needed.

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Choke Selection / Jetsub Backhead Orifice Setup

The best downhole/HDD drill performance will be achieved when a maximum volume of air can be passed through the drill with a solid choke. Under ideal conditions, the pressure required to drive this volume of air through the drill will be within the capabilities of the compressor.

All P1 Prospector Hammers have air bypass capabilities tuning the hammers. Pioneer One's 3 inch and 4 inch model R hammers use a flat orifice plate housed below the check valve spring . All P1 HDD hammers come from the factory with a “solid” choke (no bypass). Different plugs can be installed in place of the factory installed “solid” plugs to increase the air consumption of a drill, or, the orifice plate can be drilled to size to allow bypass air through the drill.

A quick rule of thumb for determining the flow through a round orifice is the following:

Where:

SCFM = orifice flow in SCFM

PSI = orifice pressure in PSI

D = orifice diameter in inches

Note that bypassing air through an internal choke has two drawbacks: It increases the backpressure on a downhole/HDD drill, which reduces

performance. Excess flow through the downhole/HDD drill increases the rate of wear on the external components of the hammer.

In most cases where additional air flow is not needed for hole cleaning, a better option is to reduce compressor output by either lowering the engine RPM, or restricting the compressor inlet.

Figur

e 1:

Orific

e

Flow

vs.

Press

ure

ORIFICE FLOW TABLE

ORIFICE SIZE (inch) 1 HOLES

0.125 0.188 0.250 0.313 0.375 0.500 0.750

PRESSURE 1/8 3/16 1/4 5/16 3/8 1/2 3/4

200 32 72 127 199 285 507 1141

225 35 80 142 222 318 566 1274

250 39 88 156 245 352 625 1407

275 43 97 171 268 385 684 1540

300 46 105 186 291 418 743 1673

325 50 113 201 314 451 802 1805

350 54 122 215 338 485 861 1938

375 58 130 230 361 518 920 2071

400 61 138 245 384 551 980 2204

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Bit Installation

Bit splines should be thoroughly lubricated with rock drill oil before the chuck is installed. Liberally grease the chuck threads with thread grease or copper based grease before threading it into the casing.

Inspect the splines on any used bit and chuck combination. Some applications (usually soft rock where there is excessive bit travel) develop uneven wear on the bit and chuck splines. When installing a new bit in a used chuck, there may be uneven mating surfaces which will lead to extreme wear on both the bit and chuck. Check the condition of bit and chuck splines prior to bit installation.

It is good practice to index the bit relative to the chuck when changing the bit or servicing the drill. This will minimize external chuck wear due to rock chip blasting from the waterways on the OD of the bit.

Makeup Torque

It is recommended that both the backhead and chuck joints on the 3 inch Model R be torqued to 4000 ft-lbs. (5423 N-m) and the 4 inch Model R torqued to 5000 ft-lbs (6779 N-m) .

Proper makeup torque guards against inadvertent loosening of tool joints in the hole. The presence of a gap between the casing and the backhead while drilling will increase the chances for loosening the backhead in the hole and possibly losing the hammer. Damage to internal parts is also likely.

Lubrication Guidelines

All Pioneer One Prospector Hammers require lubrication to resist wear, corrosion, and galling

Rock drill oil must be injected proportionally to the amount of air fed to the

downhole/HDD drill.

A good lubrication guideline is: ½ Gallon / 1000 CFM / Drilling hour. For example: A drill using 900 CFM/350 PSI compressor would need: 0.45 Gallons / hour of oil injection. (900/1000) x ½ Gallon.

Oil needs to be of sufficiently high quality.

Lubrication check: When oil is injected into an airline, it takes considerable time to coat the walls of the piping, and finally get oil to the downhole/HDD drill. It is recommended that lubricated compressed air be blown through the hammer until oil begins to appear at the bit blow holes; this will ensure proper lubrication to the hammer. You may secure cardboard or wood beneath the blow holes. The cardboard or wood will become wet with oil when the air is turned on and an adequate film of oil has been developed. Then, while drilling, monitor the oil reservoir frequently and visibly check oil level to make sure oil is being injected into the air supply.

1. Drilling fluid injection is required for proper removal of cuttings and dust suppression, the recommended

drilling fluid additive P1 recommends is “Hole Control” by Matex Control Chemical. This fluid, when properly

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mixed and injected at a rate of 1 gpm (3.8 lpm), will allow the “Hole Control” to collar the bore hole or what is

sometimes referred to as a filter cake. Hole Control will help seal off cracks and crevices along the bore path

and if any clay is encountered it will help in keeping the clay from swelling and open so that air flow is

maintained throughout the bore. In some instances, the injection rate may have to be increased if a long

period of clay is encountered sometimes 2 gpm to 4 gpm ( 8 lpm to 15 lpm). Then, once contact with rock is

made, injection rate should be adjusted back to 1 gpm (3.8 lpm).

2. P1 is a Hole Control retailer. However, if Hole Control is not available in your area, check with your drilling

fluid supplier for a foam for use in an air hammer.

3. Hole Control is an environmentally safe drilling fluid additive.

Drilling Fluid Injection

Drilling fluid injection is required while drilling for a variety of reasons. When injecting drilling fluids into the drill, there are some factors to consider:

Drilling fluids injected at a rate of more than 1 gpm (4.5 lpm) will result in a net pressure increase as the injected drilling fluid seals the leak paths between internal components. Injected drilling fluid is occupying space normally occupied by compressed air, and hence reduces the amount of air flow through the drill, which raises the drilling pressure.

Poor quality water used to make the drilling fluid can carry contamination into the drill, resulting in premature wear of hammer internals.

Never use a suction line to get drilling water off of the bottom of a pond or river.

All water used to make the drilling fluid and injected into a downhole/HDD drill should be pH neutral. Neutral water combats corrosive damage to hammer internals.

Water injection ONLY reduces downhole/HDD hammer performance, and reduces face cleaning, which causes regrinding of cuttings, and reduced bit life.

Water present at the impact face causes cavitations of the impact faces of the piston and bit, and jetting erosion of the exhaust tube OD. These will result in internal component failures.

Always cycle lubricated air through any downhole/HDD drill that will be idle for more than a couple of days. Blowing air through the hammer in “blow” mode will not properly lubricate internal components of the drill; the drill must be cycled during this procedure.

Use of Bentonite with a P1 air Hammer.

Bentonite mix may be pumped through hammer if maintaining air flow back to the drill cannot be

maintained. ONLY pump through hammer do not operate hammer with air and inject bentonite

while hammering as the sand mixture will cause internal damage. The recommended procedure is

to make sure your water has the proper PH and you need to add bentonite until you have what is

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known as a 60 second mud, if you don’t know how to do this or you are unsure then contact your

drilling fluid supplier for help and/or instructions.

Start pumping the bentonite down hole. Remember your rods are empty so allow enough time

for them to fill up, once you have determined they are full and bentonite is flowing out the

hammer, then begin pumping at an approximate rate of 10 gpm to 12 gpm (38lpm to 45 lpm). As

the bentonite is being pumped, start the removal (pull back) of the drill rods. You may have to pull

all of them out or only through the area that was causing you to lose air flow. Before pushing the

rods back in, discontinue the use of bentonite. Now you may engage the air and start back the

use of “Hole Control”. Once you are back against the rock, all bentonite should be cleared out and

you are ready to complete the bore.

Rotation Speed

Speed of drill rotation affects the amount of angular index that the bit moves from one piston impact to the next. The optimum amount of index is dependent on variables such as blow energy, rock characteristics, bit diameter, etc.. The ideal rotation speed optimizes the penetration rate of the hammer, bit life, and smoothness of operation.

To check rotation speed: Use chalk or a soapstone to scribe a spiral on the drill pipe while the drill string is rotating. The distance between the spirals can then be measured to be able to determine if the rotation speed should be increased or decreased. The measured pitch should be approximately equal to the gage insert diameter. For example, using a bit with 5/8" (16 mm) inserts, RPM should be adjusted to produce 5/8” (16 mm) of advance per revolution (Figure 2).

A general rule of thumb is to run rotation as slow as possible to maintain smooth operation along

with a balance of good performance and bit wear.

Figure 2: Setting Rotation Speed

Hole Collaring

Collaring a drill hole is a critical stage of the drilling process. In HDD bore holes, it can determine the quality of the top of the hole.

ADJUST ROTATION TO PRODUCE 0.5” to

0.75” (13mm to 19mm) PER REVOLUTION

OR THE EQUIVALENT OF ONE CARBIDE

DIAMETER

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Thrust Force

Thrust force required to operate a HDD air hammer is directly proportional to the power output of the drill.

Rule of thumb: HDD Air Hammers should be fed with a force of approximately 500 lbs./in. (9kg

/mm) of hammer diameter.

Most operators will increase the thrust pressure until the rotation gets “jerky” and then back off slightly until the rotation becomes smooth.

When drilling through varying ground conditions (hard seams, soft seams, mud, voids), every effort should be made to keep the drill fed properly. A “loose” running drill can cause damage to the piston, bit, and chuck very quickly.

Feed force should be reduced when drilling through unconsolidated or fractured

rock to avoid damage to the hammer casing and hammer internals, and to

assure straightness of the drill hole.

Hole Cleaning and Dust Suppression

Proper hole cleaning is key to maximizing hammer component life, bit life, hole quality, and hole straightness. Improper hole cleaning will increase the risk of losing the drill string in the hole.

Wet drilling is required in all HDD Air Hammer drilling applications for both hole cleaning and dust suppression. Water injection rates for dust suppression are usually very low ( ½ gpm to 1 gpm (1.8 lpm to3.8 lpm).

Water intrusion into the hole can develop mud rings where dry cuttings meet a

water seam entering the hole. Mud rings can develop where the dry cuttings

stick to the bore hole wall when they hit the wet area. Water injection is

needed to keep the bore hole wet enough to prevent these mud rings from

developing. Water injection rates will vary depending on the type of material

being drilled, the penetration rate, and many other factors.

Bit Selection

Pioneer One offers a variety of different bits for you drilling needs. Please contact your P1 salesmen or dealer for help in choosing the proper bit configuration for your drilling application to maximize the efficiency of any directional drill. Your own drilling experience in a given rock formation is the largest contributing factor in bit and insert selection.

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HAMMER TROUBLESHOOTING

Building too much pressure

Chuck body length. Verify that chuck length is still within specification. A worn chuck will shift timing points in the hammer and not allow adequate piston return pressure to be applied. Replace if needed.

Backhead properly torqued. Be sure Backhead is properly torqued so that there is no air leakage which would reduces the HDD air hammer's performance.

Air flow restrictions and blockages to hammer. Ensure there are no restrictions between compressor and hammer. For example, it is common for the inner liner of high-pressure hoses to delaminate and block the flow of air. Verify by checking off-bottom blowing pressure. If off-bottom pressure is okay than there is likely no restriction. If the pressure is elevated there may be a restriction.

Restrictions and blockages downhole/HDD.

Ensure that cuttings are freely exiting hole such that exhaust flow from the hammer is not restricted. This is sometimes referred to as “circulation”.

Mud-collars are common in holes bored through water bearing rock. Ensure adequate volumes of water are injected to keep the hole clean and wet enough to prevent formation of collars. Collars form when dry cuttings mix with water entering the bore hole and form a collar that restricts exhausting air.

Excessive water. Clearing a hole against large inflows of water requires more pressure. If pressure builds to the point where compressor begins to unload, then a hammer adjustment may be needed or a pressure booster added. The hammer adjustment may involve opening the choke or bypass jets of adjusting the valve.

Building too little pressure along with poor performance

Lack of adequate oil. A hammer operating without adequate oil can use 5% to 8% more air than one that is properly oiled. That translates into a big loss in productivity notwithstanding the rapid wear rate on internals. Use good quality oil at the highest viscosity that is practical for the oiler and conditions.

Verify that the oiler is actually pumping oil. Check oil levels before, during, and at the end of a shift to be sure oil is being pumped.

Worn hammer internals. The reciprocating action the piston within the cylinder and casing will naturally cause the bearing and sealing clearances to enlarge over time. The rate at which these clearances increase will depend on many factors:

Verify that hammer is set up properly for the air supply.

Quality and cleanliness of water used for drilling fluid and bore hole cleaning. All water injected into the hammer air supply should be filtered to at least 20 microns. Additionally, water containing contaminants with silica will be much more abrasive that water containing calcium.

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Clean drill pipe. The dust from drilling can accumulate in oil-covered drill pipe. Effort should be made to keep pipe as clean as possible and blow them clean when making connections.

Fouling from water and cuttings

Fouling (mudding) of a hammer in the presence of water in the hole is likely caused by a leaking check valve, broken check valve spring, or backhead o-ring which allows air to escape from the hammer allowing dirty water to rise in the hammer.

Inspect check valve spring for breaks, OD flats, or broken-off coils. Inspect check valve o-ring for nicks or heat damage which could allow it to leak. Inspect the backhead o-ring for flats or nicks which could allow it to leak.

Breaking or loose Blow Tubes

In most cases, a broken blow tube will render a hammer inoperable. Breaking blow tubes can be caused by a number of factors.

A tube that shears off flush with the bit striking face may indicate that either too much drilling fluid or dirty water is being injected. Impact between the piston and bit on a film of water causes a jetting action of high pressure water which erodes, weakens, and eventually allows the tube to snap off. This is aggravated by particulates in the water.

A tube that is shattered could indicate a number of problems:

(1) Worn bit or bit bearing allows excessive radial movement of the bit in the hammer making the piston hit the tube during operation.

(2) Damage during hammer assembly from getting the bit misaligned. Ensure the bit is aligned with hammer when attempting assembly.

(3) Damage and weakening from sunlight. The polymer the tubes are made of is degraded when exposed to sunlight. If a tube takes on a chalky appearance it has been exposed to sunlight.

ii) The repeated impact of the piston on bit, and resultant movement between the tube and bit, will eventually wear down the press fit between the tube and bit. If a tube can be moved up and down more than 3/16” (5 mm), it should be replaced. A loose tube can foul the precise porting of a HDD hammer.

Broken casings and pistons

One of the most costly causes for hammer failure is damage caused to the casing due to hammering or welding in an attempt to loosen the chuck or backhead joints. Many hammers have a hardened outer layer on the casing to resist wear and provide long service life. However, the hardened case can be cracked by welding or hitting with a hammer. Additionally, the casing bore can be deformed to the extent that is will interfere with the piston. A piston rubbing within a deformed casing will start friction cracks in the piston resulting in eventual failure.

CASINGS ARE DESIGNED TO BE GRIPPED BY PETOL STYLE WRENCHES…ONLY. THEY SHOULD NOT BE WELDED ON OR HAMMERED. Make the investment in a correctly sized bit basket and a Petol-style wrench.

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Steering Patterns

The hammer will sometimes need to be steered differently in certain rocks. Once steer direction has been

selected, steering is accomplished by using a carving motion, usually two clock positions (CCW/CW) off top center

of drill rod. As the HDD air hammer is being oscillated for steering, the amount of thrust pressure will be in the

range of 200 psi to 500 psi. The variance in the thrust pressure is due to the type of rock and the electric over

hydraulic thrust controls on the majority of HD drills. Always operate in low rotation and low thrust speed.

To determine how much steer is needed, start carving for a distance of 18” inches (0.48 m ). Sometimes you may

need to carve 24 inches (.60 m), pullback off of the face of the rock 6 inches to 12 inches (152 mm to 304 mm),

and then start to rotate easily. You should notice a spike in the rotation pressure gauge as you thrust slowly

forward. This usually means the HDD air hammer steered. Once you have made contact with the rock, rotate

inward approximately 18” inches to advance the sonde housing into the steer. Pull back off the face of the rock,

just enough to deactivate the hammer, and position the HDD air hammer at the 9:00 or 3:00 o’clock position so

that the hammer is lying flat. This is the proper way to check the pitch/angle of the HDD air hammer and

determine the amount of steer. As an average, you may see approximately a 1% change and in some instances

you may see a little more. The maximum steer recommended for the HDD air hammer is 5% using a 10’ ft (3m)

drill rod and 6% for a 15’ ft (4.5 m) rod. Be sure these recommended steering percentages are spread out over the

entire length of the drill rod. DO NOT try to achieve the maximums all at one time.

The definition of a steering pattern is the speed in which you carve the HDD air hammer and the amount of thrust

applied. In many instances, slow carving will increase the amount of steer in certain formations and fast carving in

others. Carbide selection will also need to match the type of rock to be drilled. For more assistance concerning

steering Pioneer One's HDD air hammers contact one of their rock specialists.

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Torque Specifications and Tong Jaw Placement

The chuck, bent sub and backhead on all hammers are torqued parts. Threads on all pats must be cleaned and

inspected for damage before being installed. The 3" hammer torques to 4000 ftlbs (5423 N-meters) and the 4"

hammers torques to 5000 ftlbs (6779 N-meters).

Chuck and backhead threads must be coated with copper impregnated rod grease before installing.

Bent sub threads are glued with Torq Loc glue. The bent sub is glued to keep threads from loosening during

drilling process. Take care when applying Torq Loc glue to keep any excess glue from entering the inside of the

hammer., Glue inside of the hammer could cause air blockage or damage to the hammer. See Figure 1 for

placement of the Tong Jaws.

Tong Jaws Must Be Placed In This Area

Figure 1

Bit End of

Hammer

Bent Sub End of

Hammer

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Removing the Drill Bit

Bit removal can be one of the most dangerous and frustrating tasks associated with the drill operation. However,

with the proper tools and techniques it should require no more than a few minutes to remove a bit. The following

list pointers which will be beneficial in helping you remove a bit quickly, safely and with reduced risk to damaging

hammer parts and components:

1. Clean outside of hammer casing.

2. Use sharp tong jaws. Worn or rolled over tong haws increase the jaw pressure and make the wrench

more prone to damaging the hammer case. Pioneer One hammer cases are case hardened which means

sharp jaws are needed to grip through the hardened case.

3. Grip the casing in the proper location. Gripping over the threads can make thread loosening extremely

difficult. Example; as the wrench tightens, it exerts an inward force which can pinch the threads if they

are under the wrench jaw. This only increases the torque needed to uncouple the thread. Also, do not

grip the casing in an area where the bore is not supported by either the piston or bearing. Gripping over

an unsupported area can distort the bore. See Figure 1 in Torque Specifications section for the

recommended locations for jaws. Use a bit basket to catch the bit to avoid personal injury.

4. Ensure the bit fits properly within the bit basket. An improper fit may result in the bit slipping from the

basket.

5. Never weld or hammer on the casing to loosen it. All casings are hardened for extended service life. The

hard casing surface can be cracked by welding or impacting with a sledge hammer. If a chuck or backhead

is difficult to loosen, repeatedly tapping the casing at the thread location with a brass bar or hammer

while torque is applied may help loosen the joint.

Warning!! Ensure chain wrenches or tongs are rated for the torque applied.

The flying parts of chain wrenches can cause injury or death when they break.

Wear eye protection as the hammer will be cycling about ground. Ensure that all drill string joints are tight and

watch to make sure other string joints do not loosen before the chuck. If they do loosen, stop the process and

retighten.

This casing has been precision heat treated, therefore, the following will void the warranty and possibly cause

damage.

WARRANTY WILL BE VOIDED BY:

WELDING ON CASING WILL DESTROY HEAT TREATMENT OF CASING CAUSING CRACKS.

HEATING CASING OVER 400 F (204 C) WILL DISTORT ORE AND RUIN HEAT TREATMENT.

GRIPPING WITH WRENCH ACTOSS THREADS CAN DISTORT BOR AND START CRACKS.

HAMMERING ON CASING CAN FORM CRACKS ON OUTSIDE OF CASING.

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Cleaning Debris from Inside of Hammer

1. Clean outside of hammer.

2. Remove sonde and sonde tubes.

3. Remove bit and chuck. See manual for proper removal of torqued parts, and bit and chuck removal.

4. a 4' (1.2192 m) long 5/8 inch (16mm) dowel rod is required to release air check valve. Insert dowel rod

through sonde housing, through bent sub, casing. Apply pressure to the end of the dowel rod to depress

spring on air check valve. This will allow debris to pass through the hammer. With the spring depressed,

wash inside of hammer casing thoroughly with pressure washer. PPE must be worn to protect personnel

from flying debris.

5. Allow all water to drain from the hammer. Oil casing with recommended oil.

6. Place bit splines through chuck and install bit retaining ring. Apply copper impregnated rod grease to

chuck threads and thread into hammer bit end. Retorque to specifications. See Torqued Parts section of

manual for recommended procedures.

Removal of Torqued Parts

1. Thoroughly clean out side of hammer.

2. Use an approved breakout system to loosen torqued parts. Never use pipe wrenches as serious damage

or personal injury could result.

3. Check tong jaws on breakout system being used. Make sure tong jaws are sharp and in good working

condition. Follow the recommended procedures for the specific breakout system being used and pat

strict attention to safety warnings. If the jaws are not sharp, placement of haws is incorrect, or proper

procedures are not followed damage could occur to the hammer. All hammer torqued parts are torqued

to 4000 ftlbs (5423 N-meters) for the 3" and 5000 ftlbs (6779 N-meters) for the 4".

4. Chuck Removal

A. Make sure piston is in up position (the bit end) in the hammer casing. This can be accomplished

by tipping the hammer up with the bit end down. This will allow the piston to slide to the bit end.

If the hammer is attached to the drill string, simply open the air valve slowly until piston is at the

bit end of the hammer casing, then turn air off. If the piston is not in the "up position," damage

could occur to the hammer. If attempting to remove any parts of the hammer while it is still on

the drill string use extreme caution to make sure drill id not operated while attempting to remove

parts.

B. Place one tong on the chuck. This tong jaw should not overlap onto the hammer casing. Place

the other tong jaw in an area between 6" (15.2 cm) to 13" (33 cm) above the bit end of the

hammer casing. (See Figure 1 in Torque Specifications section). Follow proper procedures for

the specific breakout system being used and loosen chuck. If jaws are outside recommended

positioning, damage to the hammer casing could result.

5. Bent Sub Removal from Hammer:

The bent sub has carbide buttons installation on one side. Turn the bent sub to a position with carbide

buttons up (12 o'clock) and place one tong haw on the bent sub, gripping the bent sub at 9 o'clock and 3

o'clock. Tong jaw should not overlap onto the hammer casing. (See Figure 1 in Torque Specifications

section) Place the other tong jaw between 6" (15.2 cm) and 13" (33 cm) above the bent sub end of the

hammer casing. Follow the proper recommended procedures for the specific breakout system being

used. If tong jaws are outside recommended positioning area, damage to hammer casing could result.

The glue must be heated and melted before trying to loosen the bent sub. Use a thermal heat gun to

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monitor the temperature of the metal wear sleeve. Using a small propane torch, heat the area of the

threads on the bent sub. This process may take several minutes. Do not heat casing over 400 degrees F

(204.4 C). Overheating can cause damage to the heat-treated hammer casing causing it to fail. If heat is

used, allow for a cool-down period before hammer is handled.

6. Bent Sub Removal from Sonde Housing:

Position bent sub with carbide buttons up (12 o'clock). Place one tong jaw on the bent sub gripping the

bent sub at 9 o'clock and 3 o'clock. Tong jaw should not overlap onto sonde housing casing. Place the

other tong jaw between 6" (15.2 cm) and 13" (33 cm) above the bent sub end of the sonde housing

casing. (See Figure 1 in Torque Specifications section.) Follow the proper recommended procedures for

the specific breakout system being used. If tong jaws are outside the recommended positioning area,

damage could result to the sonde housing casing. If the bent sub does not break loose, heat may need to

be applied to break the glue bond. Using a small propane torch heat the area of the threads on the bent

sub. Do not put flame in direct contact with sonde housing casing. With proper breakout pressure

applied, heat sonde housing casing until glue bond is broken. This heating process may take several

minutes. Do not heat casing over 400 degrees F (204.4 C). Overheating can cause damage to the heat-

treated sonde housing casing causing it to fail. If heat is used, allow for a cool-down period before

hammer is handled. If the glue is not melted before trying to loosen the bent sub, galling and damage to

the threads will likely occur. Use a thermal heat gun to monitor the temperature of the metal. Do not

exceed 400 F (204.4 C).

7. Backhead Removal from Sonde Housing

Place one tong haw between 6" (15.2 cm) and 13" (33 cm) from backhead end of sonde housing. If bent

sub has already been removed mark sonde housing to reference backhead end. Place the other tong jaw

on the backhead. Tong jaw should not overlap onto the sonde housing. Follow proper recommended

procedures for the breakout system being used and loosen backhead.

Blow Tube Replacement and Installation

Blow tubes (foot valves) can become damaged during handling or physically eroded while in services. The net

result is that they need to be services from time to time.

Tube failures will generally occur due to erosion caused by the jetting of water, oil, and grit, which is displaced as

the piston strikes the bit. This form of failure is common in applications where injection rates are high. This high

velocity jet of material actually erodes away the base of the tube and can eventually cause the tube to fail. Tube

erosion can be reduces by ensuring water is clean and free from particulate matter and that excessive fluid

injection is avoided. It's a good idea to monitor tube erosion and make replacements as needed before a hole is

started to avoid a costly trip out of the hole.

Blow tubes can be removed by cutting off the remaining portion of the tube and prying the remaining piece out

with a screwdriver. It may be useful to use a small rotary file to relieve the bore of the tube which remains in the

bit. However, be careful not to touch the bit tube bore with the rotary file or a heat crack followed by bit failure

may result. The tube can also be heated slightly to soften the plastic. Avoid breathing fumes which may come

from the heated plastic and also be careful not to overheat the bit.

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A new blow tube can be installed by driving the tube into the bit with a rubber-faced mallet or with a block of

wood between the hammer and tube. Do not hit the tube directly with a metal hammer or the tube may be

damaged. Be careful not to overpress the tube.

Loading Sonde and Sonde Tube Assembly

1. Clean sonde of all foreign material. Stickers on sonde may have to be removed and area sanded to allow sonde to be reinserted due to the tight tolerances in the inner sonde tube. This tight fit protects the sonde from shock due to movement.

2. Thread terminal end cap onto inner sonde tube. Tighten until snug and o-ring is engaged by cap. Do not overtighten.

3. Lock sonde into place in the timed end cap. Slide sonde into inner sonde tube taking care to make sure sonde stays locked into position.

4. Thread cap into inner sonde tube. tighten until snug and o-ring is engaged by cap. Do not overtighten. Sonde is now locked and loaded into inner sonde tube.

5. Thread terminal cap into outer sonde tube until snug and o-ring is engaged by cap. Do not overtighten.

6. With outer sonde tube in vertical position, drop in one (1) shock spring. Gently lower inner sonde tube into the outer sonde tube with the terminal cap of the inner sonde tube down. Place second shock spring inside the outer sonde tube. (Figure 2).

Figure 2

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Figure 3

7. Position the outer sonde tube timed cap over timed cap over timed cap on the inner sonde tube housing (Figure 3). Proper alignment matches the dot on the corner of the inner sonde tube timed cap to the line on the flat side of the outer sonde tube timed cap. When the timing caps are locked into position press firmly and rotate outer sonde tube until timed cap is snug and the o-ring is engaged. Do not over tighten. (Figures 4 and 5)

Figure 4 Figure 5

8. Check the rear air diffuser to see that the thrust washer is properly positioned. Place the air diffuser (open end) onto the terminal end cap end of the sonde tube assembly. (Figures 6 and 7)

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Figure 6

Figure 7

9. Insert the tee handle hex wrench into the rounded end of the air diffuser and gently thread into the terminal cap of the outer sonde tube until snug. Do not over tighten.

10. Slide the air diffuser and sonde tube assembly into the sonde housing tube. Slowly rotate until assembly drops into position and turn to lock into position. Remove the tee handle wrench by gently rotating counterclockwise. (Figure 8).

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Figure 8

11. Rotate bit to align the flat steering side of the bit with the carbide buttons on the bent sub. Check timing with locating device being used to ensure hammer and sonde are aligned. Apply copper impregnated rod grease to chuck and torque to proper specifications.

R Series Hammer Disassembly

1. Clean outside of hammer.

2. Remove sonde carriage and air diffuser from metal housing.

3. Remove hammer body from bent sub. Follow procedures for removal of bent sub outlined in the

Removal of Torqued Parts and Tong Jaw Placement section of this manual.

4. After bent sub is unscrewed from the hammer, the piston will slide out. (Figure 9).

Figure 9

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5. To remove air guide and check valve, drive pin out of the bent sub. The air guide and check valve will slide

our of the end of the bent sub. (Figure 10)

Figure 10

R Series Hammer Assembly

1. Check all parts thoroughly for wear and/or damage before assembling the hammer. If excessive wear or

damage is found, replace all damaged and/or worn parts.

2. Check inside of hammer casing for wear and scarring. If damaged, the hammer wear sleeve needs

replaced. If the housing is undamaged and not worn, apply a coat of oil to the inside of the casing.

3. Apply a coat of grease or oil to the piston and slide into position in the hammer casing (Figure 11).

Figure 11

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4. Slide check valve spring into spring rest and slide check valve onto other end of the check valve spring

(Figure 12).

Figure 12

5. Slide spring rest into air guide (Figure 13).

Figure 13

6. Apply a thin coat of oil to the air guide and slide into the bent sub with the check valve going in first

(Figure 14).

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Figure 14

7. Make sure the hole in the bent sub is aligned with the hole in the air guide. Gently slide air guide in. After

air guide is started into place, gently move the stem up and down until it slides into position. When the

holes align, drive the pin into position (Figure 15).

Figure 15

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Startup Reference Guide and Procedures

1. Select an air compressor that has sufficient air volume and air pressure to efficiently run the Prospector

Drilling System and keep the bore hole clean of fragments.

The 3" hammer is designed to run on a 400 CFM/350 PSI (9.52 m3 x 14 bars) air compressor.

The 4" hammer is designed to run on a 750 CFM/350 PSI (17.85 m3 x 24 bars) air compressor.

2. Load sonde into sonde tubes taking care to make sure all timing indicators are properly aligned. The

sonde is a very tight fit into the inner sonde tube and will require removal of stickers on sonde, and some

possible light sanding. The light sanding will not damage your sonde. After sonde is properly installed,

screw the chuck into the hammer and snug by hand. Stick the bit into the chuck and with the bit steering

flat align with the carbides on the bent sub. Allow for 3/4" travel to complete torqueing of the chuck. The

bit may be off by 1 clock position either way. Make sure to note this or the drill operator. Unscrew the

chuck while keeping the bit pushed in so timing is not lost. Install bit retaining ring on the end of the bit

and coat chuck threads with copper impregnated rod grease and thread into hammer. Some hammers

had dual thread starting positions so make sure to check the bit position after chuck is tightened by hand

before torqueing. Before torqueing the backhead, calibrate the sonde to the locator to check proper

alignment.

With the bit in position and properly timed, apply coat of copper impregnated rod grease to backhead

and torque. The 3" torques to 4000 ftlbs (5423 N-meters) and the 4" torques to 5000 ftlbs (6779 N-

meters). See Torque Specifications and Tong Jaw Placement section of this manual.

3. Weld back cutters on crossover sub before it is attached to drill rod and hammer. Take caution when

welding on back cutters to avoid any damage to ends of the crossover sub or crossover sub threads. Pay

particular attention not to let material onto the shoulders of the crossover. This can prevent proper

makeup torque resulting in the hammer coming loosed in the holes (See Figure 15)

Figure 15

To ensure proper balance and efficient operation, the crossover sub should be no longer than 10" (25.4 cm). Coat

threads with copper impregnated rod grease and thread backhead into sonde housing and tighten to 4000 ftlbs

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(5423 N-meters) for the 3" and 5000 ftlbs (6779 N-meters) for the 4" hammer. Coat threads on crossover and drill

rod with copper impregnated grease. Thread crossover onto drill rod and then thread backhead into crossover.

Tighten the crossover at 4000 ftlbs (5423 N-meters) for a 3" hammer and 5000 ftlbs (6779 N-meters) for a 4".

See Torque Specification and Tong jaw Placements section of this manual for proper procedures.

4. Set up the support pack.

A. Check water source for foreign material and clean 800 micron filter on a 1" (25.4mm) water hose

before connecting water source to the support pack

B. Air compressor. With air compressor running at low, slowly open air supply valve to blow any foreign

debris from compressor air system. Return valve to off position.

C. Connect one end of the 20' air hose to air compressor and the other end to the Pioneer One Support

Pack's "Air In" port. Connect the first end of the 30' x 2" air hose to the "Air Out" port on the support

pack and the other end to the "Air In" port on the directional drill. Make sure all hoses are properly

tightened and all air whip protectors are properly installed. Must tighten 1/4 turn beyond hand tight

with hammer. Check to make sure 2" ball valve (air out port) is in off position. Slowly turn air supply

valve on air compressor to on position and leave on. Slowly open 2" ball valve (air our port) on the

Pioneer One Support Pack and blow all foreign debris from the air hose and drill rod. Return 2" valve

on the Support Pack to the off position. It is very important to keep all foreign material from air

system and water system. Failing to do so can cause clogging of air supply or damage to blow tube. It

is also very important that drill rods are clean and free of foreign material since they are attached to

the air supply. This could require blowing each rod out before make up to cleat rod scaling and

bentonite residue.

D. Attach power cord from Prospector Support Pack to a 12-volt D.C. power source. Inspect power

source to make sure it is a 12-volt D.C. power source. Note: The large air compressors are often 24-

volt and can damage the power pack. Hooking up to any power source other than a 12-volt D.C. could

result in serious damage to components on the Prospector Support Pack.

E. With the remote control turn on the air supply and water supply to the support pack. the support

pack is not fully charged and operational.

5. Thread the crossover sub onto the hammer. Align the hammer with the end of the drill rod and tighten.

The 3" torques to 4000 ftlbs (5423 N-meters) and the 4" torques to 5000 ftlbs (6779 N-meters). See

manual for proper positioning for tongs or jaws when torqueing to prevent damage to the hammer's

threads. Always use approved methods and instructions according to the breakout and torqueing system

being used. Never use pipe wrenches to torque up or break loss a Prospector Hammer as serious injury

could occur.

6. Check oil reservoir level. Fill with recommended oil supplied with system. Oil specs and

recommendations are in this manual. Set the automatic oiler dial to 100% open. Slightly allowing air to

flow through system. Flip the manual oiler switch 20 times to prime the oil injection system. See manual

to see procedure to check oil flow through the Prospector Hammer. The Prospector Drilling System is

now ready for operation.

7. Before initiating the boring process, ensure that all crewmembers have sufficient PPE. This includes, but

not limited to, shoes, eye protection, hearing protection, and proper clothing.

8. Position directional drill to begin bore. Excavate launching trench at minus 18%. Excavate blast pit 10

feet (3.048 m) from end of launch trench. Blast pit should be 8-10 feet (2.44-3.048 m) long, 8-10 feet

(2.44-3.048 m) wide and 18 to 24 inches (45.72-60.96 cm) below drill string.

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Blast pit must be large enough to accommodate suction equipment. Blast pit must also be large

enough to allow equipment to remove spoils. It is recommended to cover the blast pit with a protective

plate and hold down with a backhoe. Turn 2" ball valve on Prospector Support Pack to 1/4 open. Drill

past the blast pit so that the hammer has moved completely through the blast pit. Turn 2" ball valve off.

Move the protective plate enough to inspect the distance between the bottom of the drill string to the

bottom of the blast pit. This measurement must be 18-24 inches (5.72-60.96 cm). If the blast pit is not

deep enough, pull hammer back, re-excavate blast pit, and push hammer back through blast pit. Move

protective plate enough to visibly see the exhaust hole in the blast pit. Turn 2" ball valve on Prospector

Support Pack to fully open position. The hammer is now ready for operation.

9. When entering the rock if the hammer deflects off the rock, dig up the end of the hammer and break a

notch our of the rock to allow the hammer to engage the rock. Under no circumstances use equipment to

force the hammer on drill rods down. Serious damage could result from such actions.

10. All rock is different and you hammer will steer differently according to the rock. Steering is accomplished

by rocking the drill string in a side-to-side motion, similar to the process for a Railhead or TriHawk. The

directional drill should be operated at 1200-1500 RPMS and 500-750 PSI thrust at 30-40 RMP. Let the air

compressor and the hammer do the work. Do not force the hammer. When steering, steer for 6" (15.24

cm) at a time until rotation pressure appears on gauge on the directional drill. Drill a minimum of 3' (0.91

m) before attempting to steer. For best results, steer at 1% every 5' (4.57 m) of drill rod. In soft rock, do

not steer more than 4" (10.16 cm) at a time. Do not steer over 5% (1.524 m) of a drill rod. Oversteering

can cause severe damage to the hammer. Beware of the possibility of a break off. Repeat the steering

procedure as needed to meet the bore profile. As a precaution and preventative measure, add 3 ozs.

(88.7 ml) of recommended oil directly into the rods every 30' (9.144 m). Visually check the oil reservoir

occasionally for the oil level. If the reservoir runs out, repeat priming procedures. Oil is the key to the life

and performance of the hammer. Run the automatic oiler at 50% for the first 2 hours of each bore then

reset 40% of maximum for duration of the bore.

11. Keep fragments, water, and mud clear of exhaust hole in blast pit. Failure to do so could result in the hole

sealing up . Visually check blast pit constantly for airflow and fragment evacuation. If airflow drops, swab

the hole by moving the drill string forward and backward until hole is opened up and air is flowing

sufficiently. If dry swabbing does not work, a bentonite solution will be required. Mix mud as you

normally would for rock conditions and inject into hole. Allow enough time for the mud to fill the rods

and exit the bit into the holes. Do this with the hammer pulled back at least to the back of the rod you

are experiencing clogging issues. Resume the forward and back motion, working the mud into the clog.

When the hole begins to feel free, stop the mud injection and return to air. Allow enough time for the air

to displace the mud in the drill rods and until it appears in the blast pit. Make sure you get your flow back

to normal before continuing forward production. You may need to repeat this air/mud swab several

times before proper flow is re-established. In certain ground conditions, it is best to swab each rod using

the bentonite solution, and make forward production with the air/water and polymer solution. Do not

run the hammer with bentonite and air as a mixture. The sand content in the bentonite will cause the

internal parts to wear rapidly if the striker is allowed to operate with the bentonite owing with the air.

After pushing mud through the rods, make sure to allow enough time to allow the air/water and polymer

solution to push the mud out the rods and through the head before engaging the head and continuing

forward production.

12. After each use, clean and oil the hammer. It is best to blow out the hammer with a heavy oil blast at the

end of each bore before breaking it off the drill rods. If hammer will be stored for more than a day,

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proper storage method is to store the hammer vertically with the bit end up. At the time the hammer is

stored, pour 8 ozs of recommended oil into the air ports on the bit.

13. If for any reason either end of the bent sub becomes loose, remove that end, clean and inspect the

threads, then glue and retorque if no damage id found. Use only the approved 2-part epoxy glue on the

threads. Pioneer One recommends Torq Loc. Loctite and other similar types of thread compounds are

not sufficient to hold up to the stresses during boring. Before retorqueing, inspect all threads for wear. If

thread damage had occurred due to the loose joint, replace affected parts. When using the epoxy glue,

mix thoroughly according to directions and apply only to the threaded areas, taking care to keep glue on

the outside of interior air way. Glue inside the airway could cause clogging affecting the performance of

the Prospector Hammer. Properly retorque all connection to recommended specifications.

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Support Pack

The Prospector Support Pack is designed to be used with all Prospector Hammers.

The purpose of the support pack is to regulate and supply air, drilling fluid, and oil to the Prospector Hammer.

The automatic oil pump injects oil into the air stream through a venturi tube to keep the hammer lubricated. Make sure to use recommended oils in the Prospector Support Pack. See chart for recommended oil(s).

The Support Pack also has a drilling fluid pump which injects the drilling fluid into the air stream. The amount of flow can be regulated from 0.5 gpm to 5 gpm (1.8 lpm to 18 lpm)

SETTING UP THE PROSPECTOR SUPPORT PACK

1. Set the support pack on a level location that is out of the way of moving equipment and vehicles.

2. Attach power supply line to 12 volts only. Connecting to the HDD rig is preferred.

3. Install whip check safety cables (aka break away cables) prior to making airline connections. Connect the 30' ft x 2" inch air line to the connection point on the Support Pack labeled "AIR IN" and then to the air compressor's air outlet fitting. Tighten connections using a hammer. Be sure to wear approved safety glasses. Usually 3 strikes with a hammer on the striking tabs seats and seals the connections.

4. Install whip check safety cables (aka break away cables) prior to making airline connections. Connect the 20' ft x 2" inch air line to the connection point on the Support Pack labeled "AIR OUT" and then to the air fitting on the HDD rig. Tighten connections using a hammer. Be sure to wear approved safety glasses. Usually 3 strikes with a hammer on the striking tabs seats and seals the connections.

5. Connect the 1" inch x 50' ft to the drilling fluid supply tank. Before connecting to the support pack, prime the 1" in line until all of the air is purged from it. Make the connection to the Support Pack's drilling fluid pump. The 1" in line comes with a filter that is not pre-installed. Install it into the 1" in fluid line 2 feet away from drilling fluid pump. Be sure to clean the filter after every bore.

6. Set the handle on the drilling fluid pump to half open. Adjust as needed during the bore.

7. The automatic air valve, drilling fluid pump, and automatic oiler needs 100 psi to operate effectively. Once you have charged compressor and air line from the compressor, you will need to prime the oil pump. Make sure oil tank is full of the recommended oil for the Prospector hammer. Prime the oiler by pushing down on the toggle switch on the oiler controller 20 times. Once you have done this, place the toggle switch in the 'up' position. This will keep the oiler in automatic mode as long as it has service air and 12 volts. Always keep a check on oil level.

8. Introduce air to the HDD rig: (1) Press the green 'on' button on the hand held transmitter (remote) labeled 'TX'. An indicator light will blink for 3 minutes on the hand held transmitter before it shuts itself off or you may turn it off by pressing the red button under the TX button. (2) Press the green button labeled AIR. This will open the automatic ball valve. Before you open the manual ball valve on the support pack, make sure your drilling fluid pump on the HDD rig is off and NO ONE is standing in front of

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the HDD rig where the hammer is attached. (3) Open the manual ball valve on the support pack. Now you have supplied air to the HDD rig.

9. Once air is blowing to the hammer you now may activate the drilling fluid pump on the Support Pack. Make sure the hand held transmitter is activated, the red light is blinking, press the green/on button labeled water and/or pump. Now the drilling fluid pump is activated.

10. Always connect the air lines the same way every time you use them. For Example: 30 ft air line from compressor to Support Pack and 20 ft air line from Support Pack to the HDD rig. The 20' ft air line will have a slight coating of oil in it after its first use. The air line connecting between the compressor and Support Pack needs to be dry and clean.

11. If the oiler is allowed to empty during operation, then it will need to be re-primed after filling the oil tank with the recommended oil. Refer to line 7 above for oiler priming instructions.

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Hammer Oiler

The Prospector Hammer Oiler is designed to be used with all Prospector Hammers.

The purpose of the hammer oiler is to supply oil to the Prospector hammers and allow the use of the drilling fluid pump on the HDD rig. The hammer oiler will supply drilling fluid of 1 gpm to 2 gpm (3.8 lpm to 7.6 lpm) to the Prospector Hammer.

The Oiler has an automatic oil pump located inside a non pressurized tank, a manual ball for introducing air to the HDD rig, and a back flow preventer rated at 2000 psi (138 bar). It requires 12 volts preferably connected to the HDD rig and air.

SETTING UP THE PROSPECTOR HAMMER OILER

1. Set the oiler on a level location which is out of the way of moving equipment and vehicles.

2. Attach power supply line to 12 volts only. Connecting to the HDD rig is preferred.

3. Install whip check safety cables (aka break away cables) prior to making airline connections. Connect the 20' ft x 2" inch air line to the connection point on the Hammer Oiler labeled "AIR IN" and then to the air compressor's air outlet fitting. Tighten connections using a hammer. Be sure to wear approved safety glasses. Usually 3 strikes with a hammer on the striking tabs seats and seals the connections.

4. Install whip check safety cables (aka break away cables) prior to making airline connections. Connect the 15' ft x 2" inch air line to the connection point on the Hammer Oiler labeled "AIR OUT" and then to the air fitting on the HDD rig. Tighten connections using a hammer. Be sure to wear approved safety glasses. Usually 3 strikes with a hammer on the striking tabs seats and seals the connections.

5. Introduce air to Hammer Oiler by starting the air compressor and opening the air compressor's supply valve. Once you have charged compressor and air line from the compressor, you will need to prime the oil pump. Make sure oil tank is full of the recommended oil for the Prospector hammer. Prime the oiler by pushing down on the toggle switch on the oiler controller 20 times. Once you have done this, place the toggle switch in the 'up' position. This will keep the oiler in automatic mode as long as it has service air and 12 volts. Always keep a check on oil level.

6. Always connect the air lines the same way every time you use them. For Example: 20 ft air line from compressor to Hammer Oiler and 15 ft air line from Hammer Oiler to the HDD rig. The 15' ft air line will have a slight coating of oil in it after its first use. The air line between the compressor and Hammer Oiler needs to be dry and clean

7. If the Oiler is allowed to empty during operation, then it will need to be re-primed after filling the oil tank with the recommended oil. Refer to line 5 above for instructions for priming oiler.

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3" R Hammer Wear Limits

NEW

DISCARD LIMIT

WEAR SLEEVE O.D.

3.476"(88.290mm)

3.14" (79.756mm)

Piston Bore

2.761"(70.129mm)

2.765" 70.231mm)

Piston Large O.D.

2.757" 70.027mm)

2.753"(69.926mm)

Piston small O.D.

2.365"(60.071mm)

2.361"(59.969mm)

Air Guide Bore I.D.

0.902" (22.91mm)

0.912"(23.164mm)

Blow Tube Bore I.D.

0.996"(25.298mm)

1.0" (25.4mm)

Air Guide small end O.D. 0.892"(22.656mm)

0.888" 22.555mm)

Bent Sub Piston Bore 2.370"(60.198mm)

2.375" 60.324mm)

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4" R Hammer Wear Limits

NEW

Discard Limit

Wear Sleeve O.D.

4.051"(102.895mm)

3.651"(97.735mm)

Piston Bore

3.197" (81.203mm)

3.201"(81.305mm)

Piston Large O.D.

3.193" (81.102mm)

3.189" (81.00mm)

Piston Small O.D.

2.673" (67.894mm)

2.669"(67.792mm)

Air Guide Bore I.D.

0.902" (22.91mm)

0.912"(23.164mm)

Blow tube Bore I.D.

1.075" (27.304mm)

1.085"(27.558mm)

Air Guide Small End I.D. 0.892" (22.656mm)

0.888"(22.555mm)

Bent Sub Piston Bore 2.677" (67.741mm)

2.682"(68.122mm)

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4” MODEL R PROSPECTOR...

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