PHQ250 Jackleg - Parts HeadQuarters Inc.
Contents
1. ONS OOo 40 071 0 I DhD ocodoo 1o00040ht20 0 48 49 49 50 51 52 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 PARTS HEADQUARTERS INC 20015 C1521PC1 164231 D1406 C1522PC1 164521 164301 B1181PC4 D1673 C2144 D1674 C1574A D1675 C1572C D1385 149163MT C1509 D1384 B1176 D1388 A660 D1383 D1382 2422P C1525N D1601 C1526 C1811A 355538A 164999 1356588 164731 D6177 52134 D1611C B1173B B1170 52128 A745 C1648 A744 1218UF 149122MT 300822 30088 C1518 164631 B1180B B1180 B1183B B1183 1125NF02 164811 A697B A697 C151415 D1424 D1425 D1427 145M30 D8247 D1454 D1454D 52141 C1809 52487 D1402 C1272 D2441 C1811W D1982 A693A od 3 ad am td am AD am ad on of add ad ad ad A am am td ad ad PEN Circlip 20014 Water Valve Spring Cap O Ring Water Valve Spring Water Valve O Ring O Ring Water Control Valve Body Water Valve Seat Water Valve Seat Retainer Water Tube Spacer Water Tube Swaged Water Tube Seal Side Rod Throttle Valve Handle Nut Disc Spring Thr2. DOGS Anti vibration Control Handle Anti vibration Handle Schematic Water Control and Water Tube Water Valve Removal Air Connection Remowval Water Connection Removal Throttle Valve Assembly Removal Steel Retainer Removal Side Rod and Front End Removal Ratchet Ring and Rifle Bar Valve Chest Disassembly Cylinder Lug Bushing Removal Inspection of Cylinder and Piston Front Cylinder Assembly Inspection Chuck Insert Removal Rifle Nut Removal Chuck Nut Remowval Assembly Procedures Piston Valve and Ratchet Ring Rifle Bar Backhead and Fronthead Steel Retainer Water Valve Air and Water Connection Assembly Throttle Handle and Ratchet Control Handle NNN BW DR IFI 10 11 11 11 12 13 15 16 16 17 18 18 19 20 20 21 22 23 24 25 26 A 27 28 29 30 30 Page 4 Assembly Procedures C levis DOGY ERR 31 Running in the 31 Testing the Jackleg 32 Water testing procedure 33 Joy Football Style Lubricator Lubricator Parts Schematic 34 Parts Performance Anti Vibration Jackleg Parts Performance
3. PICTURE SHOWS 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 Connect 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 drills is 7 bar 100psi The ideal water pressure is 3 bar 45 psi ISO 9001 2000 OMI CERT 0017623 REGIS Version 200711 34 JOY Football Style Lubricator Filler Flug 17411821 Regulator Pin 13595404 Push Hut 9088825 Ring 910660224 Line Ciler Body 3500851 Ring 91
4. 35 Troubleshooting Guides Rock drill will not start 37 Rock drill runs erratically 37 Water DJ Sluggish running sseeeee 38 Drill sounds good but runs poorly 38 Bronze cuttings coming out of the drill 30 Drill parts wearing prematurely 30 Faulty 30 Pusher Leg not working properly 40 Drill Steel failing at the collar 40 Drill steel does not rotate or weak rotation 41 Stuck drill steel 0 ccc cece eee e ee ees 4 Drill overhe attliba iode 41 Version 200711 ae 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 f
5. PARTS HEADQUARTERS INC 1175 APPLEBY LINE UNIT C2 BURLINGTON ONTARIO L7L 5H9 TEL 905 332 3271 FAX 905 332 9497 TOLL FREE 1 800 267 2082 ERNET www partshg com PRINTED 2 12 2008 Parts and Service Manual PHQ250JHMAVL Anti vibration Jackleg c w 51 Retractable Air Leg 5048912 JOY Football Style Lubricators Version 200711 P x2 PARTS HEADQUARTERS INC 7 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 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 safe distance and away from the work area where they may be injured Wear protective equipment hard hat safety glasses hearing protection gloves and hard toed 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 te
6. new bushing until it seats using the T225 lug bushing punch Version 200711 PARTS HEADQUARTERS INC Page 22 Inspection and repair of the striking face of the Piston 59 Inspect the striking face of the piston B2334 If the striking face 1 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 proper machine shop where the piston 1s 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 1s 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 1s chipped or cracked in any way 60 The case hardening on the face of the piston is 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 15 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 Inspection of the fit of Piston B2334 and the Cylinder E393 E393M bore 61 To establish consistency in testing always test the cylinder with inner surfaces
7. Adapter Nut Piston Rod 51 Stroke 1 Piston Rod 39 Stroke 1 Piston Rod 30 Stroke 1 O Ring Sinker Handle Assembly Part No 19049 117 118 119 120 121 122 123 124 125 126 127 128 129 ISO 9001 2000 OMI REGISTERED B3352 2120 C3844 B3263 C1582C D2584 C1940 B1729 D1388D D2154 C1939 D1454 D1453 CERT 0017623 1 2 1 2 2 2 1 1 2 2 1 1 1 Tee Handle c w Nuts Tee Handle Grip Tee Handle Guide Tee Handle Nylock Nuts Side Rod Tee Handle Springs Cylinder Lug Bushing Stirrup Handle Side Rod Nuts Side Rod Nut Wahser Backhead Lug Bushing Nut Washer 12812UF Version 200711 PARTS HEADQUARTERS INC Page 11 Maintenance Procedures The maintenance of all rock drills follows the same routine First clean the exterior of the drill then make quick visible check to look for items requiring minor repair that could have shut the drill down before disassembly of the drill 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 15 still not evident shut th
8. C1648 A1502 D1515A A639A C1523 C1526 D1406 2128 C1525N B1170 A2598A A2599 A745 B1181PC4 B1308 AVH660 C1791 D1383 E393M Description WATER STEM NUT FRONT CYLINDER WASHER LINER HOSE STEM THREADED TYPE RIFLE BAR REVESIBLE THROTTLE VALVE WATER INLET SCREEN VALVE HANDLE ASSEMBLY BUCKET SPACER UPPER CLEVIS BODY CYLINDER LUG BUSHING 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 CARRYING HANDLE C W BOLTS AND NUTS BACKHEAD AVHB BOTTOM CAP 4 PRONG PLUNGER FOR THROTTLE VALVE JACKLEG CYLINDER MUFFLED ISO 9001 2000 CERT 0017623 Meters Drilled Page 36 Feet Drilled Soft Hard Soft Ground Ground Ground 15000 15000 4600 16000 12000 4900 18000 18000 5500 20000 12000 6100 20000 15000 6100 20000 20000 6100 20000 20000 6100 28000 20000 8500 28000 26000 8500 30000 20000 9100 30000 20000 9100 30000 26000 9100 35000 35000 10700 40000 30000 12200 45000 45000 13700 50000 35000 15200 50000 40000 15200 60000 50000 18300 60000 50000 18300 90000 80000 27400 90000 80000 27400 90000 80000 27400 100000 100000 30500 100000 100000 30500 200000 150000 61000 Version 200711 Ground 4600 3700 5500 3700 4600 6100 6100 6100 7900 6100 6100 7900 10700 9100 13700 10700 12200 15200 15200 18300 18300 18300 30500 30500 45700 s VE Troubleshoot
9. 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 41 Remedy Return drill to rock drill shop to replace rifle bar SM 80 or rifle nut SM 73 74 Return drill to rock drill shop to replace chuck driver nut SM 70 72 Return drill to rock drill shop to replace piston SM59 60 or chuck driver nut SM75 76 Relax side rod nuts re tighten properly SM 85 SM 111 Hone or ream front cylinder washer to proper fit or replace Remove and clear water tube Replace water tube SM 23 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 bits and color code by diameter size SM 115 Version 200711
10. of customer orders for parts and to eliminate delays and errors in shipping incorrect parts 1 List the model of the assembly EG PHQ250JHMAVL Anti vibration Jackleg Drill 2 State the exact quantity of each item of parts required 3 Identify items with the description and part number as shown in the parts section of this manual 4 Specify the preferred method of shipment EG Parcel Post Courier Truck Freight 5 For overseas shipments specify the preferred method of shipment EG Air freight or sea freight Pricing 15 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 Qpartshq com Phn 905 332 3271 Fax 905 332 9497 This letter should specify the model number of the PHQ product EG PHQ250JHML Jackleg 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 s
11. 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 62 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 1s 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 15 evident it indicates that the piston 15 worn oversize and must be replaced ISO 9001 2000 CERT 0017623 Version 200711 PARTS HEADQUARTERS INC Page 23 Front Cylinder Assembly Inspection 63 The clearance between the outer diameter of new piston stem and the inner diameter of the bronze front cylinder washer liner C1
12. 0660132 Spring 1741210 sant Sleeve 17411792 Washer 254246 EE Pipe Reducing Bushing 1 1 4 1 Hot Included Cptianal Pipe Reducing Bushing 1 1 4 1 Hot Included Optional P Ring 906512125 Washer 17412022 Weight 17404203 w Washer 17404311 Ring 906512125 Rivet Regulator Pin over Washer 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 1 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 1t can not be gripped by a wrench and needs to be replaced ISO 9001 2000 CERT 0017623 Version 200711 Pr gt PARTS HEADQUARTERS INC 7 PHQ250 Anti Vibration Jackleg Parts Performance Part Number D1611C C1418A AVH665 AVH666 D2105 C1512 D6177 C1574A S2134 AVH697 C1509 C1508 B2334 JC45 AVH662 C2144 D1675 B1178 D1388 D6205M C1572C D1433 355538A C1
13. 1 1 1 2 1 1 1 1 Page 10 Spindle Locating Pin D2546 Clevis Body Spindle Cone Clevis Body Spindle Lock Washer Key Cylinder Lug Bushing Rifle Nut Piston O Ring Cylinder Ferrule Front Cylinder Washer Liner Cylinder Muffled 1 Cylinder Standard Spindle Thrust Washer Spindle Spring Spindle Lock Washer Spindle Nut Chuck Nut Chuck Nut Spacer Chuck Fronthead Fronthead Gasket Plastic Fronthead Gasket Copper Steel Retainer Pin Bushing Steel Retainer Pin Nut D1932 Steel Retainer Steel Retainer Pin Chuck Insert 7 8 Hex Leg Assembly 51 A755451 39 A755B 30 A755A30 95 96 97 98 99 100 101 102 103 104 104A 104B 105 106 107 108 109 110 111 112 113 114 115 115 115 116 C1672 C1791 225414 D1073A D2038 D1439A 1796740 D1438A D1515A C1788A C1790A C3519 B1851RK 1216W 143M10 B1308 1026W12 1973854A B1287 D1069 1973854 C1520 B1851A B1849 B3004 164531 N lo 1 Bottom Cap Spike Standard Bottom Cap 4 Prong Split Pin Piston Rod Lock Nut Piston Rod Lock Washer Bucket Spacer Lower Bucket Piston Rod Spacer Bucket Spacer Upper Cylinder 51 Stroke 1 Cylinder 39 Stroke 1 Cylinder 30 Stroke 1 eb d od A at ND AD 1 Nylon Tubing c w Ferrules and O Rings 2 Nut Washer Carrying Handle c w Bolts and Nuts Bolt Hat Packing Double Lip Top Cap Top Cap Bushing Hat Packing
14. 487 inlet washer rubber D1402 from the backhead of the drill Remove the water inlet screen C1272 with a small screw driver or a scriber 34 Replace both O rings 164811 as well as the stem thrust washer S2487 and washer rubber D1402 whenever the drill is in the shop for repair Check the screen filter C1272 and replace if damaged ISO 9001 2000 CERT 0017623 Version 200711 PARTS HEADQUARTERS INC Page 18 Throttle Valve Assembly Removal 35 Unscrew the throttle valve handle nut D1385 on the end of the throttle valve B1176 Remove the nut and disc spring 1491623MT and slip off the throttle valve handle C1509 Remove the throttle valve key D1384 36 Unscrew the plug 2422P that retains the throttle valve plunger assembly and throttle valve plunger 01383 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 Replace any faulty parts 37 The throttle valve B1176 should push out easily If it is tight tap gently on the end of the valve with a bronze hammer and remove from backhead Steel Retainer Removal 38 Remove the steel retainer pin nut 12812UF D1932 from the steel retainer pin C6908 Tap the end of the steel retainer pin wit
15. 517 is nominally 0 047mm 0 0015 The clearance between a worn piston stem and a worn bronze cylinder liner bore is 0 160mm 0 0063 or larger If the cylinder liner does not visibly appear to be worn it still should be tested with the piston B2334 installed in the normal operating position in the cylinder bore with the stem through the cylinder liner 64 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 eripping 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 it 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 65 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 66 A good air cushion prevents the piston from bottoming too hard on the cylinder liner during the down stroke and provides a bounce to start the pis
16. 809 D1601 D2441 Description SHOP TRIP PAWL PLUNGER SPRING CHUCK INSERT 7 8 HEX ANTI VIBRATION SPRING ANTI VIBRATION O RINGS 4 ANTI VIBRATION PLUG CHUCK NUT RATCHET PAWL REVERSIBLE WATER TUBE SWAGED PAWL PLUNGER OPERATING HANDLE THROTTLE VALVE HANDLE RIFLE NUT PISTON SPUD ASSEMBLY C W SCREEN LIMIT STOP WATER VALVE SEAT RETAINER WATER TUBE SEAL CHUCK SIDE ROD NUT BUFFER FOR RETAINER SIDE ROD JACKLEG VALVE ASSEMBLY FEED RELEASE SCREEN HOSE STEM THREADED TYPE AIR BEND NUT WASHER WATER INLET ADAPTER SPUD ISO 9001 2000 CERT 0017623 Meters Drilled Page 35 Feet Drilled Soft Hard Soft Ground Ground Ground 4000 3000 1200 4000 3000 1200 4000 3000 1200 4000 3000 1200 4000 3000 1200 4000 3000 1200 4500 3500 1400 5000 3500 1500 5000 3500 1500 5000 3500 1500 6000 4000 1800 6000 5000 1800 7000 2500 2100 8000 7000 2400 9000 9000 2700 10000 10000 3000 10000 10000 3000 10000 10000 3000 12000 6000 3700 13000 11000 4000 13000 11000 4000 13000 12000 4000 14000 13000 4300 15000 15000 4600 15000 15000 4600 15000 15000 4600 15000 15000 4600 Version 2007 I I Hard Ground 900 900 900 900 900 900 1000 1000 1000 1000 1200 1500 800 2100 2700 3000 3000 3000 1800 3300 3300 3700 4000 4600 4600 4600 4600 Pr gt PARTS HEADQUARTERS INC 7 PHQ250 Anti Vibration Jackleg Parts Performance Part Number 52141 C1517 C1809 1173 1176 1272
17. Belt Sand Paper Grinder c w back support for grinding piston faces 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 should include e PHQ 5250 Tools Repair kit Part Number PHQ250T Torque Wrench with 12 7 mm 1 2 drive up to 250 ft Ibs e 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 gt 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 1 2 column bar short arm with swing and dump and short guide shell for 5 36 repairs Repair Tags and Report Sheets ISO 9001 2000 CERT 0017623 Version 2007 I I wr d 2 lt P EE PARTS HEADQUARTERS INC Page 8 PHQ250JHML Repair Tool Kit 1 CISI1A O Air Inlet Cover Used to cover JC45 inlet adapter 2 CI8ITIW Water Inlet Co
18. Ibs Use a proper torque wrench if available 86 To assemble the steel retainer mechanism insert the two steel retainer pin bushings 06205 into the fronthead lug Hold steel retainer A2599 in position over the fronthead Insert steel retainer pin C6908 from the side taking care to align the location flat on the retainer pin and retainer Drive the retainer pin home with a copper mallet Tighten the steel retainer pin nut 12812UF 87 Make sure the O ring 164231 is in position inside the drill backhead before starting to install the tube Lightly oil the water tube C1574A and slide the water tube spacer D1674 and water tube seal 01675 onto the tube making sure these parts face the right direction to properly seal Place the end of the tube into the end of the water valve assembly A1506PC1 ISO 9001 2000 CERT 0017623 Version 200711 88 Check to insure the proper fit of the water valve the tube Apply anti seize lubricant to the threads of the water control valve to prevent them from galling and insert the tube and water control valve assembly together into the backhead Tighten the water valve assembly to torque of 1313Nm 90ft Ibs 89 Fit water bend assembly parts into the backhead in order Water inlet screen C1272 water inlet washer rubber D1402 water stem thrust washer 52487 water stem C1809 with both O Rings 164811 and water stem nut S2141 Tighten the water stem nut Fit water
19. S INC 94 Place the end of the anti vibration spring AV H665 in the stop on the backhead Install four new O rings 910660216 on the shaft of the anti vibration handle adapter Lightly grease the shaft and slide the anti vibration handle adaptor AVH697 into the backhead Fit the coil of the anti vibration spring AVH665 into the groove machined around the shaft 95 Place the short end of the spring between the two stops on the control handle shaft Put the limit plate AVH664 complete with a new rubber bumper D2105 on the square end of the handle adapter Tighten grub screw AVH661 on the anti vibration spring where it meets the backhead MAXIMUM 20 DEGREES 96 Set the anti vibration operating handle adapter at the proper angle maximum 20 degrees off vertical Tighten the operating handle nut nyloc 12812UF on the outside of limit plate AV664 Test movement of the operating handle relative to the backhead The handle should oscillate approximately one half inch 97 Check the control handle friction ring 164631 Grease control spindle 1183 straight fit and push it into the control body Fit the twist grip f C1518 disc washer 149122MT and tighten nut 1218UF in position 98 Check rotation of the twist grip The feel should be firm with the new O ring but not rigid Check that the anti vibration handle assembly moves 1 relation to backhead and is not rigid 99 Lightly oil the retract valv
20. aged steel from the circuit Check piston face Replace the piston Check drill steel for chipped ends Remove damaged steel from the circuit Check piston face Replace the piston in the rock drill shop SM 59 60 Check the chuck insert with gauge If worn replace in the rock drill shop SM 44 Replace the worn parts Check the drill steel ends are 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 Version 2007 I I s VE Troubleshooting Guides Problem 114 Drill steel does not rotate in the rock drill or has weak rotation 115 Stuck drill steel 116 Drill overheating 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 tightened 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
21. anti vibration spring with that of a new AV spring and replace the AV spring it 1s not exactly the same Check the grub screw to be sure it is ok for re use 21 If the limit stop dowel pin AVH662 is worn remove it with a punch inserted in the hole behind the pin Replace with a new pin Water Control Valve and Water Tube 22 Unscrew the water control valve assembly A1506PC1 from the backhead using an expandable wrench or a large open end wrench This valve automatically adjusts water flow through the water tube to flush drill cuttings from the hole Air pressure from a port in the backhead competes with a spring loaded valve to regulate the flow of water 23 Always remove the water control valve and the water tube with the water tube seal 01675 and spacer D1674 still in place from the bore of the backhead Push the water tube from the front end of the machine if necessary using end of the wooden handle of a hammer 24 Remove O ring 164231 within the recess inside the backhead bore This O ring is always replaced regardless of condition ISO 9001 2000 CERT 0017623 Version 200711 PARTS HEADQUARTERS INC Page 16 Water Control Valve Automatic Valve 25 Remove circlip 20015 from water control valve body 1181 4 with a pair of circlip pliers that are designed just to remove circlips Remove the water valve spring cap C1521PC1 Replace the circlip and cap if damaged or worn 26 Remove the
22. ants that the product is 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 factory The obligation under this warranty shall be limited to the replacement or repair of the failed product returned to warranty 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 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 Version 200711 a PARTS HEADQUARTERS INC Page 6 Ordering Parts PHQ requires the following procedures be followed and the proper information be supplied to expedite the filling
23. ar 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 52 Using the piston removal tool 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 it emerges from the drill cylinder and catch it in your hand Examine the striking face of the piston and flutes for signs of wear If the striking face 15 chipped the piston must be replaced Valve Chest Disassembly 53 Valve chest disassembly must be done using the proper valve punch T206 Hold the valve chest box in the palm of one hand Place with the small end of the valve plug A744 facing up Fit the punch in the bore of the plug Strike the punch with a brass hammer until the valve box A745 separates from the valve plug A744 Handle the precision ground parts of the valve with care ISO 9001 2000 CERT 0017623 Version 200711 PARTS HEADQUARTERS INC Page 21 54 Once the valve plug A744 is loosened remove the valve plug from the valve box A745 Next 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 eme
24. chnicians to repair rock drills An un trained mechanic could possibly make errors in installing parts and cause severe damage to mating parts 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 its 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 Breathing protection must be worn when working with materials which produce 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 representative WARNING Operating a Rockdrill without lubricant or with incorrect lubricant 1s the leading cause of failure of rock drill parts Lack of lubrication can rapidly cause EXTENSIVE DAMAGE to the working parts of this machine 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 th
25. 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 Jackleg 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 is 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 cylinder built into the torque test bench Insert the rod shank adapter on the torque tester into the chuck bushing and close the steel retainer Release the feed pressure on the drill by shutting off the air to the pusher leg 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 When the drill stalled the reading on the torque gauge should be minimum 2000 Nm 140 ft Ibs When testing a sinker drill the same test procedure 1 used ISO 9001 2000 CERT 0017623 Version 200711 33
26. d there has been no contact between the bushing and the chuck and the chuck should be discarded as it no longer 1s 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 1s worn out ISO 9001 2000 CERT 0017623 Version 200711 PARTS HEADQUARTERS INC Page 25 72 replace the chuck bushing C1418A invert the chuck under the piston of hydraulic press and insert the chuck bushing and tool 1 1221 for collared insert 7555 for collarless insert in the open end Align the chuck chuck bushing and the pressing tool and press 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 73 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 C1508 RIFLE NUT NEW C1508 RIFLE NUT 50 WORN C1508 RIFLE NUT 100 WORN 74 The mechanic can make a tool to remove a
27. e assembly C151415 with five new O rings 164811 Insure the valve and valve sleeve are properly assembled Insert the assembly into the bore of the adaptor Fit the two springs 01424 21425 into the bore of the handle adaptor Screw plunger plug 112FN502 in position 100 Check the clevis body spindle and install three new O rings 164231 If a new cone 1s required assemble with a new spindle Ensure the pin in the spindle 1 aligned with the key way in the clevis body ISO 9001 2000 CERT 0017623 Version 200711 31 101 Fit the clevis body A693A onto the shaft of the clevis body spindle with the spindle locating pin D2546 lined up properly Thread on the clevis body spindle nut 01982 and tighten 102 Insert the clevis body spindle assembly into the cylinder lug bush Fit the spindle thrust washer 01392 two lock washer keys 01426 spindle spring C1571 spindle lock washer C1519 and spindle nut C1527 103 Take care when slipping the lock washer over the spindle that the keys are 1n the proper place Tighten the spindle nut to give the desired degree of friction between the clevis assembly and the cylinder lug bush Your PHQ250JHMA VL Anti vibration drill is now complete and ready for testing Running in 104 Place the assembled drill on the PHQ test bench and run for approximately 15 minutes at low throttle to run in the assemble parts and insure the parts in the drill are
28. e drill down disconnect the air line and disassemble the drill examining the parts as they are 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 Clevis Body 1 Once the drill is cleaned place it upside down in the chain vice on work bench gripping the cylinder 2 Using an adjustable wrench unscrew the clevis body spindle nut D1982 If it 1s tight compress the spindle spring C1571 by inserting a screw driver between lock washer C1519 and spindle nut 3 Remove the spindle nut spring lock washer and trust washer Remove the keys from the stem end of the spindle CERT 0017623 Version 200711 PARTS HEADQUARTERS INC Page 12 4 Strike the end of the spindle B1182A with a copper mallet and withdraw the spindle complete with the clevis body A693A from the cylinder lug To remo
29. ension of the plunger spring seem weak replace that spring The sleeve spring 1 less critical ISO 9001 2000 CERT 0017623 Version 2007 I I PARTS HEADQUARTERS INC Page 13 1218UF NUT 12812UF LOCK NUT NYLOC M20 149122MT LOCK WASHER AVH664 LIMIT PLATE C1518 TWIST GRIP AVH662 STOP PIN pe y 2 81180 CONTROL BODY CO DAES WASHER lt 5 PM 64631 FRICTION R 02105 PLUG 164631 N RING i NN LEG AVH666 O RINGS 2 NE AVH660 BACKHEAD 81183 SPINDLE HANDLE Y Y li emen ANTI VIBRATION SPRING p AVH661 GRUB SCREW Km PLUNGER 164811 70 RINGS 01382 PLUNGER SPRING 164811 0 RING 242 2P PLUG 667 VALVE ASSEMBLY 2 250 Anti Vibration T P Parts 01425 SPRING SLEEVE A M el D1427 PLUG EL ISO 9001 2000 OMI CERT 0017623 REGISTERED Version 200711 PARTS HEADQUARTERS INC 9 Unscrew the spindle nut 1218UF on end of the control spindle 1183 straight fit to remove the twist grip C1518 from the control handle 10 If tight gently tap on the end of the control spindle with ball peen hammer 11 Turn the twist grip C1518 several times to check the tension of the friction ring 164631 inside If the grip turns too freely check the friction ring 164631 for wear when removing it later on 12 Remove control spindle 1183 straight fit from the cont
30. 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 Remove the pusher leg from the jackleg drill and connect the drill to the adapter on the saddle Move the drill saddle forward with the pneumatic pusher cylinder built into the test bench Insert the spring loaded collared rod shank into the chuck bushing of the rock drill and close the steel retainer locking the drill into position so that it does not jump back if leg pressure releases ISO 9001 2000 CERT 0017623 Version 200711 P x2 PARTS HEADQUARTERS INC Page 32 Rotate the control handle forward so the piston in the built in cylinder pushes the drill forward 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 drill 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
31. h a bronze hammer to loosen Push the steel retainer pin through the front end lug bore using a screwdriver or punch 39 Pull the steel retainer pin through the lug on the front end and remove the steel retainer 2599 40 Remove both of the square plastic steel retainer pin bushings 06205 from the housing using a screw driver lt 150 9001 2000 0017623 Version 200711 PARTS HEADQUARTERS INC Page 19 41 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 Side Rods and Front Head Removal 42 Loosen the side rod nuts 01388 with an adjustable wrench and remove both nuts from the side rods Check the thread on the side rods and the threads in the side rod nuts Replace the side rod nuts if worn 43 The fronthead A2598A should slip easily off of the cylinder E393 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 44 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 i
32. he collar end Pistons in drills have chips out of the striking face or are failing at the striking face Experience has proven chipped piston can damage lot of new drill rods One chipped drill rod can damage lot of new pistons They need to be removed 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 chipped or broken front striking face Drill steel does not have square face on the striking end Refaced piston in the drill was not machined properly Worn chuck insert Worn chuck parts caused by poor alignment of steel with the hole 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 40 Remedy Check the Clevis body for loose fitting or damage SM 1 Leg control handle assembly O Rings worn out SM 1 Retract valve O Rings worn out or damaged SM 7 Replace parts rockdrill shop Examine and replace bucket seals See Leg Manual Check piston rod Return to rockdrill shop Replace if bent Check the cylinder for dents and return to rockdrill shop for replacement if dented Remove dam
33. icator flooded by oil Lubricator stuck with grease Excessive water in the air supply Page 39 Remedy Rifle bar heat checked from lack of lubrication SM 111 Rifle Bar failing or broken Replace at rockdrill shop Piston heat checked from lack of lubrication SM 111 Piston failing or broken Replace at rock drill shop SM 111 Check front end blow Plug or cover all openings in the drill when in storage or moving between drill sites If using rock drill fill 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 lubricator flow setting Lubricant high viscosity too thick for ambient temperature Drill hose maximum 12 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 may be damaged Excessive water will wash lubricant out of the drill SM 106 ISO 9001 2000 0017623 REGISTERED Version 2007 I I sanae yr 7 Troubleshooting Guides Problem 112 Pusher Leg not functioning properly Drill is jumping on the leg during drilling operations 113 Drill steel failing at the collar or forming coke bottle shape Drill steel showing chips or chunks out of striking face at t
34. ing Guides Problem 104 Rock drill will not start when throttle handle is advanced 105 Rock drill runs erratically or lacks power during drilling operations Penetration is erratic or slower than normal PARTS HEADQUARTERS INC Probable Cause Air 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 Lubricant too heavy thick for the ambient operating temperature Improper amount of lubricant Valve chest sticking Side rods tightened unevenly Parts broken inside the drill Pawls and springs worn out Insufficient air supply to leg 106 Water coming out of the exhaust ports on the drill Rockdrill freezing up and the muffler or exhaust ports are blocked with ice Excess fogging in the work place area Excess water in the air entering the rock drill Page 37 Remedy Always blow the air hose Check air connection screen Cylinder may be dented or damaged Replace cylinder at the rockdrill shop SM 61 66 Return drill to rock drill shop to repair valve SM 53 56 SM I 11 SM 106 Hone or ream front cylinder washer or replace SM 63 66 SM 111 SM 111 Check parts for sharp edges Check operation SM 53 56 Relax side rod nuts re tighten properly SM 85 Re
35. inlet cover C1811W to protect the water stem threads and prevent ingress of dirt 90 Lightly oil the throttle valve B1176 and insert it into position in the backhead Check fit and function to be sure the valve slides easily into place in the backhead and turns freely inside the bore Align the large opening in the side of the throttle valve with the opening in the backhead 9 Invert the drill in the chain vice Insert the throttle valve plunger 01383 and throttle valve plunger spring D1382 into the hole in the bottom of the backhead with a dab of grease Look through the handle end of the hole to check the alignment of the detent with the ratchet grooves of the throttle Tighten plug 2422P into the backhead 92 Fit the air bend nut C1526 with the air bend C1525N into backhead AVHA660 using a new air bend copper washer 01601 Tighten the air bend nut in position and thread the hose spud 1356588 onto the air bend Fit the air line cap C1811A to protect threads on the hose spud and prevent the ingress of dirt 93 Fit the throttle valve handle key D1384 into the slot in the throttle handle and slide the throttle handle C1509 onto the shaft over the key Note the key is designed as a tight fit in the handle for longer life Install disc spring 149163MT Tighten the throttle valve handle nut D1385 and test ratchet action of the throttle valve ISO 9001 2000 Version 200711 PARTS HEADQUARTER
36. llar of a drill rod that has 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 76 An alternate method of removing a chuck nut 1 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 ISO 9001 2000 CERT 0017623 Version 200711 PARTS HEADQUARTERS INC Page 27 Assembly Procedures TT install 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 it with care not to strike the step for the valve chest seat in the cylinder 78 To replace the valve box assembly Parts A745 C1648 A744 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 52128 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 tigh
37. must keep the machine ligned up with the drill rod 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 61 66 Check air lines Blow hose Check air connection screen Minimum air pressure 80 psi Ideal air pressure 100 110 psi SM 111 Check front cylinder washer and piston in rockdrill shop Replace if worn SM 64 65 Check the drill cylinder at the rockdrill shop Look for wear to mating faces and check interior wear SM 61 62 If worn replace the drill cylinder body in the rockdrill shop Check the chuck at the rock drill shop SM 44 5 70 76 Replace worn or damaged part Check the front end at the drill shop SM 42 44 Replace SM 112 Version 200711 s gt PARTS HEADQUARTERS INC Troubleshooting Guides Problem Probable Cause 109 Bronze cuttings exhausting from rock Nut Failing drill ports Rifle nut burned by overheating Chuck Nut Failing Chuck nut burned by overheating 110 Drill parts wearing Improper Lubrication faster than normal Service trips to rockdrill Dirt or debris entering the drill shop too frequent 111 Faulty Lubrication According to experts in the maintenance field Lack of lubrication is Lack of Lubrication the leading cause of failure of parts in machinery Wrong Lubrication Excessive Lubrication Lubr
38. ndicating 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 the 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 45 Remove both side rods C1572C from the backhead end of the drill Examine the threads for wear Tap the backhead AVH660 with a brass hammer to loosen it from the cylinder 46 Remove the backhead AV H660 from the cylinder 47 Remove the cylinder ferrule D1390 complete with O ring 164311 from the blower port in the back face of the drill cylinder ISO 9001 2000 Version 200711 PARTS HEADQUARTERS INC Page 20 Removal of Ratchet Ring Rifle Bar and Valve Chest 48 Using piston removal tool SECP1 push the piston B233 back until it touches the valve chest A745 Hammer gently on the tool pushing ratchet ring B1170 until it protrudes about one inch out of the cylinder bore 49 Remove the valve box locating pin S2128 from the groove in the cylinder using needle nose pliers 50 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 maximize part life 51 Remove the rifle bar B1173B and check the spiral flutes for we
39. or 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 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 1s 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 1s 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 warr
40. ose manufactured by PHQ are deemed to have caused the failure ISO 9001 2000 CERT 0017623 Version 200711 PARTS HEADQUARTERS INC Page 3 Certificate of Performance This certificate supplied with each drill and is signed by the assembly mechanic assuring that product has been tested and meets PHQ s quality standards It lists the actual test results achieved by running the drill on PHQ test bench at the time of assembly Parts HeadQuarters Inc Rae 2600 1901 A1 OG Rockdrill Torque Test Report NN N A s TT C ylinder Part Number Test Level Acceptance Test FiddTeg Operating i Retract Maximum Torque Pressure i LegFeed Full Throttle M SI Parade At Full Throttle Remarks Lubricated with Vultrex EP000 Rockdnll grease during assembly OMI REGISTERED ISO 9001 2000 CERT 0017623 Version 200711 Introduction and General Information Safety Identification and Safeguards Certificate of Performance Standard Ordering Patisiosoesseer rete Returning Maintenance Procedures Rockdrill Repair Shop PHQ 5250 Repair Tools PHQ250JHML Jackleg Airleg Drill PHQ250JHML Parts Schematic PHQ250JHML Parts Last Maintenance Procedures Disassembly Procedures
41. ottle Valve Handle Throttle Valve Key Throttle Valve Side Rod Nut Backhead Throttle Valve Plunger Throttle Valve Plunger Spring Plug Air Bend Air Bend Copper Washer Air Bend Nut Air Line Cap Air Inlet Screen O Ring Hose Spud O Ring Ratchet Pawl Reversible Pawl Plunger Pawl Plunger Spring Rifle Bar Reversible Ratchet Ring 35 Teeth standard Valve Box Pin SD1397 Valve Box Valve Valve Plug Spindle Nut Disc Spring Sellok Pin Long Sellok Pin Short Twist Grip Friction Ring Control Body Taper Fit Control Body Straight Fit Control Spindle Taper Fit Control Spindle Straight Fit Spindle Plug O Ring Operating Handle Taper Fit Operating Handle Straight Fit Retract Valve Assembly Plunger Spring Sleeve Spring Plunger Plug Operating Handle Washer Operating Handle Nut Operating Handle Adapter Nut Nylock Operating Handle Adapter Nut Water Stem Nut Water Stem Threaded Type Water Stem Thrust Washer Water Inlet Washer Rubber Water Inlet Screen Water Inlet Adapter Spud Water Stem Cap Clevis Body Spindle Nut Clevis Body 70 71 72 73 74 75 76 77 78 79 80 80 81 82 83 84 85 86 87 88 89 89 90 91 92 93 94 30066 01398 B1182A D1426 C1523 C1508 B2334 164311 D1390 C1517 E393M E393 D1392 C1571 C1519 C1527 C1512 C1516 B1178 A2598A NB500P NB500C D6205 12812UF A2599 C6908 C1418A 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
42. place broken parts at the rockdrill to shop Replace broken parts at the rockdrill to shop SM 80 SM 112 Install water trap in pipeline Blow moisture out of hoses Check water tube for breakage cracks or missing rubber seal Check the O Ring 164231 inside the Backhead SM 87 Water pressure must be less than air pressure by 30 psi Version 200711 s gt Troubleshooting Guides Problem 107 Drill runs sluggish 108 Drill sounds like it is running properly but it lacks drilling power Penetration into the rock face is too slow 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 Drill not aligned with drill rod during drilling operation Loss of bit gauge causing binding of the bit in the drill hole Drill shank is 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 38 Remedy SM 106 SM 111 Use direct blow to remove cuttings throttle handle back Check and clean SM 23 Driller
43. rol handle 13 Remove twist grip C1518 from control body 1180 straight fit 14 Carefully lift the friction ring 164631 from the end of the control body using a scriber or small screw driver If the ring did not provide adequate tension when tested at step 6 check to see if it is worn or damage and if so the ring should be replaced It is usually advisable to replace the friction ring 164631 if the drill has been in use for long 15 Check the movement of the anti vibration operating handle AVH697 relative to the backhead AVH660 before removing It should move back and forth one half inch with minimal resistance ISO 9001 2000 CERT 0017623 Version 200711 PARTS HEADQUARTERS INC 17 Remove the operating handle adapter nut 12812UF with the limit plate AVH664 Check the limit stop dowel pin AVH662 that protrudes from the control body for wear Always replace the rubber bumper D2105 in the limit plate regardless of appearance or wear 18 Remove the operating handle assembly with the control handle still intact The anti vibration backhead operating handle has a straight shaft and it should slip out easily If 1 is tight rethread the nut and tap gently on the nut with a hammer 19 Replace all four O rings AV H666 on the operating handle shaft regardless of the condition of the O rings 20 Remove the grub screw AVH661 and the anti vibration spring AVH665 Compare the tension of the
44. ry cloth Take care to just remove the sharp edge 55 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 15 no suction created and the valve is worn 56 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 disassembled 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 Cylinder Lug Bushing Removal 57 Examine the cylinder lug bushings C1523 for sign of wear The three large O nngs 164231 often wear into the inside diameter of the bushing and can cause air crossover leaking To remove the cylinder lug bushing turn the cylinder on its side in the chain vice Insert service tool T225 into the bore of the bushing and strike repeatedly with a hammer until the bushing drops through the cylinder boss 58 To insert a new cylinder lug bushing C1523 turn the cylinder over in the chain vice align the locating flats on the new bushing with flats on the cylinder lug Drive home the
45. shrink inwards due to the pressure on the outside diameter as it is 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 Chuck Insert Removal 70 Inspect the hexagon bore of the chuck bushing C1418A with the gauge tool C3720 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 is very sloppy in the chuck bushing Chipped bushings damage drill steel 71 To remove the chuck bushing C1418A place the chuck assembly in tool T1218 under the piston of a hydraulic press Place the service tool T555 for collared chuck inserts 1n 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 It toll T218 is not available place the chuck assembly in a used fronthead A2598A inverted and supported between two steel blocks Check the top outer diameter of the chuck bushing and the top inner diameter of the chuck If either 1s corrode
46. t Punch To insert collared chuck insert place the insert io al a in chuck 218 and push insert in hydraulic press until flush with chuck 17 T24 Jackleg Cylinder Mandrill Remove small dents from Airleg by LL forcing T224 through the inside diameter of the cylinder 18 7225 Lug Bushing Punch Used to install cylinder lug bushing on Jackleg Chuck Insert Punch Insert and remove collarless steel chuck insert 19 T555 FI 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 Feed Cylinder Clamp Used to grip the Jackleg pusher leg cylinder 20 T209 Oo in a shop vice Minimum order quantity 20 ISO 9001 2000 CERT 0017623 Version 200711 2 79 ae lt TI lt Page 9 1exurgs quiossy 397 saoer OSC Hd 67061 ON Ajqweassy sayuis gt M worbysyed mam 213 2802 192 008 L 33H4d TIOL 2676265506 3 1228 288 506 7131 GHE 11 OIHYLNO NOLDNNYNS 22 A83714dV SLL SYILYVNOAVIH SLUVd OL WSSLV Hed 6937 0E 8991Y Ved 697 68 LSPSSLV ON Hed 697 ba ajgepeay 955985 ON ved Ajqwessy ajpuey xoer ISO 9001 2000 OMI CERT 0017623 REGISTERED Version 200711 PHQ250 Jackleg HHA HAA AHA ROGO OQ Q Q Q
47. tate 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 shipped prepaid to PHQ ISO 9001 2000 CERT 0017623 Version 200711 PARTS HEADQUARTERS INC Rockdrill Repair Shop The rock drill repair shop should be clean area equipped with all the usual filters tools work benches component cleaning tanks and 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 e allows the drill to be run under load and leg pressure f 4 bm 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
48. the head carefully into the ratchet ring slowly turning at the same time Oil the pawls 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 Version 2007 I I PARTS HEADQUARTERS INC 82 With the cylinder in the horizontal position in the bench vice insert ferrule 01390 and O ring 164311 Slide the backhead AVHA660 into position over the ratchet ring taking care to fit the valve box locating pin 52128 in the appropriate groove in the backhead 83 Insert the two side rods C1572C from the back end of the drill by sliding them alongside the cylinder body in the grooves provide Seat the square heads of the side rods to match with the machined area on the backhead 84 Lightly oil the splined end of the piston before proceeding Install the fronthead end assembly complete with the chuck driver assembly into position on the front of the cylinder Move the holes in the front end over the threaded ends of the side rods and at the same time sliding the chuck driver nut over the splines of the piston inside the cylinder 85 Thread the side rod nuts 01388 on the side rods C1572C Tighten progressively and evenly on both sides Even tightening is critical to the life of the side rods in service Working from side to side tighten the side rod nuts to a minimum torque of 1313NM 90ft
49. tly in the bore of the rock drill cylinder The valve chest assembly is the heart of the drill The valve controls the working of the drill by directing air 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 79 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 80 Assemble the rifle bar parts Rifle bar reversible B1173B four ratchet pawls reversible D6177 four pawl plungers 52134 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 PHQ does not recommend grinding the face of rounded P pawls Itis often more economical to replace these in expensive and fast wearing parts when drill is in the shop for repair 81 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
50. ton on its backward stroke during operation If the piston head has proper clearance with the cylinder bore and there 15 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 ISO 9001 2000 CERT 0017623 Version 200711 24 67 remove the bronze front cylinder washer liner C1517 place the cylinder body under the piston of hydraulic press Use T201 to press the bronze liner out of cylinder If a press 1 not available the liner can be driven out by striking the T201 tool carefully with a hammer 68 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 1 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 69 Often the inside diameter of the bronze front cylinder washer C1517 will
51. ve the spindle from the clevis body unscrew the clevis body spindle nut 01982 nut and hold the clevis body in a gloved hand Strike the end of the spindle with a copper mallet to break the taper joint 5 Inspect the various components for wear and damage and replace if necessary Always replace the three O rings 164231 It 1 not necessary to separate the spindle from the clevis body spindle cone 01398 These two parts should be considered as a single component and when worn replace both parts Anti vibration Control Handle 6 With the machine still upside down and the cylinder in a workbench chain vice Start work on the back end of the machine Unscrew the plug 1125NF02 in the back of the handle adaptor to access the parts that make up the retract valve assembly AVH667 7 Remove the retract valve assembly AVH667 the plunger spring D1424 and sleeve spring D1425 from the open end of the valve bore in the handle adaptor Wash the assembly in Varsol and test If the valve is moving freely do not disassemble If the valve seems to be sticking separate the retract valve sleeve from the valve wash and clean all parts and inspect for wear damage or corrosion 8 The fit between the valve and valve sleeve 15 critical The two parts are a matched pair and 00000 both must be replaced together if either 15 worn Always replace all five O Rings AVH666 whenever the valve 1s disassembled Should the VP MA opum t
52. ver Used to cover 3 8 1 adapter 3 3720 Chuck Insert Wear Gauge Place in chuck insert across flats If top of the insert 1s more than halfway up gauge insert should be changed Piston Removal Tool Remove Piston and Valve Assy from 4 SECPI Cylinder Remove fronthead and chuck insert punch into piston and hammer out T Air Gauge Adapter Measure Airleg pressure Attach to jackleg clevis body 6 SG002 Air Gauge Measure Airleg pressure Attach qty 2 to 56001 7 7201 Cylinder Bushing Extractor Used to remove brass bushing from inside cylinder and remove bushing from the Stoper Leg 8 7203 m r Stoper Punch Remove Stoper handle bushing form cylinder 9 7204 Retract Valve Assembly Tool Place retract valve in handle Insert retract valve in handle and gently hammer in with retract valve tool Valve Chest Assembly Tool For assembling valve chest and A installing valve chest in cylinder Valve Chest Punch To disassemble valve chest Insert punch into 11 1206 top of valve box hammer out 12 T214 Retract Valve Hand Reamer Use to remove burrs from the retract alve bore 13 7217 gt 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 14 1218 in support and use T555 or 217 punch to push out on hydraulic press Chuck Inser
53. water valve seat retainer C2144 and the spring 01406 Check the tension on the spring and replace if too loose 27 Remove water valve C1522PC1 Check O rings 164521 and 164301 Replace if damaged or worn 28 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 The grease will make it easy to insert the valve without damage later on 29 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 is well seated in the water control valve Air Connection Assembly Removal 30 Unscrew hose spud 1356588 from air bend C1525N Check the air inlet screen 3555384 for damage and replace along with O ring 164999 ISO 9001 2000 CERT 0017623 Version 200711 31 Unscrew bend nut C1526 from the backhead Always replace the copper washer 01601 Replace any worn or damaged parts as the air connection nut and bend are safety critical If the air connection releases from drill during operation the hose will injure the driller Water Connection Assembly Removal 32 Unscrew the water inlet adapter stud D2441 from the water stem C1809 and unscrew water stem nut S2141 from the backhead of the drill 33 Remove water stem thrust washer S2
54. worn rifle 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 ISO 9001 2000 CERT 0017623 Version 200711 PARTS HEADQUARTERS INC Page 26 Chuck Nut Removal 75 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 is 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 76 Place the chuck insert onto the co
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