Breakout

bench DTH Equipment

Safety and operating instructions

Accessories

© Epiroc Drilling Tools AB | 9866 0045 01 | 2020-06-15

Original Instructions
 Contents

Table of Contents
1 Introduction ................................................................................................................................ 4
1.1 About the Safety and Operating Instructions................................................................................................... 4
1.2 Intended use ........................................................................................................................................................ 4
1.3 Measurements ..................................................................................................................................................... 4
1.4 Abbreviations ...................................................................................................................................................... 4

2 Safety Instructions..................................................................................................................... 5
2.1 Safety signal words ............................................................................................................................................ 5
2.2 Personal precautions and qualifications .......................................................................................................... 5
2.2.1 Transport ........................................................................................................................................................... 5
2.2.2 Personal protective equipment ..........................................................................................................................  5
2.2.3 Drugs, alcohol or medication .............................................................................................................................  6
2.2.4 Operation........................................................................................................................................................... 6
2.3 Operation, precautions....................................................................................................................................... 6
2.4 Laws and regulations ......................................................................................................................................... 7
2.4.1 Environment ...................................................................................................................................................... 7

3 Overview ..................................................................................................................................... 7
3.1 Design and function............................................................................................................................................ 7
3.2 Guarantee ............................................................................................................................................................ 8

4 Installation and Operation......................................................................................................... 8

5 Tools.......................................................................................................................................... 12

6 Technical data .......................................................................................................................... 15

© Epiroc Drilling Tools AB | 9866 0045 01 | 2020-06-15 3

Original Instructions
Safety and operating instructions

• The instructions, illustrations, and specifications in

1 Introduction this manual are based on the latest information
Epiroc is a leading productivity partner for the mining, in- available at time of publication. Your DTH may have
frastructure and natural resources industries. With cut- improvements and options not yet contained in this
ting-edge technology, Epiroc develops and produces in- manual.
novative drill rigs, rock excavation and construction
equipment, and provides world-class service and con-
sumables. The company was founded in Stockholm, 1.2 Intended use
Sweden, and has passionate people supporting and col- The equipment must not be used for purposes other
laborating with customers in more than 150 countries. than those prescribed by Epiroc. That is the following:
Epiroc Drilling Tools AB P.O. Box 521, SE-737 30 • Only use for breaking out DTH hammers.
Fagersta – Sweden

1.3 Measurements
1.1 About the Safety and Measurements in this manual are given in both Metric
Operating Instructions and Imperial units, and are used to provide additional
worldwide understanding.
• The aim of the instructions is to provide you with
knowledge of how to use the DTH equipment in an Imperial units are shown between parentheses ‘’( )’’.
efficient and safe way.
• The Safety and Operating instructions should be
considered a permanent part of the DTH equipment 1.4 Abbreviations
and should remain with the DTH and available for
acfm Actual cubic feet per
reference at all times.
minute
• Always follow the advice given in the instructions.
• Measurements in this manual are given in both Im- API American Petroleum Insti-
tute
perial and Metric units, and are used to provide ad-
ditional worldwide understanding. Metric units are C Centigrade
shown between parentheses ‘’( )’’.
dia. Diameter
• Consult your Epiroc Drilling Tools Dealer if you do
not understand the instructions in this manual or deg. Degree
need additional information. F Fahrenheit
• Keep the Breakout bench in good working condition
ft. Feet
• Unauthorized modifications to the Breakout bench
may impair the function and/or safety and effect the ft.-lb Foot pounds
Breakout bench life.
gpm Gallons per minute
• Make sure all safety devices, including shields are
installed and functioning properly. in. Inches
• Visually inspect the Breakout bench daily before us- kg kilogram
ing.
l liter
• Do not operate the Breakout bench with loose, worn
or broken parts. lbs. Pounds
• Operating equipment requires the full attention of
lpm Liters per minute
the operator.
• Do not wear radio or music headphones while oper- m Meter
ating the Breakout bench. mm Millimeter
• Protection cover must always be used during opera-
mm Hg Millimeters of mercury
tion.
3
• For large Breakout bench wrench should be used m /min Cubic meters per minute
along with stop piece.
psi Pounds per square inch
• Only use the hoses with Epiroc approved part num-
ber. psig Pounds per square inch
gauge pressure

4 © Epiroc Drilling Tools AB | 9866 0045 01 | 2020-06-15

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 Safety and operating instructions

rpm Revolutions per minute WARN- indicates a hazardous situation which, if

ING not avoided, could result in death or seri-
scfm Standard cubic feet per ous injury.
minute
CAU- indicates a hazardous situation which, if
m/s Meters per second TION not avoided, could result in minor or mod-
erate injury.

NOTICE contains information considered important,

yet not related to bodily injury. In a "NO-
2 Safety Instructions TICE" the damage is related to machines,
components, systems or environment.
To reduce the risk of serious injury or death to yourself
or others, read and understand the Safety and operating
instruction carefully before installing, operating, repair- 2.2 Personal precautions and
ing, and maintaining the DTH hammer and the DTH
equipment. qualifications
• Post this Safety and operating instruction at work lo- Only qualified and trained persons may operate or main-
cations, provide copies to employees, and make tain the DTH hammer and the DTH equipment. Always
sure that everyone reads the Safety and operating use your common sense and good judgement.
instruction before operating or servicing the DTH
hammer and the DTH equipment.
• For professional use only. 2.2.1 Transport
• In addition, the operator or the operator's employer Transport of the DTH hammer and DTH equipment may
must assess the specific risks that may be present only be undertaken by persons who:
as a result of each use of the machine. • are authorized to operate mechanical lifting equip-
• Save all warnings and instructions for future refer- ment in conformity with the applicable national direc-
ence. tives.
• Consult your Epiroc Drilling Tools dealer if you do
not understand the instructions in this manual or
need additional information. 2.2.2 Personal protective equipment
• This manual should be considered a permanent part Always use approved protective equipment. Also ob-
of the DTH hammer and the DTH equipment and serve any local regulations. Operators and all other per-
should remain with the DTH hammer and the DTH sons in the working area must wear protective equip-
equipment, available for reference at all times. ment and confine long hair during operation, including at
• Warranty is provided as part of Epiroc Drilling Tools a minimum:
support program for customers who operate and • protective helmet
maintain their equipment as described in this man- • hearing protection
ual. • impact resistant eye protection with side protection
• The instructions, illustrations, and specifications in • respiratory protection when appropriate
this manual are based on the latest information • protective gloves
available at time of publication. • proper protective boots
• Your DTH hammer and DTH equipment may have • appropriate work overall or similar clothing (not
improvements and options not yet contained in this loose-fitting) that covers your arms and legs.
manual.

2.1 Safety signal words

The safety signal words Danger, Warning, Caution and
the property damage message Notice have the following
meanings:

DAN- indicates a hazardous situation which, if

GER not avoided, will result in death or serious
injury.

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 Safety and operating instructions

2.2.3 Drugs, alcohol or medication Dust and fumes in the air can be invisible to the naked
eye, so do not rely on eye sight to determine if there is
WARNING Drugs, alcohol or medication dust or fumes in the air. To reduce the risk of exposure
Drugs, alcohol or medication may impair your judgment to dust and fumes, do all of the following:
and powers of concentration that can lead to poor reac- u Perform site-specific risk assessment. The risk as-
tions and incorrect assessments that can cause to se- sessment should include dust and fumes created by
vere accidents or death. the use of the machine and the potential for disturb-
u Never use the machine when you are tired or under ing existing dust.
the influence of drugs, alcohol or medication. u Use proper engineering controls to minimize the
u No person who is under the influence of drugs, alco- amount of dust and fumes in the air and to minimize
hol or medication may operate the machine. build-up on equipment, surfaces, clothing, and body
parts. Examples of controls include: exhaust ventila-
tion and dust collection systems, water sprays, and
2.2.4 Operation wet drilling. Control dusts and fumes at the source
• Do not let anyone operate this Breakout bench with- where possible. Make sure that controls are properly
out proper instruction. If you do not understand any installed, maintained and correctly used.
part of this manual and need assistance, contact u Wear, maintain and correctly use respiratory protec-
your local Epiroc dealer. tion as instructed by your employer and as required
by occupational health and safety regulations. The
respiratory protection must be effective for the type
2.3 Operation, precautions of substance at issue (and if applicable, approved by
WARNING Flying parts chain wrenches relevant governmental authority).
u Work in a well ventilated area.
The flying parts of chain wrenches can cause injury or
u If the machine has an exhaust, direct the exhaust so
death when they break.
as to reduce disturbance of dust in a dust filled envi-
u Ensure chain wrenches or tongs are rated for the
ronment.
torque applied.
u Operate and maintain the machine as recommended
WARNING Heavy drill bit in the operating and safety instructions
Heavy drill bit can cause damage to the DTH parts or se- u Select, maintain and replace consumables/ working
rious injury if the bit fall down when the bit is removing. tools/ other accessories as recommended in the op-
u Use proper tools to remove the drill bit. erating and safety instructions.
u Incorrect selection or lack of maintenance of con-
WARNING Dust hazard sumables/ inserted tools/ other accessories may
Dusts and/or fumes generated or dispersed when using cause an unnecessary increase in dust or fumes.
the machine may cause serious and permanent respira- u Wear washable or disposable protective clothes at
tory disease, illness, or other bodily injury (for example, the work site, and shower and change into clean
silicosis or other irreversible lung disease that can be fa- clothes before leaving the work site to reduce expo-
tal, cancer, birth defects, and/or skin inflammation). sure of dust and fumes to yourself, other persons,
Some dusts and fumes created by drilling, breaking, cars, homes, and other areas.
hammering, sawing, grinding and other construction ac- u Avoid eating, drinking, and using tobacco products in
tivities contain substances known to the State of Califor- areas where there is dust or fumes.
nia and other authorities to cause respiratory disease, u Wash your hands and face thoroughly as soon as
cancer, birth defects, or other reproductive harm. Some possible upon leaving the exposure area, and always
examples of such substances are: before eating, drinking, using tobacco products, or
u Crystalline silica, cement, and other masonry products. making contact with other persons.
u Comply with all applicable laws and regulations, in-
u Arsenic and chromium from chemically-treated rubber.
cluding occupational health and safety regulations.
u Lead from lead-based paints. Dust and fumes in the air u Participate in air monitoring, medical examination
can be invisible to the naked eye, so do not rely on eye programs, and health and safety training programs
sight to determine if there is dust or fumes in the air. To provided by your employer or trade organizations
reduce the risk of exposure to dust and fumes, do all of and in accordance with occupational health and
the following:

6 © Epiroc Drilling Tools AB | 9866 0045 01 | 2020-06-15

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 Safety and operating instructions

safety regulations and recommendations. Consult WARNING Damaged chain should not be replaced
with physicians experienced with relevant occupa- with old or used components, it can compromise
tional medicine. and cause damage to the equipment and serious in-
u Work with your employer and trade organization to jury.
reduce dust and fume exposure at the worksite and u Discard and exchange the entire chain if it breaks.
to reduce the risks. Effective health and safety pro-
grams, policies and procedures for protecting work- WARNING Heating a chain with a cutting touch
ers and others against harmful exposure to dust and can cause serious injury or damage to the equip-
fumes should be established and implemented ment.
based on advice from health and safety experts. u Do not re-use the chain if it has been heated.
Consult with experts. NOTICE If welding spatter comes in contact with the
u Residues of hazardous substances on the machine chain or the components, it can cause damage to the
can be a risk. Before undertaking any maintenance equipment.
on the machine, clean it thoroughly. u Do not weld the chain components.

WARNING Untightened DTH hammer

Untightened DTH hammer can cause the hammer to 2.4 Laws and regulations
open or break during operation and cause serious injury
Follow all local laws and regulations that apply to your
and damage.
work situation.
u Properly tighten each threaded part before operating
with drill rig or hydraulic bench.
2.4.1 Environment
WARNING Noise hazard
Be mindful of the environment and ecology. Before
High noise levels can cause permanent and disabling
draining any fluids, find the correct way of disposing
hearing loss and other problems such as tinnitus (ring-
them. Observe the relevant environmental protection
ing, buzzing, whistling, or humming in the ears). To re-
regulations when disposing of oil, fuel, coolant, brake
duce risks and prevent an unnecessary increase in noise
fluid, filters and batteries.
levels:
u Risk assessment of these hazards and implementa- When using any solvent to clean parts, make sure:
tion of appropriate controls is essential. • it is non-flammable
u Operate and maintain the machine as recommended • it will not harm the skin
in these instructions. • it meets current O.S.H.A. standards, and appropri-
u Select, maintain and replace the working tool as rec- ate governing agency
ommended in these instructions. • it is used in an area that is adequately ventilated.
u If the machine has a silencer, check that it is in place
and in good working condition.
u Always use hearing protection.
u Use damping material to prevent work pieces from
3 Overview
'ringing'. To reduce the risk of serious injury or death to yourself
or others, read the Safety instructions section found on
WARNING Entanglement hazard working on and
the previous pages of this manual before operating with
maintaining the breakout bench.
the DTH hammer.
u Keep your hands and clothing away and confine long
hair when working on and maintaining the breakout
bench.
3.1 Design and function
WARNING Chain lengths build from individual The Breakout bench from Epiroc is a new addition to the
components can cause serious injury or damage to product range of DTH equipment. The Breakout bench is
the equipment if they break. available in two designs, A standard or a Heavy Duty
u Use lengths of an assembled chain version equipped with either a hydraulic hand pump (as
shown in the photo) or with a pneumatic foot pump. This
handy but powerful Breakout bench can easily be placed

© Epiroc Drilling Tools AB | 9866 0045 01 | 2020-06-15 7

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Safety and operating instructions

in a workshop or container and it breaks DTH hammers WARNING Damaged chain should not be replaced
between 3–8" in standard version or 5-12" in heavy duty with old or used components, it can compromise
version. and cause damage to the equipment and serious in-
The Breakout bench is delivered without wrench keys, jury.
ordered separately. u Discard and exchange the entire chain if it breaks.

Standard Breakout bench WARNING Heating a chain with a cutting touch

can cause serious injury or damage to the equip-
ment.
u Do not re-use the chain if it has been heated.
NOTICE If welding spatter comes in contact with the
chain or the components, it can cause damage to the
equipment.
u Do not weld the chain components.

3.2 Guarantee
Warranty is provided as part of the Epiroc Drilling Tools
support program for customers who operate and main-
tain their DTH hammer and DTH equipment as de-
scribed in this manual.
Use only authorized parts.
Any damage or malfunction caused by the use of unau-
Heavy duty Breakout bench
thorized parts is not covered by Warranty or Product Lia-
bility.
The warranty or product liability will be invalidated by the
following:
• Use other than intended.
• Maintenance work not being carried out or being
carried out incorrectly.
• The use of the wrong consumables.
• The use of non-approved parts.
• Damage due to wear.
• Special applications without the required safety facil-
ities.
• Damage due to improper storage.
• Changes not carried out by or in consultation with
the manufacturer.
• Only Pneumatic foot pump option.
• Hand pump option is NOT available.
The threaded connections of the driver chuck and top
sub may become very tightly tensioned during drilling. It 4 Installation and Operation
is convenient to break the hammer threads on the rig,
WARNING Flying parts chain wrenches
but if the threads cannot be loosened or tend to get
stuck, a Breakout bench is the solution. The flying parts of chain wrenches can cause injury or
death when they break.
WARNING Chain lengths build from individual u Ensure chain wrenches or tongs are rated for the
components can cause serious injury or damage to torque applied.
the equipment if they break.
u Use lengths of an assembled chain

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 Safety and operating instructions

WARNING Heavy drill bit 3. Install the hydraulic cylinder in to the adjustable
bracket, use the same bolt and nut to secure the
Heavy drill bit can cause damage to the DTH parts or se-
cylinder.
rious injury if the bit fall down when the bit is removing.
u Use proper tools to remove the drill bit.

WARNING Untightened DTH hammer

Untightened DTH hammer can cause the hammer to
open or break during operation and cause serious injury
and damage.
u Properly tighten each threaded part before operating
with drill rig or hydraulic bench.
1. Unpack the Breakout bench and install it in a proper
location preferably in a workshop.

The Breakout bench can be ordered with two differ-

ent types of Hydraulic pumps, either a manual pump
for field application or a pneumatic foot operated
pump for workshop use.

4. Install the hydraulic hose from the hydraulic pump in

to the hydraulic cylinder, pull back the lock on the
quick coupling and press it on to the male coupling
on the cylinder until lock will snap in to right position.

2. Unscrew bolts from both side of the hydraulic cylin-

der, lift up the cylinder from the transport position.

5. Open up the safety hood by pulling out the two locks

and lift the hood backwards.

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Safety and operating instructions

8. Lift up the DTH hammer preferably with a lifting crane

on to the Breakout bench, lift the chain over the ham-
mer and put lock nut in to its position Typical weight
of a DTH hammer. 3.5" Hammer 20-30 kg (45-65 lbs)
4" Hammer 40-45 kg (90-100 lbs) 5" Hammer 55-80
kg (125-180 lbs) 6" Hammer 90-110 kg (200-240 lbs)
8" Hammer 200-250 kg (450-550 lbs) 10" Hammer
450-500 kg (990-1100 lbs) 12" Hammer 650-700 kg
(1460-1580 lbs)

6. Put the chain lock in to upper position to free the

chain.
9. Put lock nut in right position and tight by hand.

7. Un-tight the nut on chain and lift it up from its posi-

tion, put the chain over to the lock side to free the
wise so the Down the hole (DTH) hammer can be in-
stalled on to the Breakout bench. 10. Lock the chain by pulling the level in the lower posi-
tion under the pin.

10 © Epiroc Drilling Tools AB | 9866 0045 01 | 2020-06-15

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 Safety and operating instructions

11. Measure the distance and adjust the position of ham-

mer so the chain is in the right grip position, see table
on page 7 for correct grip position of the DTH ham-
mer that will be opened.

15. Fold back the safety cover so it is in locked position.

12. Mark the casing and backhead so you can see if the
backhead opened up or not.

13. Open up the return on the pump so the built-in spring

will extend the hydraulic cylinder to max length. In-
16. Start operate the hydraulic pump from safe distance
stall the proper wrench supplied from Epiroc Drilling
either by hand with the manual pump or by pressing
Tools, see the DTH hammer manual for size of
the pedal on the pneumatic pump, see further instruc-
wrench needed. Product No. on wrench keys you will
tions that comes with the supplied pump.
find in the .

14. When wrench is installed and the DTH hammer is in

right position tight the nut with the tool provided until
chain wise have a firm grip on the hammer.

© Epiroc Drilling Tools AB | 9866 0045 01 | 2020-06-15 11

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Safety and operating instructions

Size Product No. Product code

Flat 77 90029528 9912

Flat 95 mm 89009522 8484-0211-02

Flat 102 mm 89000667 8484-0214-13

Flat 120 mm 89009548 8484-0211-36

Flat 140 mm 89009553 8484-0211-44

Assembly Flat 90029529 9922

128 mm

Assembly Flat 90029519 9916

150 mm

Assembly Flat 90029522 9918

180 mm

Assembly Flat 90029527 9921

235 mm
Table 1: Wrench keys for DTH hammer back head

17. When the DTH Hammer has opened up disassembly

and service of hammer can be made. If the hammer
is not opened, it has probably slipped on the chain
tong. If this is the case, the hammer must be reposi-
tioned on the Breakout bench and chain nut should
be tightened harder for a new attempt.

Wrench keys for bit breaking

There are three dimensions of blanks, made for cutting
out a DTH bit profile between 85-130 mm, 134-178 mm
and 179-280 mm. Remark: Order your bit design draw-
ing from Epiroc Drilling Tools and cut out the profile at a
work shop corresponding to the bit design that is in use.

Blank size Product No. Product code

Bit diameter 85– 89001233 9172

130 mm

Bit diameter 89001234 9173

134–178 mm

Bit diameter 89011505 9302

179–280 mm
5 Tools Table 2: Wrench keys for bit breaking

Size Product No. Product code

Flat 55 mm 89009552 8484-0211-43

Flat 65 mm 89009520 8484-0211-00

Flat 75 mm 89001334 8484-0146-23

12 © Epiroc Drilling Tools AB | 9866 0045 01 | 2020-06-15

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 Safety and operating instructions

Hammer A B C D
model mm (in) mm (in) mm (in) mm (in)

QL 40 120 (4.7) 70 (2.8) 70 (2.8) 120 (4.7)

QL 90 (3.5) 70 (2.8) 70 (2.8) 90 (3.5)

50/55,
QLX
50/55

QL 100 (3.9) 70 (2.8) 70 (2.8) 100 (3.9)

60/65,
QLX
60/65 Parameter Standard Heavy duty
Breakout Breakout
QL 140 (5.5) 70 (2.8) 70 (2.8) 140 (5.5)
80/85, bench bench

QLX 35 50 (1.9) 70 (2.8) 70 (2.8) 40 (1.6) Ambient temper- -15ºC to 40ºC -15ºC ~40ºC
ature range,
QLX 40 50 (1.9) 70 (2.8) 70 (2.7) 50 (1.9)
Humidity range 10 to 90% 10 to 90%
QLX 100 140 (5.5) 70 (2.8) 70 (2.8) 440
(17.3) Altitude m.a.s.l. <1000 m. <1000 m.

COP W4 75 (2.9) 70 (2.8) 70 (2.8) 75 (2.9) Transportation -15ºC to 40 ºC, -15ºC to 40ºC,
and storage 10% to 90% hu- 10% to 90% hu-
COP 44, 90 (3.5) 70 (2.8) 70 (2.8) 55 (2.2) midity midity
44 G
Hammer size 3 to 8 in. 5 to 12”
COP 54 130 (8.5) 70 (2.8) 70 (2.8) 75 (2.9) range
G
Bench size, 43,3 x 39,4 x 78,7 x 45,8 x
COP 64 140 (5.5) 70 (2.8) 70 (2.8) 110 (4.3) length*height*wi 27,6 (1100 x 39,4 (2000 x
G dth, in. (mm) 1000 x 700) 1163 x 1000)

COP 35 170 (6.7) 70 (2.8) 70 (2.8) 80 (3.1) Weight kg (lbs) 325 (716) 725 (1589)

COP 34 140 (5.5) 70 (2.8) 50 (2.0) 145 (5.8) Max break out 14000 ft.lb 50000 ft.lb
torque
COP M6 114 (4,5) 55 (2,2) 126 (5,0) 170 (6,7)
Operation 34,25 (870) 39,76 (1010)
COP M7 155 (6.1) 55 (2.2) 170 (6.7) 207 (8.1) height, in. (mm)
COP M8 115 (4.5) 290 150 (5.9) 320 Hydraulic pres- 70 Mpa 70 Mpa
(11.4) (12.5) sure range
Table 3: Where to position the tongvise on DTH ham- Table 4: Operational specifications of the machine
mers
Item Product No. Product code

Petol tongvise, 90514074 9177

complete

Insert tongvise 90514077 9195

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Safety and operating instructions

Item Product No. Product code

Chain assembly 90514076 9194

Hose 90514594 9193

Hand pump 90514665 9196

Pneumatic foot 90514666 9197

pump

Cylinder, com- 90514667 9198

plete

Cylinder, sealing 90514668 9199

kit
Table 5: For Breakout bench Standard version 3-8"

Item Product No. Product code

Petol tongvise, 90029490 9909

complete

Insert tongvise 90029492 9910

Chain assembly 90029495 9911

Hose 90514594 9193

Pneumatic foot 90514666 9197

pump

Cylinder, com- 90514667 9198

plete

Cylinder, sealing 90514668 9199

kit
Table 6: For Breakout bench Heavy Duty version 5-12"
Heavy duty version will have only pneumatic foot pump.

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 Safety and operating instructions

6 Technical data
Operates hammers between 3–8" Product No. Product code

With hydraulic hand pump 90514057 9178

With pneumatic foot pump, Req. 6–12 90514348 9176

bar air pressure

Specifications

Length 1100 mm 43.3"

Height 1000 mm 39.4”

Width 700 mm 27.6"

Weight 325 kg 716 lbs

Table 7: Technical data breakout bench

Operates hammers Product No. Product code

between 5–12"

With pneumatic foot pump, Req. 6–12 90029494 9908

bar air pressure

Specifications

Length 2000 mm 78.7"

Height 1163 mm 45.8"

Width 1000 mm 39.4"

Weight 725 kg 1589 lbs

Table 8: Heavy duty breakout bench

© Epiroc Drilling Tools AB | 9866 0045 01 | 2020-06-15 15

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 © Epiroc Drilling Tools AB | 9866 0045 01 | 2020-06-15

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