PHQ250 Stoper - Parts HeadQuarters Inc.
Contents
1. PARTS HEADQUARTERS INC 75 With the machine returned to the horizontal position in the bench vice insert the ferrule D1390 and O ring 76 Lightly o1l the chuck and fit 1t into the fronthead and place the fronthead and chuck together over the peg on the workbench Lightly oil the splines of the chuck nut 77 Put the cylinder assembly over the fronthead assembly 78 Fit the valve box locating pin S2128 and the backhead complete with all 1ts sub parts in position Insert the water tube with the water tube spacer and rubber in the same way as on the jack leg Airleg drill 79 Fit the backhead cap Note the relationship between the locating pin in the backhead cap and the backhead Ensure the O rings have been installed ISO 9001 2000 CERT 0017623 PARTS HEADQUARTERS INC 80 Fit the thrust leg assembly over the backhead cap 81 Insert the side rods Tighten the side rods evenly from one to the other and back to a torque of 1313Nm 90 ft lbs 82 Screw the control body hand tight Insert the operating handle in the cylinder lug Fit the D shaped thrust washer and adapter nut Newer drills have this washer incorporated machined as a part of the cylinder lug bushing Tighten the adaptor nut and control body into the operating handle 83 Fit the twist grip two washers and the operating handle nut Remember order in which the washers are fitted Tighten the nut on the end of the c2. Inspection of the fit of Piston B2334 and the Cylinder E393 E393M bore 45 To establish consistency in testing always test the cylinder with inner surfaces of the cylinder bore and outside surfaces of the drill piston free from oil The test relies on the feel of the fit and function of movement of the piston within the bore and the sounds generated during testing 46 The piston must be replaced when the head of the piston is worn down Proper sophisticated measuring equipment to accurately gauge the wear on a piston head or in a cylinder bore is not available in most rockdrill service workshops Cylinder and piston wear can be gauged by simple but effective established workshop practices Place the cylinder so the font end is face down on a flat work bench Align a new piston with the large head in the cylinder bore wrong way down Always use a piston free of oil so that the comparison is always done under the same conditions Grasp the splined end of the piston and slowly rock the piston back and forth in the cylinder to check the clearance If the rocking motion of the striking end of the piston 1s greater than 3mm 0 12 the cylinder is oversize If the new piston is tight remove the new piston and replace with the used piston If the same rocking motion 1s evident it indicates that the piston 1s worn oversize and must be replaced Front Cylinder Assembly 47 The clearance between the outer diameter of a new piston stem a
3. Y A Page 9 wor DUSUBO mmm L3NHIINI 2902 192 008 1 3383 NOL 6p6 ZE0 506 XW3 1L2 2 8 506 131 ONI SHILYVNOCVIH SLUVd Iq 19d03S YSINSOSZOHdA 1 dols Ajquassy ajpueH Z0SLV xv INN 4ONYD MJ Ajquiessy 49NYD W8ZLLE Hesu 2 INN YONYD M 2 quiassy x9ny SV82119 dg OY lt i Ajquiassy u i5s 1Y Syor Ajquiassy SAJLA SVSr V INN Y M S UO SId peczg W 8403S 0E Alquassy Ba7 Jado3s vr 0LV x 9401 S pZ Alquassy 627 1adojs pLOLV x Aiquiessy BAIA JOIEM LOd90SLy ISO 9001 2000 QMI CERT 0017623 ISTERED REG PARTS HEADQUARTERS INC Page 10 KEY PART NUMBER ASSY DESCRIPTION COMPONENT OO N O Q L G N gt N N N N N NI NA ala ala lala O al al al o O Mm 00 N ODO WAN OO YN O 2738 28 29S 30S 31 32 33 34 35A 35 36 A10506PC1 20015 C1521PC1 1643903 D1406 C1522PC1 1645704 1648102 B1181PC4 D1673 C2144 D1674 C1574A D1675 D1383 D1382 2422P C1272 D1402 52487 C1809 1646503 52141 1358356 C1811W D1385 149163MT C1509S D1384 A705 B1176S C1525N D1601 C1526 1648114 JC45 910660211 355538 AA aaa La Lal i LN Oy AA al al al LALA Lal ll xl xl al Alal a WATER VALVE ASSEMBLY CIW 1 2 3 4 5 6 7 8 9 10 CIRCLIP CAP WATER VALVE O RING 164231 SPRING WATER VALVE VALVE POPPET O RING 164521 O RING 164301 HOUSING WATER VALVE SEAT WATER VALVE RETAINER WATER VALVE
4. 25 Assembly Procedures 27 Piston Valve and Ratchet Ring PA Rifle Bar Fronthead and Backhead 28 Leg Side Rods and Holding Handle 28 Running in the drill 29 Testing the Stoper 30 Water testing procedure 31 ISO 9001 2000 CERT 0017623 k PARTS HEADQUARTERS INC Page 5 NOTE PHQ continuously updates product literature to provide customers with the most current technical information available Portions of this literature in time could contain Information that may not be exactly representative of the current configuration of PHQ products Contact your nearest PHQ representative for information on the latest product improvements and replacement literature available The purpose of the manual Is to provide service technicians with detailed information to achieve the maximum operating performance from PHQ products Parts lists with corresponding exploded view schematic drawings are provided to aid in identifying parts needed for repairs and to facilitate ordering of proper parts for the assembly Drawings are included at the appropriate area within the text The drawings included are small through necessity Large wall posters are available PHQ personnel are proud to say they are backed up by over 50 years of experience in design manufacture and operation of Percussive Drilling Equipment Many of the accepted practices
5. S2134 C1418A C1509 C1508 B2334 JC45 C2144 D1675 B1178 D1388D D6205M C1582C 355538A C1809 D1601 D2441 52141 C1517 C1809 B1173B Description SHOP TRIP PAWL PLUNGER SPRING CHUCK NUT RATCHET PAWL REVERSIBLE WATER TUBE SWAGED PAWL PLUNGER CHUCK INSERT 7 8 HEX THROTTLE VALVE HANDLE RIFLE NUT PISTON SPUD ASSEMBLY C W SCREEN WATER VALVE SEAT RETAINER WATER TUBE SEAL CHUCK SIDE ROD NUT BUFFER FOR RETAINER SIDE ROD STOPER SCREEN HOSE STEM THREADED TYPE AIR BEND NUT WASHER WATER INLET ADAPTER SPUD WATER STEM NUT FRONT CYLINDER WASHER LINER HOSE STEM THREADED TYPE RIFLE BAR REVESIBLE ISO 9001 2000 PARTS HEADQUARTERS INC CERT 0017623 Feet Drilled Soft Hard Ground Ground 4000 3000 4000 3000 5000 3500 5000 3500 5000 3500 5000 3500 6000 5000 6000 5000 7000 2500 9000 7000 9000 9000 10000 10000 10000 10000 12000 6000 13000 11000 13000 11000 15000 15000 15000 15000 15000 15000 15000 15000 15000 15000 15000 15000 16000 12000 18000 18000 20000 12000 Page 33 Meters Drilled Soft Ground 1200 1200 1500 1500 1500 1500 1800 1800 2100 2700 2700 3000 3000 3700 4000 4000 4600 4600 4600 4600 4600 4600 4900 5500 6100 Hard Ground 900 900 1000 1000 1000 1000 1500 1500 800 2100 2700 3000 3000 1800 3300 3300 4600 4600 4600 4600 4600 4600 3700 5500 3700 PARTS HEADQUARTERS INC PHQ250 Stoper Parts Performance Part Nu
6. Worn chuck assembly Collaring holes with drill steel longer than four feet Running out the full length of the leg so that the lack of push makes the drill bounce on the drill rod ISO 9001 2000 CERT 0017623 Page 38 Remedy Leg control handle assembly O Rings worn out SM 6 Replace parts in rockdrill shop Examine and replace bucket seals in drill shop SM 67 Check piston rod Replace in drill shop if bent SM 67 Check the cylinder for dents and replace in drill shop if dented SM 67 Remove damaged steel from the circuit Check piston Replace the piston SM 43 Replace steel chipped ends Remove the drill rod from use and check the piston SM 43 Replace the piston in the rock drill shop SM 43 44 Check the chuck insert with gauge If worn replace in the rock drill shop SM 33 Replace worn parts Check drill steel ends for square Holes should be collared with two foot or four foot drill rods Side pressure enlarges chuck inserts or breaks the insert Always pull in the leg before reaching full extension and reposition to continue drilling Troubleshooting Guides Problem 96 Drill steel does not rotate in the rock drill or has weak rotation 97 Stuck drill steel 98 Drill overheating k PARTS HEADQUARTERS INC Probable Cause Rifle bar or rifle nut worn out Worn chuck driver assembly Piston flutes badly worn or chuck nut worn out and stripped Side rods t
7. drilling power Penetration into the rock face is too slow k PARTS HEADQUARTERS INC Probable Cause Excess water in the air Too much lubricant in drill Cuttings not being removed from the drill hole fast enough Plugged drill steel or water tube Loss of bit gauge causing binding of the bit in the drill hole Drill shank 1s too long or short Broken piston or worn piston face Partially blocked air supply Low air pressure Lack of lubrication Loss of cushion compression in the drill due to worn buffer ring or worn piston Damage to the drill cylinder body Drill cylinder body heating up Damaged Chuck Assembly Damaged Front End Pusher Leg not functioning ISO 9001 2000 CERT 0017623 Page 36 Remedy SM 88 Above SM 93 below Use direct blow to remove cuttings throttle handle back Check and clean SM 25 Gauge grind worn bits and color code by diameter size Check drill shanks regularly for damage or collar wear Replace the drill piston at the rockdrill shop SM 45 46 Check air lines Blow hose Check air connection screen Minimum air pressure 80 psi Ideal air pressure 100 110 psi SM 93 Check front cylinder washer in the rockdrill shop and replace if worn SM 47 50 Check the drill cylinder at the rockdrill shop Look for wear to mating faces and check interior wear SM 45 46 If worn replace the drill cylinder body in the rockdrill shop Check the chuck a
8. in use today were pioneered by some of the personnel working at PHQ To obtain the best performance and life of the equipment regular maintenance is required To obtain the best performance the machines should be operated in accordance with the instructions Ensure proper safety apparel is worn when transporting servicing or using the equipment Ensure quality lubricant is used and the delivery system provides amounts sufficient to run the drill Inspect and replace worn front end and chuck parts promptly to improve the life of drill rods Ensure the drill is being operated correctly to avoid steel and drill rod misalignment Check air supply pipes and hoses and connections for flow restrictions or ingress of contaminants Listen to the drill for erratic running and insure the side rod bolts on the drill are properly torqued Provide new employees with time to read this manual before allowing them to operate the equipment Keep a master copy of this manual at hand at all times for reference should any questions arise Standard Warranty For each new or used PHQ manufactured product and accessory PHQ warrants that the product 1s free from defects in material and workmanship under normal use and service for a 180 days from the date of first use not to exceed one year from the date of shipment from a PHQ factory The obligation under this warranty shall be limited to the replacement or repair of the failed product returned to PHQ All warranty
9. should include PHQ 5250 Tools Repair kit Part Number PHQ250T Torque Wrench with 12 7 mm 1 2 drive up to 250 ft lbs Pneumatic Impact Socket Wrench 12 7 mm 1 2 Drive Standard Pipe Wrench 61 cm 24 Standard Pipe Wrench 30 5 cm 12 Miner s Combination Crescent Wrench 38mm 1 1 2 Drive Socket 38mm x12 7mm 1 1 2 x 1 2 Drive Socket 36 5 mm x 12 7mm 1 7 16 x 1 2 Sockets 15 16 1 1 16 1 7 16 1 1 2 15 Allen Key 3 16 Allen Key 3 8 Pick Set and Miscellaneous carbide grinding heads for 2 electric drill Mechanic s Hammer 12 7 mm x 304mm 1 2 x12 plate c w chuck nut removal tool rifle nut removal tool Rigid 3 Y column bar short arm with swing and dump and short guide shell for S 36 repairs Repair Tags and Report Sheets ISO 9001 2000 CERT 0017623 La PARTS HEADQUARTERS INC Page 8 PHO S250SMCS Repair Tool Kit 20 21 C1811A C1811W C3720 SECPI SG002 T201 T203 T205 T206 1217 T218 T221 T223 T555 T556 T209 O O Minimum order quantity 20 Air Inlet Cover Used to cover JC45 inlet adapter Water Inlet Cover Used to cover 3 8 1 adapter Chuck Insert Wear Gauge Place in chuck insert across flats If top of the insert is more than halfway up gauge insert should be changed Piston Removal Tool Remove Piston and Valve Assy from Cylinder Remove fronthead and chuck ins
10. the drill down disconnect the air line and strip the drill down examining the parts as each is removed Clean the parts inspect each part in detail replace damaged parts rebuilt and test the drill Most drill shops lack sophisticated measuring equipment to accurately gauge wear on components An experienced drill doctor relies on his experience to visually check parts for wear and to test for fit feel and function to determine if the parts should be replaced or not Parts can be assessed using simple but effective work shop practices and knowledge gained over years of experience NOTE After unit is completely disassembled and prior to full inspection all components must be thoroughly cleaned in a suitable pump driven solvent wash tank and blown clean Disassembly Procedures Most of the moving parts inside PHQ250 Stoper drills are interchangeable with parts in PHQ250 Jackleg drills and the disassembly maintenance repair replacement and assembly is the same 1 With the drill secure in the chain vise on the bench unscrew the large closed ended domed nut D1454D on the stem end of the operating handle B1194 This nut holds the control handle firmly in the boss protruding from the cylinder of the rock drill 2 With the nut loose and partially removed tap with a copper mallet to break the grip of the taper on the handle and remove the complete handle from the drill k 3 Unscrew the twist grip lock nut D1990 a
11. 000 OMI CERT 0017623 REGISTERED PARTS HEADQUARTERS INC Page 32 Ring_91066013 3 Regulator Fin 13595484 A Push Nut 9088825 Spring 1741210 Washer 354346 t6 we REN Pipe Reducing AN Bushing 1 1 4 1 i Hit WN i Hot Included III Optional Sleeve 17411797 NN Pipe Reducing U 1 IN A y Bushing 141437 4 Y Hot Included i Optional iin re Washer 17412022 BON ERE Weight 17404303 Ring 906542125 Washer 17404311 Rivet Regulator Pin over Washer Ring 906512125 The JOY football style lubricator 50481912 requires little or no servicing as the parts experience very minor wear in operation over long service intervals When a used lubricator is returned to the drill shop it is usually sufficient to thoroughly wash out any accumulated dirt or debris in the reservoir of the lubricator with Varsol Blow dry and rinse with oil before returning the lubricator to service Relacement parts are avaliable though customers seldom buy any parts for lubricators The threaded pipe bushings in the ports in the lubricator may need to be replaced after prolonged use The safety filler plug 17411821 could be hammered on by drillers to the point where the shape has been damaged to the extent it can not be gripped by a wrench and needs to be replaced ISO 9001 2000 CERT 0017623 PHQ250 Stoper Parts Performance Part Number D1611C C1512 D6177 C1574A
12. 01 2000 CERT 0017623 PARTS HEADQUARTERS INC Page 3 Certificate of Performance This certificate supplied with each drill and 1s signed by the assembly mechanic assuring that the product has been tested and meets PHQ s quality standards It lists the actual test results achieved by running the drill on a PHQ test bench at the time of assembly Parts HeadQuarters Inc pean A 819 1601 5401 Partor Assembly Number Rockdrill Torque Test Report N A a a Cylinder Part Number Test Level Unit Test System Test Acceptance Test FiddTeg Operating Retract Maximum Torque Break Off Water Pressure LegFeed Full Throttle M SI Ca At Full Throttle Torque Pressure FtAbs Test OMI REGISTERED ISO 9001 2000 CERT 0017623 PARTS HEADQUARTERS INC Page 4 Introduction and General Information Joy Football Style Lubricator Safety Identification and Safeguards Lubricator Parts Schematic 34 Certificate of Performance Standard Warranty Ordering Parts Returning Parts re 5 e CD d ON ON Vi U IN Maintenance Procedures Parts Performance Rockdrill Repair Shop 7 PHQ S250 Repair Tools 8 Stoper Parts Performance 33 PHO 5250 Stoper Drill Troubleshooting Guides PHQ250SMCS Stoper Schematic 9 Rock
13. 64301 Replace if damaged or worn ISO 9001 2000 CERT 0017623 PARTS HEADQUARTERS INC x Page 18 29 Check all the valve parts to be sure they are in good condition Reassemble the valve coating parts lightly with Vultrex triple zero grease and set aside to wait reassembly in the drill 30 Whenever the water tube is inserted into the drill always place the raised washer end of the tube into the water control valve to re insert into the backhead to be sure the end of the tube 1s well seated in the water control valve Back Head Removal 31 Lightly tap the backhead A705 to free 1t from the ratchet ring B1170 The backhead components are similar to those used in the Jackleg Airleg Front Head Removal 32 The fronthead A2598A should slip easily off of the cylinder E394 If not tap the fronthead gently with brass hammer to loosen Remove the front head and examine the mating surfaces between the fronthead and the drill cylinder for wear If the surfaces are cracked indented or irregular these major components may need to be replaced 33 Remove the chuck driver assembly from the fronthead Check the hexagon bore of the chuck bushing C1418A in the chuck B1178 with the chuck gauge provided in the service kit If the gauge drops 0 75 into the bushing indicating wear the bushing must be replaced If the bushing is cracked or chipped it must be replaced before it does damage to drill steel Set th
14. BOX VALVE PLUG VALVE RIFLE NUT PISTON ASSEMBLY cm 48 49 PISTON LINER FRONT CYLINDER O RING 164311 RUBBER PLUG STOPER CYLINDER MUFFLED CHUCK NUT CHUCK NUT SPACER CHUCK CHUCK ASSEMLY C W 53 55 CHUCK ASSEMLY C W 53 55 63 FRONTHEAD GASKET PLASTIC FRONTHEAD GASKET COPPER FRONTHEAD STEEL RETAINER LOCK NUT M20 NYLOCK BUFFER PIN STEEL RETAINER NUT SIDE ROD STOPER SINKER NUT SIDE ROD STOPER SINKER CHUCK INSERT 7 8 HEX SAFETY WHIPCHECK 1 8 X 22 SIDE ROD WASHER STOPER SINKER COTTER PIN ISO 9001 2000 CERT 0017623 KEY 113 118 119 120X 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 134X 135 135X 136 137 138 139 140 141 142 143 144 170 PARTS HEADQUARTERS INC Page 12 PART NUMBER ASSY DESCRIPTION COMPONENT 1973854 D1454D C2549 A1502 B1194 D1433 164221 164311 C86271 B1193A 164921 C1570 D1989 D2014 D1989 D2547 D1707 C1582C B1657 A1074 B1654 A1074A B1659 B1656 C2214 1 90385 C2213 D1664 D1665 164671 B1583 9048912 Nana GQ ali aj ala tl ll j ll 2 HAT PACKING OPERATING HANDLE ADAPTER NUT CYLINDER LUB BUSHING HANDLE ASSEMBLY STOPER C W 118 120 121 122 123 124 125 126 127 128 129 130 ADAPTER OPERATING HANDLE STANDARD VALVE ASSEMBLY FEED RELEASE O RING O RING TUBE OPERATING HANDLE SPI
15. NDLE For B1194 O RING 1647804 TWIST GRIP OPERATING HANDLE WASHER LOCK WASHER 3 4 BELLEVILLE LOCK NUT 3 4 16UNF NYLOCK SPIKE END CAP BUSHING SIDE ROD STOPER SINKER LEG CYLINDER 24 STROKE STOPER LEG ASSEMBLY 24 STROKE c W 97 113 131 132 134 136 138 139 140 141 142 143 144 LEG CYLINDER 30 STROKE STOPER LEG ASSEMBLY 30 STROKE c W 97 113 131 132 135 137 138 139 140 141 142 143 144 PISTON ROD 24 STROKE PISTON ROD 30 STROKE PISTON ROD SPACER BUCKET BUCKET SPACER PISTON ROD SPRING CLIP PISTON ROD LOCK NUT O RING 1647824 BACKHEAD CAP LUBRICATOR ISO 9001 2000 CERT 0017623 PARTS HEADQUARTERS INC gt Page 13 Maintenance Procedures The maintenance of all rock drills follows the same routine First clean the exterior of the drill then make a quick visible check to look for items requiring a minor repair that could have shut the drill down before stripping the drill down EG worn chuck bushing broken water tube air connection missing or damaged water valve loose water connection damaged or missing side rod nut missing or broken side rod If no visible problem exists connect the air line with the leg still connected to the drill and start the drill up on low throttle if possible Look into the front end to check the end of the piston for rotation and check the action of the leg using the control handle Listen for leaking air If the problem is still not evident shut
16. Post Courier Truck Freight MA a a 5 For overseas shipments specify the preferred method of shipment EG Air freight or sea freight Pricing is specified by PHQ in formal quotations and shipping terms can be included in quotations All normal repeat part orders are priced according to INCOTerms2000 Ex Works and FOB our factory in Burlington Ontario Separate charges for transportation and export packing may apply Returning of New or Damaged Parts If a customer wishes to return parts to PH due to overstocking or whether for repairs replacement or warranty a letter of explanation should first be sent by e mail mailed or faxed to Parts HeadQuarters Inc C2 1175 Appleby Line Burlington Ontario Canada L7L 5H9 ATTN Sales Department sales partshq com Phn 905 332 3271 Fax 905 332 9497 This letter should specify the model number of the PHQ product EG PHQ250SMCS Stoper Drill and list the parts by item that the customer wishes to return The list should contain the Item part number description and the quantity of each item The letter should state the date of purchase or order number as well as a valid reason for requesting return Parts returned by customers due to overstocking at the customers location will be subject to a percentage restocking charge by PHQ DO NOT ship parts until authorized by PHQ Sales Department and shipping instructions are received All Parts returned to PHQ regardless of reasons must be ship
17. SEAT SPACER WATER TUBE WATER TUBE SEAL WATER TUBE PLUNGER THROTTLE VALVE SPRING THROTTLE DETENT PLUG DETENT SCREEN WATER INLET WASHER WATER INLET WASHER WATER STEM THRUST WATER STEM THREADED O RING 164811 NUT WATER STEM HOSE SPUD 3 8 F D2441 CAP PLASTIC NYLOC NUT 5 8 18UNF LOW PROFILE LOCK WASHER M16 BELLEVILLE HANDLE THROTTLE STOPER KEY THROTTLE BACKHEAD STOPER VALVE THROTTLE STOPER AIR BEND WASHER AIR BEND NUT NUT AIR BEND O RING 164731 AIR SCREEN ASSEMBLY C W 35 36 37 O RING JC45 SCREEN ISO 9001 2000 CERT 0017623 KEY 37 38 39 40 41 41A 42 43 44 45AS 45 46 47 48 49A 49 50 51R 518 528 53 54 55 55A 55AS 56 56A 57 58 59 60 61 628 62S 63 93 94 97 PARTS HEADQUARTERS INC Page 11 PART NUMBER ASSY DESCRIPTION COMPONENT 1356588 C1811A B5053 D6177 S2134 S2134P D1611C B1170 52128 A745AS A745 C1648 A744 C1508 B2334A B2334 C1517 1643403 D2105 E394M C1512 C1516 B1178 B1178A B1178AS NB500P NB500 A2598A A2599 12812UF D6205C C6908 D1388D D1388D C1418A WHIPCHECK D2154 225414 L A a alla a al ll a Na a NI N IN HOSE SPUD 3 4 FX 1 M REDUCER CAP PLASTIC RIFLE BAR REVERSIBLE B1173R PAWL RATCHET REVERSIBLE D1381R PLUNGER PAWL PLUNGER PAWL NYLON SPRING PAWL RATCHET RING 35 TOOTH PIN VALVE BOX D1397 VALVE ASSEMBLY C W 45 46 47 VALVE
18. ake errors in installing parts and cause severe damage to mating parts in the machine Ensure that the drill and accessories comply with applicable company safety and health regulations Do not exceed the rated capacity of any piece of equipment Do not change or alter the drill 1ts components or accessories without prior approval from PHQ Unauthorized alteration voids the warranty and could render the equipment unsafe Before moving a control be certain what function it operates and the ramifications of that function Proper breathing protection must be worn when working with materials producing airborne particles Prolonged exposure to vibration causes serious arm hand vibration syndrome disease White Finger For additional information on training or start up contact your PHQ representative WARNING Operating a Rockdrill without lubricant or with incorrect lubricant is the leading cause of failure of rock drill parts Lack of lubrication can rapidly cause EXTENSIVE DAMAGE to the working parts of this machine All Rockdrill repairs should be preformed by properly trained and equipped personnel NOTE No claim for product warranty of premature failed parts will be considered when it 1s evident that the failures were caused by a prolonged lack of proper lubrication No claim for product warranty of premature failed components will be considered by PHQ if parts other than those manufactured by PHQ are deemed to have caused the failure ISO 90
19. alled the reading on the torque gauge should be minimum 2000 Nm 140 ft lbs ISO 9001 2000 CERT 0017623 Li PARTS HEADQUARTERS INC i Page 31 en a i lt j a Fo WE i d F ir _ a Pa E Ba ERE PICTURE SHOWS A STOPER DRILL DURING RUN IN PROCEDURE Water Testing Procedure Testing of water connections and the flow of water through the drill can be accomplished while the drill is running in on the test bench The air connection to the drill is already in place leave the air valve turned on Shut the hammering of the drill down temporarily using the throttle handle Comnect the water hose to the proper connection on the drill and turn on the water valve Connect the banjo fitting on the spring loaded shank assembly to a drain hose into a bucket Advance the throttle handle forward to engage the valve to the second notch Water should be exiting from the water tube at the front of the drill and coming out of the drain hose Return the throttle lever to the off position and the water should stop running in the drain With the water pressure still on check for leaks around the water inlet and automatic water valve NOTE The water regulation control valve will not work if the water pressure supplied to the drill is equal to or greater than the air pressure supplied to the drill The ideal air pressure for PHQ drills is 7 bar 100psi The ideal water pressure is 3 bar 45 psi ISO 9001 2
20. bricant too heavy thick for the ambient operating temperature Improper amount of lubricant mme Valve chest sticking Penetration is erratic or slower than normal Side rods tightened unevenly Parts broken inside the drill Pawls and springs worn out Insufficient atr supply to leg 88 Water coming out of the exhaust ports on the drill Excess fogging in the work place area Excess water in the air entering the rock drill Rockdrill freezing up and the muffler or exhaust ports are blocked with ice ISO 9001 2000 CERT 0017623 Page 35 Remedy Always blow the air hose Check air connection screen Cylinder may be dented or damaged Replace cylinder at the rockdrill shop SM 45 50 Return drill to rock drill shop to repair valve SM 39 42 SM 93 SM 88 Hone or ream front cylinder washer or replace SM 47 50 SM 93 SM 93 Check parts for sharp edges Check operation SM 39 42 Relax side rod nuts re tighten properly SM 81 Replace broken parts at the rockdrill to shop Replace broken parts at the rockdrill to shop SM 73 SM 94 Install water trap in pipeline Blow moisture out of hoses Check water tube rubber seal Check water tube for cracks or for breakage at the shank end Water pressure must be less than air pressure by 30 psi Troubleshooting Guides Problem 89 Drill Runs Sluggish 90 Drill sounds like it is running properly but it lacks
21. drill will not start 35 PHQ250SMCS Stoper Parts List 10 Rock drill runs erratically 35 Maintenance Procedures 13 Water problems 35 Disassembly Procedures 13 Sluggish running ses 36 Stoper Control Handle Removal 13 Drill sounds good but runs poorly 36 Air Connection Assembly Removal 14 Bronze cuttings coming out of the drill 37 Water Connection Assembly Removal 14 Drill parts wearing prematurely 37 Throttle Valve Assembly Removal 15 Faulty Lubrication 37 Steel Retainer Removal 16 Pusher Leg not working properly 38 Water Control Valve Automatic 17 Drill Steel failing at the collar 38 Backhead Removal 18 Drill steel does not rotate or weak rotation 39 Front Head Removal 18 Stuck drill steel 39 Ratchet Ring and Rifle Bar Removal 19 Drill overheating 39 Valve Chest Disassembly 19 Inspection of Cylinder and Piston 21 Front Cylinder Assembly Inspection 21 Chuck Insert Removal 23 Rifle Nut Removal 23 Chuck Nut Removal 24 Servicing the Stoper Leg
22. e driver assembly aside until later If the chuck shows no sign of lubrication check the port that carries lubrication to the chuck in the front end to see if it is plugged ISO 9001 2000 CERT 0017623 PARTS HEADQUARTERS INC gt Page 19 Removal of Ratchet Ring Rifle Bar and Valve Chest 34 Using the piston removal tool push the piston back until 1t touches the valve chest Hammer gently on the face of the piston to push the ratchet ring until 1t protrudes about one inch out of the cylinder bore HD 35 Remove the valve box locating pin S2128 from the groove in the cylinder using needle nose pliers 36 Remove the ratchet ring B1170 Examine the teeth on the inner diameter of the ring for chipping or wear The ratchet ring is reversible and it is advisable to reverse sides whenever removing the ratchet ring to even out wear 37 Remove the rifle bar B1173B and check the spiral flutes for wear Set the rifle bar complete with ratchet pawls aside to examine in detail later Reversible pawls can safely be turned to the un used side to get more life 38 Using the piston removal tool hammer push or hammer gently on the face of the drill piston to push the valve chest assembly out of the cylinder until it drops in you hand Continue pushing on the piston B2334 until 1t emerges from the drill cylinder and catch 1t in your hand Examine the striking face of the piston and the flutes for signs of wear Ift
23. end of the piston rod Unscrew the bucket spacer and locking rung components from the end of the piston rod 67 Inspect the thrust leg parts Replace as necessary gt D1707 End cap bushine 1973864 Lip seal packing C2214 Piston rod spacer we S yy 17970383 Bucket J C2213 Bucket spacer D1665 Piston rod lock nut 68 The lip side of the seal should be facing outwards from the cylinder If the steel end cap bushing is worn scored or corroded it should be replaced Remove with service tool T201 by striking several blows with a copper mallet 69 Always refit the end cap bushing using an assembled piston rod to ensure correct alignment ISO 9001 2000 CERT 0017623 PARTS HEADQUARTERS INC Assembly Procedures 70 To install a piston with the cylinder horizontal in the jaws of a vice use a rifle bar for alignment Oil the stem end of the piston and insert into the cylinder bore guiding 1t with care not to strike the step for the valve chest seat in the cylinder 71 To replace the valve box assembly A745 place the cylinder upright on a flat work bunch and carefully insert the valve box assembly into the bore of the cylinder Align the valve locating pin S2128 in the groove in the valve box and cylinder Place tool T205 on top of valve box assembly and gently tap the valve box home with a brass mallet The valve box should fit fairly tight ui The valve chest assembly is the heart of t
24. ert punch into piston and hammer out Air Gauge Measure Airleg pressure Attach qty 2 to SG001 Cylinder Bushing Extractor Used to remove brass bushing from inside cylinder and remove bushing from the Stoper Leg Stoper Punch Remove Stoper handle bushing form cylinder Valve Chest Assembly Tool For assembling valve chest and installing valve chest in cylinder Valve Chest Punch To disassemble valve chest Insert punch into top of valve box hammer out Chuck Insert Remover For collared steel chucks Place chuck in chuck removal support ST218 and push insert out with hydraulic press Chuck Removal Support To remove chuck inserts place chuck Assy in support and use T555 or T217 punch to push out on hydraulic press Chuck Insert Punch To insert collared chuck insert place the insert in chuck T218 and push insert in hydraulic press until flush with chuck Stoper Cylinder Mandrill Remove small dents from Stoper leg by forcing T233 through the inside diameter of the cylinder Chuck Insert Punch Insert and remove collarless steel chuck insert Place the chuck in support T218 Push the insert in using the hydraulic press until the face of the insert 1s level with circumference of chuck Socket Use with an impact gun to remove the spike from Stoper Leg Feed Cylinder Clamp Used to grip the Stoper pusher leg cylinder in a shop vice ISO 9001 2000 CERT 0017623 Z Y p gt pc lt 2 a
25. f the chuck If either Is corroded there has been no contact between the bushing and the chuck and the chuck should be discarded as it no longer is supporting the front of the chuck bushing Rule of thumb says that up to five chuck bushings can be replaced in one chuck before the chuck is worn out 56 To replace the chuck bushing invert the chuck under the piston of a hydraulic press and insert the chuck bushing and tool T221 for collared insert and T555 for collarless insert in the open end Carefully align the chuck chuck bushing and the pressing tool and drive the chuck bushing home until fully sealed The interference fit between the chuck bushing and the chuck is nominally two thousanths of and inch and requires from six to fifteen tons of force to push into place The bushing hits bottom with an audible bang when properly pushed into place in a hydraulic press Rifle Nut Removal 57 Inspect the flutes splines of the rifle nut C1508 and replace when the splines are worn down past 50 of original thickness Rule of thumb says that the rifle nut should be replaced whenever the mechanic knows the drill will be used in a remote inaccessible or difficult to get to work place to prevent the premature return of the drill to the repair shop ISO 9001 2000 CERT 0017623 PARTS HEADQUARTERS INC C1508 RIFLE NUT NEW C1508 RIFLE NUT 50 WORN C1508 RIFLE NUT 100 WORN 58 The mechanic can make a tool to remove a worn rif
26. g too hard on the cylinder liner during the down stroke and provides a bounce to start the piston on its backward stroke during operation If the piston head has proper clearance with the cylinder bore and there is no bounce of the piston on a cushion of air during the test then the bronze front cylinder washer liner C1517 must be changed to Improve compression NOTE It is very important that the distinct pop pop sound of a good air cushion is heard during this test not the jarring clank sound of metal on metal impacting of the two parts S1 To remove the bronze front cylinder washer liner C1517 place the cylinder body under the piston of a hydraulic press Use service tool T201 to press bronze liner out of the cylinder If a press 1s not available the liner can be driven out by striking the T201 tool with a hammer 52 To install a new liner stand the cylinder body on the press bench with the front end down Carefully place a new bronze liner C1517 in the front cylinder washer using the lead on the liner to align the bushing in the bore A good method 1s to place the liner on a piston and insert the liner with the piston to be sure of alignment Insert a second piston B2334 with the head into the bore resting on the bronze liner or head of the first piston Push the bushing with the hydraulic press until it bottoms out inside the cylinder with an audible click 53 Often the inside diameter of the bronze fron
27. he drill The valve controls the working of the drill by directing atr to the proper ports to activate all the moving parts in the drill Great care must be taken when removing cleaning examining and replacing the valve chest assembly in the drill 72 Insert the ratchet ring B1170 into the cylinder taking care to align the groove in the ratchet ring to fit the valve locating pin already installed Gently tap around the circumference of the ratchet ring home with a brass mallet until the ratchet ring seats down snugly on top of the valve chest assembly 73 Assemble the rifle bar parts Rifle bar reversible B1173B four ratchet pawls reversible D6177 four pawl plungers S2134 and four pawl plunger springs D1611C If the pawls appear rounded reversible pawls can be turned once to present the square not worn side of the pawl to the teeth of the ratchet ring This provides for extended life for these fast wearing parts 74 To Insert the rifle bar assembly lightly oil the splined end of the rifle bar Holding all four ratchet pawls closed with the fingers of both hands guide the stem of the rifle bar into place in the rifle nut Insert the head carefully into the ratchet ring slowly turning at the same time Oil the pawls in the ratchet ring Check the pawl sequence by slowly turning the piston and listening to the action the pawls should click into place in a 1 2 3 4 sequence ISO 9001 2000 CERT 0017623
28. he striking face 1s chipped the piston must be replaced Valve Chest Disassembly 39 Valve chest disassembly must be done using the proper valve punch T206 Hold the valve chest box in one hand Place with the small end of the valve plug facing up Fit the punch in the bore of the plug and strike the punch with a brass hammer until the valve box A745 separates from the valve plug A744 ISO 9001 2000 CERT 0017623 PARTS HEADQUARTERS INC A Page 20 40 Once the valve plug A744 1s loosened remove the valve plug A745 from the valve box Remove the valve C1648 from the valve box A745 Wash all the valve parts in Varsol and blow dry Check that the parts are clean and free from debris Check for sharp edges on the components caused by long use Sharp edges cause the drill to run erratically and should be removed with emery cloth Take care to just remove the sharp edge 41 Align the valve properly on the stem of the valve plug Push to mate with the face of the plug Cover the two holes in the large diameter of the valve plug with your fingers Pull the valve away from the mating surface If it moves easily there is no suction created and the valve is worn 42 Reassemble the valve and holding the assembly firmly in both hands shake back and forth Listen for a clicking noise that signifies the automatic valve is moving inside the valve If no distinct clicking Is heard the valve is jamming The valve must be disassemb
29. ightened unevenly Lack of lubrication to front end Damaged front cylinder washer Plugged drill steel or water tube Broken water tube Poor alignment of drill with hole Low water pressure Intermittent water supply Over feeding rock drill can cause overheating of the drill body Pulling drill steel with a machine run at high throttle and insufficient feed pressure allows the piston to freewheel in the drill and build up excessive heat Following worn bits with oversize bits or using bits with gauge loss Drilling with insufficient water to clear cutting drill rod stuck ISO 9001 2000 CERT 0017623 Page 39 Remedy Return drill to rock drill shop to replace rifle bar SM 72 or rifle nut SM 57 58 Return drill to rock drill shop to replace chuck driver nut SM 59 61 Return drill to rock drill shop Replace piston SM 43 44 or chuck driver nut SM 59 61 Relax side rod nuts re tighten properly SM 81 SM 93 Hone or ream front cylinder washer to proper fit or replace Remove and clear water tube Replace water tube SM 30 Always drill in line with hole Check for water line blockage crimped water hose or plugged screen in water connection Maintain proper leg pressure so drill rod visibly rotates When a drill hole is completed always pull the drill steel with the machine running at partial throttle Use occasional bursts of full throttle to clear a hole Gauge grind worn bit
30. le nut C1508 from a good piston B2334 without damaging the piston by welding a steel handle across the bottom end of a used rifle bar to form a wrench A good tool to hold the piston can be made by brazing a used but fairly good chuck nut C1512 into a used chuck B1178 and welding the chuck to the side of the work bench at working height in a convenient location Insert the splines on the stem of the good piston into the spines of the chuck nut Insert the wrench tool made from a used rifle bar into the rifle nut and unscrew the rifle nut from the piston head Note the rifle nut is left hand threaded so unscrew in a clock wise direction Chuck Nut Removal 59 Inspect the splines of the chuck nut C1512 and replace when splines are worn to half their original thickness The mechanic can make a tool to remove chuck nuts by welding a steel handle across the head of a piston B2334 to create a wrench A good tool to hold the chuck 1s the collar of a drill rod welded to the side of the shop bench at work height in a convenient location Slide the chuck insert onto the drill rod collar and using the fabricated wrench unscrew the chuck nut out of the chuck The nut is left hand threaded so unscrew in a clockwise direction C1512 CHUCK NUT NEW C1512 CHUCK NUT 50 WORN C1512 CHUCK NUT 100 WORN ISO 9001 2000 CERT 0017623 PARTS HEADQUARTERS INC Page 25 60 Place the chuck insert onto the collar of a drill rod that ha
31. led to find the cause before returning it to the drill The valve surfaces are precision ground to within thousands of an inch so never hand grind the faces of the automatic valve or the inner faces of the valve box Inspection and repair of the striking face of the Piston 43 Inspect the striking face of the piston B2334 If the striking face 1s not dished more than 1 0 mm 0 04 inch you may reface the piston Grinding of the face of pistons should be carried out in a proper machine shop where the piston is steadied in a turning jig to align the face to be ground square to the piston axis The head must be quickly ground on a good belt grinder so that low heat is produced Remove the raised portion and try to leave the original dished surface of the piston face The piston should be replaced if the outer thickness of the splines at the front end are worn down to half the original size or if the piston striking face is chipped or cracked in any way 44 The case hardening on the face of the piston 1s approximately1 3 mm 0 050 inch deep so that removal of material must not exceed 0 7 mm 0 040 inch An egg shell affect is created grinding the piston face by seriously reducing the case hardened depth The life of a reconditioned piston can be expected to be about one half of what is normally expected performance It is often more economical to replace worn pistons ISO 9001 2000 CERT 0017623 PARTS HEADQUARTERS INC Page 21
32. ll doctor places his hand on the cylinder of the drill near where the front head joins the cylinder to check for heat that may be generated If the drill sounds smooth during the running and the body remains fairly cool to the touch during and after the run in period the Rock Drill Doctor can be satisfied that the repairs were done properly and that the drill is running properly This ensures smoother running later on when the drill is run at full throttle in actual drilling operations The drill is now ready for torque testing and already in the proper position on the test bench Testing the Stoper Remove spring loaded shank steel assembly from the bench and replace with the torque test head Before engaging the drill to the head make sure the torque head ts loosened off at least five rotations This will allow the drill revolution to build up momentum going into the torque test Move the drill forward with the pneumatic pusher leg of the Stoper Insert the rod shank adapter on the torque tester into the chuck bushing and close the steel retainer Release the feed pressure by shutting off the air supply to the pusher leg and pushing the release With the drill in position and no pusher leg pressure suddenly throw the throttle handle forward opening the valve fully to operate the drill for a short burst at full throttle ending in a stall Observe the reading on the air consumption gauge which should read 5000 LPM 170 CFM When the drill st
33. mber B1176 C1272 C1648 C2213 C1526 D1406 S2128 C1525N B1170 A2598A A2599 A745 B1181PC4 D1383 E394M Description THROTTLE VALVE WATER INLET SCREEN VALVE BUCKET SPACER AIR BEND NUT WATER VALVE SPRING VALVE BOX PIN AIR BEND RATCHET RING 35 TEETH STANDARD FRONTHEAD STEEL RETAINER VALVE BOX WATER CONTROL VALVE BODY PLUNGER FOR THROTTLE VALVE STOPER CYLINDER MUFFLED ISO 9001 2000 Feet Drilled Soft Ground 20000 20000 20000 28000 30000 35000 40000 45000 50000 50000 60000 60000 90000 100000 200000 CERT 0017623 Hard Ground 15000 20000 20000 26000 26000 35000 30000 45000 35000 40000 50000 50000 80000 100000 150000 Page 34 Meters Drilled Soft Ground 6100 6100 6100 8500 9100 10700 12200 13700 15200 15200 18300 18300 27400 30500 61000 Hard Ground 4600 6100 6100 7900 7900 10700 9100 13700 10700 12200 15200 15200 18300 30500 45700 La PARTS HEADQUARTERS INC Troubleshooting Guides Problem Probable Cause 86 Rock drill will not start when throttle handle is advanced Atr line supply blocked Piston sticks air hissing past Dirt in automatic valve assembly or valve gummed by thick oil Automatic valve flooded by lubricant or gummed by grease Ice in the muffler or exhaust ports Damaged front cylinder washer 87 Rock drill runs erratically or lacks power during drilling operations Lu
34. nd remove the twist grip C1570 ISO 9001 2000 PARTS HEADQUARTERS INC Page 14 4 Unscrew the pressure release valve D1433 and remove from bore Clean and replace 5 Unscrew the operating handle spindle B1193A from the handle adapter 6 Replace the three O rings 164921 whenever the handle is disassembled 7 Inspect all parts and replace the one small O ring 164311 in the orifice into which the small end of the operating handle is fitted eee i oe lt coo 8 Measure the working diameter of the control body and replace if worn Check the bore of the twist grip and replace 1f deep groove are present from the wear caused by rubbing of the O rings Air Connection Assembly Removal 9 Unscrew hose spud 1356588 from atr bend C1525N Check the air inlet screen 355538A for damage and replace along with O ring 164999 10 Unscrew the air bend nut C1526 from the backhead Always replace the copper washer D1601 Replace any worn or damaged parts as the air connection nut and bend are safety critical If the air connection releases from a drill during operation the hose will injure the driller ISO 9001 2000 CERT 0017623 PARTS HEADQUARTERS INC Page 15 Water Connection Assembly Removal 11 Unscrew the water inlet adapter stud D2441 from the water stem C1809 and unscrew water stem nut S2141 from the backhead of the drill 12 Remove water stem thrus
35. nd the inner diameter of the bronze front cylinder washer liner is nominally 0 047mm 0 0015 The clearance between a worn piston stem and a worn bronze cylinder liner bore is 1 6mm 0 063 or larger If the cylinder liner does not visibly appear to be worn it still should be tested with the piston installed in the normal operating position in the cylinder bore with the stem through the cylinder liner 48 To measure the compression fit of the piston and cylinder liner place the drill cylinder body flat on the bench and advance the piston fully through the liner With one hand gripping the spline end of the piston and the other the front part of the cylinder body push the piston back into the drill as far as it will go then pull it rapidly forward until 1t stops on the cushion of air above the liner Hold a thumb against the splines of the piston and slowly pull the piston out of the cylinder One should be able to pull the piston face approximately three quarters of an inch further through the cylinder PARTS HEADQUARTERS INC Page 22 49 An alternate method to measure the compression fit of the piston and bronze cylinder washer liner is to hold the cylinder in a vertical position and push the piston up from underneath to let it free fall down into the cylinder The piston should bounce and then move slowly to the bottom of the bore against the cushion of air 50 A good air cushion prevents the piston from bottomin
36. ontrol body 84 Fit the pressure relief valve Make sure you have replaced the O ring prior to installing the relief valve Running in 85 Place the assembled drill on the PHQ test bench and run for approximately 15 minutes at low throttle to run 1n the assemble parts and insure the parts in the drill are fully lubricated before testing the torque of the drill The PHQ test bench supplied with compressed air at a minimum volume of 5 0 cu m m 175 cfm and minimum pressure of 620 kPa 6 Bar 90 psi 1s required to adequately test Jackleg and Stoper Pneumatic Rock Drills Move the drill saddle forward with the pneumatic leg on the Stoper drill pressing against the stop Remove the Stoper control handle assembly from the drill Connect the drill to the Stoper control adapter on the saddle ISO 9001 2000 CERT 0017623 PARTS HEADQUARTERS INC Page 30 Insert the spring loaded collared rod shank into the chuck bushing of the rock drill Rotate the control handle so the leg 1s at full force pushing the drill against the spring tension Run the drill under full leg pressure at partial throttle for no more than 15 minutes Running the drill under controlled conditions in the shop accomplishes several things e The rifle bar polishes the bronze of the rifle nut e The piston splines polish the bronze of the chuck driver nut e The drill doctor listens for irregular sounds and to be sure the drill runs smoothly e The dri
37. ped prepaid to PHQ ISO 9001 2000 CERT 0017623 PARTS HEADQUARTERS INC Page 7 Rockdrill Repair Shop The rock drill repair shop should be a clean area equipped with all the usual filters tools work benches component cleaning tanks and a hydraulic press Your work shop should have the following items e PHQ Test Bench custom designed and made to test torque generated by the drill and leg pressure Every drill that 1s repaired in the drill shop should be run in on the test bench using the spring loaded device that allows the drill to be run under load and leg pressure sa gt a E e Work Bench 91 4cm x 213 4 cm 36 x 84 c w air bulkhead optional e 15 2 cm 6 Vice fixed type mounted on the corner of the bench e 10 2 cm to 20 3 cm 4 to 8 Chain Vice mounted on opposite corner of bench e Steel block or press two 7 6 cm x 7 6 cm x 45 7 cm 2 x 3 x18 with slider stop bars e Electric pump driven solvent wash cleaning tank e Bench Grinder 8 diameter one coarse and one fine stone optional e Belt Sand Paper Grinder c w back support for grinding parts e Acetylene Oxygen Cutting torch set c w twenty foot hoses e Welding machine optional e Sliding eight to ten drawer metal cupboards for parts e Pin Skids e Electric cord with auto rewind fancily wall mounted e Four foot four bulb fluorescent lighting over work bench Small pencil light Your tools
38. replacement is subject to inspection by a PHQ representative and the Quality Control Department at PHQ in Burlington Ontario PHQ will replace only parts that are judged to have been defective at the time of manufacture and assembly This warranty does not apply to a product which has been altered changed or has been used and repaired then returned to a drill where the repaired part failed while in operation PHQ states that the product described in this manual shall not be merchantable or fit for any other purpose other than the operations described in the manual No other warranties are expressed or implied Exclusive of Liability for Consequential Damages In no event shall PHQ be liable for a customer s cost of lost production increased cost loss of profit special indirect incidental or consequential damages and freight brokerage and shipping and storage charges ISO 9001 2000 CERT 0017623 k PARTS HEADQUARTERS INC Page 6 Ordering Parts PHQ requires the following procedures be followed and the proper information be supplied to expedite the filling of customer orders for parts and to eliminate delays and errors in shipping incorrect parts List the model of the assembly EG PHQ250SMCS Muffled Stoper Drill State the exact quantity of each item of parts required Identify items with the description and part number as shown in the parts section of this manual Specify the preferred method of shipment EG Parcel
39. s and color code by diameter size SM 97
40. s been cut and welded to a steel bench or other rigid support Place the splines of the Chuck Nut Wrench tool into the splines of the chuck nut Turn the handle clockwise to remove the left hand threaded chuck nut 61 An alternate method of removing a chuck nut 1s to grip the chuck firmly in the jaws of a bench vice with copper jaw inserts across the flats provided for the purpose Unscrew the chuck nut using a service tool made from an old piston stem welded onto a handle or with flats ground to take a large crescent wrench The parts are left hand threaded These same tools are used to install rifle nuts in pistons and chuck nuts in chuck drivers Servicing the Stoper Leg 62 Pull the piston rod B1659 out of the cylinder B1654 Inspect cylinder for dents Remove small dents from cylinder with service tool T223 Remove O ring from large bore and replace 63 Whenever it is required to firmly hold the pusher leg for the stoper always clamp the leg in the shop vice using a set of 64 Remove the lip seal packing 1973864 in the bottom end cap of the leg cylinder and replace each time the leg is disassembled as this part wears out fairly rapidly ISO 9001 2000 PARTS HEADQUARTERS INC Page 26 a E o bo s m 65 To replace the spike D2547 unscrew from the bottom end of the piston rod using tool T556 66 To replace the bucket seal pick out the split pin from the small
41. t cylinder washer C1517 will shrink inwards due to the pressure on the outside diameter as it 1s pressed into place Check that the piston stem moves freely through the bronze washer and if required hone the inside diameter until the fit 1s correct The front cylinder washer liner test should be repeated after installing a new bronze liner and if metal on metal contact occurs repeat the inspection of the cylinder bore and piston head ISO 9001 2000 CERT 0017623 By PARTS HEADQUARTERS INC Chuck Insert Page 23 54 Inspect the hexagon bore of the chuck bushing with the plate gauge SC3720 provided in the service tool kit Replace the chuck bushing if it 1s cracked chipped or worn oversize If the gauge enters the bushing across the flats 19 19mm 0 7555 or more the insert is worn oversize Worn chuck bushings damage drill steel and can cause the water tube to break off when the drill steel 1s very sloppy in the chuck bushing Chipped bushings damage drill steel 55 To remove the chuck bushing CC1418A place the chuck assembly in a used fronthead A2598A inverted between two steel blocks under the piston of a hydraulic press Place the service tool T555 for collared chuck inserts in the bore of the chuck and press out the chuck bushing It is Important that all parts are correctly aligned in this pressing operation to avoid damage to the chuck Check the top outer diameter of the chuck bushing and the top inner diameter o
42. t the rock drill shop SM 33 54 61 Replace worn or damaged part Check the front end at the drill shop SM 32 33 Replace SM 94 Troubleshooting Guides Problem 91 Bronze cuttings exhausting from rock drill ports 92 Drill parts wearing faster than normal Service trips to rockdrill shop too frequent 93 Faulty Lubrication According to experts in the maintenance field Lack of lubrication is the leading cause of failure of parts in machinery k PARTS HEADQUARTERS INC Probable Cause Rifle nut falling Rifle nut burned by overheating Chuck nut failing Chuck nut burned by overheating Improper Lubrication Dirt or debris entering the drill Lack of Lubrication Wrong Lubrication Excessive Lubrication Automatic valve flooded by oil Automatic valve stuck with grease Excessive water in the air supply ISO 9001 2000 CERT 0017623 Page 37 Remedy Rifle bar heat checked from lack of lubrication SM 93 Rifle Bar failing or broken Replace at rockdrill shop Piston heat checked from lack of lubrication SM 93 Piston failing or broken Replace at rock drill shop SM 93 Check front end blow Plug or cover all openings in the drill when in storage or moving between drill sites If using rock drill oil fill the lubricator at beginning of shift and check level mid shift If using rock drill grease fill the lubricator at the beginning of each shift Check l
43. t washer S2487 inlet washer rubber D1402 from the backhead of the drill Remove the water inlet screen C1272 with a small screw driver or a scriber 13 Replace both O rings 164811 as well as the stem thrust washer S2487 and washer rubber D1402 whenever the drill 1s in the shop for repair Check the screen filter and replace if damaged Throttle Valve Assembly Removal 14 Unscrew the throttle valve handle nut D1385 on the end of the throttle valve Remove the nut and disc spring 1491623MT and slip off the throttle valve handle C1509 Remove the throttle valve key D1384 15 Unscrew the plug 2422P that retains the throttle valve plunger assembly and throttle valve plunger D 1383 and spring D1382 This should be done before removing the throttle valve to prevent scratching or damaging the surface of the throttle valve Check the throttle valve plunger to be sure it is still properly shaped to engage the ratchet teeth on the throttle valve Check the spring for tension ISO 9001 2000 CERT 0017623 16 The throttle valve B1176 should push out easily If it 1s tight tap gently on the end of the valve with a bronze hammer and remove from backhead Steel Retainer Removal 17 Remove the steel retainer pin nut 12812UF D1932 from the steel retainer pin C6908 Tap the end of the steel retainer pin with a bronze hammer to loosen Push the steel retainer pin through the front end l
44. ubi PARTS HEADQUARTERS INC 5 APPLEBY LINE UNIT C2 BU e pri 3271 FAX 905 332 8497 TOLL FREE 1 ug INTERNET www partshq com PRINTED 7 26 2010 PHO250 Stoper Parts and Service Manual PHO2505MCSR Stoper Drill c w Pusher Leg 5048912 JOY Football Style Lubricator La PARTS HEADQUARTERS INC Page 2 Safety Identification and Safeguards WARNING Read and understand all safety instructions carefully before operating this machine Failing to follow these instructions may result in serious personal injury Important Safeguards Keep clear of rotating equipment and never wear loose clothing to tangle in machinery Always maintain a clean and tidy work area Pick up unnecessary items Store tools Avoid dangerous working environments and lack of ventilation Do not operate equipment while under the influence of drugs alcohol or medication Keep visitors at a safe distance and away from the work area where they may be injured Wear protective equipment hard hat safety glasses hearing protection and hard toed work boots Read and understand the operations manual and any and all labels affixed to the machine Use only genuine PHQ replacement parts Failure to do so could cause rapid and severe damage to the machine or ultimately the operator Pirate replacement parts may void the warranty of mating parts Employ qualified service technicians to repair rock drills An un trained mechanic could possibly m
45. ubricator flow setting Lubricant high viscosity too thick for ambient temperature Drill hose maximum12 feet Use EP100 rockdrill oil or Triple zero Vultrex grease at temperatures 10 40 Celsius Check lubricator setting Oil at a viscosity too low for a warm ambient temperature Grease may be too thick for a cold ambient temperature Lubricator damaged Excessive water will wash lubricant out of the drill SM 88 Troubleshooting Guides Problem 94 Pusher Leg not functioning properly Drill is jumping on the leg during drilling operations 95 Drill steel failing at the collar or forming a coke bottle shape Drill steel showing chips or chunks out of striking face at the collar end Pistons in drills have chips out of the striking face or are failing at the striking face Experience has proven One chipped piston can damage a lot of new drill rods One chipped drill rod can damage a lot of new pistons They need to be removed La PARTS HEADQUARTERS INC Probable Cause Insufficient lack of volume or erratic pressure supply of air to the pusher leg Bucket seals in leg worn Bent piston rod Dented pusher leg cylinder Drill steel was worn or chipped to begin with Piston in the drill has a chipped or broken front striking face Drill steel does not have a square face on the striking end Refaced piston in the drill was not machined properly Worn chuck insert
46. ug bore using a screwdriver or punch 18 Pull the steel retainer pin through the lug on the front end and remove the steel retainer A2599 19 Remove both of the square plastic steel retainer pin bushings D6205 from the housing using a screw driver 20 Examine all the parts for wear and replace any parts that are worn Check the area of the steel retainer where the collar of the drill steel rides to be sure it is not worn out 21 Unscrew the two side rod nuts D188D and washer D2154 and remove from the side rods ISO 9001 2000 CERT 0017623 PARTS HEADQUARTERS INC 22 Withdraw the side rods through the backhead of the stoper C1582C and lift off the thrust leg as a complete assembly 23 Remove the backhead cap B1583 using two screwdrivers as shown 24 Remove O ring 164671 and replace 25 Unscrew and remove the water control valve Remove the water tube with the water control valve and separate the water tube from the valve Water Control Valve Automatic Valve 26 Remove circlip 20015 from water control valve body B1181PC4 with a pair of circlip pliers that are designed just to remove circlips Remove the water valve spring cap C1521PCT Replace the circlip and cap if damaged or worn 27 Remove the water valve seat retainer C2144 and the spring D1406 Check the tension on the spring and replace if too loose 28 Remove water valve C1522PC1 Check O rings 164521 and 1
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