Boart Longyear S250 Parts & Service Manual
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Boart Longyear S250 Parts & Service Manual

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S250 ROCKDRILL
PARTS & SERVICE MANUAL

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Summary of Contents for Boart Longyear S250

  • Page 1 S250 ROCKDRILL PARTS & SERVICE MANUAL...
  • Page 2 The safety alert symbol is used to warn of potential personal injury hazards. The signs DANGER, WARNING, CAUTION, and NOTICE are defined as follows: Indicates an imminently hazardous situation, which if not avoided, will result in serious injury. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 3 Apply safe lifting procedures and two-person lifts when manually handling the rockdrill. • Ensure that the drill, accessories, and all actions always comply with applicable site and local health and safety regulations. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 4 Improper or homemade tools can cause injury or machine damage and will void your warranty. • Use only Boart Longyear replacement parts. Failure to do so could cause severe damage to the machine or the operator and will void your warranty.
  • Page 5 NO CLAIM AGAINST PRODUCT WARRANTY will be considered by the manufacturer if Boart Longyear replacement parts are not used in repair. All rockdrill repairs should be performed by properly trained and equipped service technicians.
  • Page 6 WARNING SIGNS AND SAFETY LABELS: Figure 1. Caution Label Figure 2. S250 Standard Caution Label Location S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 7 Figure 3. S250 Muffled Caution Label Location S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 8: Table Of Contents

    Rockdrill Repair Shop .....................14 2.1.1 Recommended Workshop Set-Up ............14 2.1.2 Recommended Tools and Equipment ..........14 S250 Tool Kit ......................15 General Maintenance Overview ................17 Chapter 3: S250 Jackleg/Sinker Drill Maintenance ..............18 Disassembly Procedures ..................18 3.1.1 Clevis Body ..................18 3.1.2 Control Handle .................20 3.1.3 Water Valve &...
  • Page 9 Side Rods & Fronthead ..............54 3.2.8 Ratchet Ring & Rifle Bar ..............55 3.2.9 Piston ....................57 3.2.10 Valve Box ..................57 Chapter 4: S250 Stoper Drill Maintenance ................58 Disassembly Procedures ..................58 4.1.1 Drill ....................58 4.1.2 Stoper Air Leg ..................63 Assembly Procedures .....................66 4.2.1...

  • Page 10: Chapter 1: Introduction And General Information

    Boart Longyear is backed by over 125 years of experience in the design, manufacture, and operation of Percussive Drilling equipment. Many of the accepted practices in use today were pioneered by Boart Longyear.

  • Page 11: Standard Warranty Policy

    1.2 Standard Warranty Policy A. Consumables Boart Longyear warrants for a period of one (1) year after the date of shipment of the consumable products manufactured by it, or the performance of related services, under the Contract,...
  • Page 12 With respect to consumable products purchased through an authorized Boart Longyear distributor, the party making the warranty claim must also deliver to Boart Longyear reasonable evidence of the date of purchase. Boart Longyear shall perform its examination of the goods so...

  • Page 13: Ordering Parts

    1.3 Ordering Parts Please contact your local authorized spare parts dealer or customer service representative. A schematic of parts can be found on the S250 Rockdrill Wall Chart, available for download at www.boartlongyear.com. 1.4 Returning Parts If you desire to return parts, whether for repairs, replacement, or warranty, please contact our order desk with S250 ROCKDRILL | PARTS &...

  • Page 14: General Description

    1.5 General Description The S250 hand-held pneumatic rockdrill is available in various configurations, providing maximum utility for specific customer needs. The S250 is available in the standard unmuffled and optional muffled version to reduce operator fatigue. 1.6 Features PREMIUM MATERIALS...

  • Page 15: Chapter 2: Maintenance Procedures

    Electric Rewind Extension Cord • Lighting over work bench 2.1.2 Recommended Tools and Equipment • S250 Repair Kit (refer to section 2.1) • Torque Wrench with 12,7 mm (1/2”) drive (up to 250 ft-lbs) • Impact Wrench 12,7 mm (1/2”) drive •...

  • Page 16: S250 Tool Kit

    • Repair Tags and Report Sheets S250 Tool Kit The S250 Tool Kit contains the full line of tools required to service all S250 rockdrill configurations. Using Boart Longyear- supplied equipment is essential in order to limit the potential to damage drill parts while improving service shop efficiency.
  • Page 17 VALVE CHEST DISASSEMBLY TOOL 5600106 5600117 Disassembles valve chest. Insert punch into top of valve box and hammer out. 3/8” HEX KEY LUG BUSHING DRIFT TOOL 5600107 5600118 Installs cylinder lug bushing on jackleg S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 18: General Maintenance Overview

    The jackleg rockdrill is similar in many respects to the stoper. The stoper maintenance is referred to in Chapter 4. NOTE: After the unit is completely disassembled, all components should be cleaned prior to inspection. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 19: Chapter 3: S250 Jackleg/Sinker Drill Maintenance

    2. Using an adjustable wrench, unscrew the spindle nut. If the nut is tight, compress the clevis body spindle spring by inserting a screwdriver between the spindle lock washer and the spindle nut. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 20 Remove the keys from the stem end of the spindle. 4. Strike the end of the spindle with a copper mallet or punch and withdraw the spindle complete with the clevis body from the cylinder lug bushing. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 21: Control Handle

    Replace the three O- rings (5600224). 3.1.2 Control Handle 1. Place the machine the right way up with the cylinder lug in a workbench vice. Start work on the back end of the machine. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 22 Push on the small end of the valve to free it, if necessary. Inspect valve bore and remove any burrs with service tool 5600116. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 23 5. Unscrew the nut on the end of the control spindle using a 19 mm (¾”) wrench. 6. Remove the twist grip from the control spindle. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 24 9. Carefully lift the friction ring from the end of the control body using a scriber or a small screwdriver. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 25 “break” the taper joint between it and the handle adaptor. 11. Unscrew the domed nut from the stem of the handle adaptor TWO TURNS. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 26: Water Valve & Water Tube

    19.2 mm (.756”) diameter. Replace the friction ring and spindle O-ring each time these parts are disassembled. 3.1.3 Water Valve & Water Tube 1. Unscrew the water control valve. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 27: Water Valve

    3.1.4 Water Valve 1. Remove the circlip from the water control valve body with circlip pliers and remove the cap from the water control valve body. Remove the water valve seat retainer. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 28 Please note that the large face of the water tube rubber faces towards the front of the machine. Place it on one side for final assembly. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 29: Water Inlet

    3. Inspect all water inlet parts for wear or damage and replace, as necessary. Replace the O-rings and seals each time these parts are removed. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 30: Air Inlet

    Replace the O-ring in the bore of the air bend nut. Replace the copper washer each time the air bend is removed. This prevents the air bend nut working loose in operation. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 31: Throttle Valve Assembly

    2. Unscrew the nut from the end of the throttle valve. 3. Using a copper mallet, lightly tap the end of the throttle valve to “break” the taper joint between it and the throttle valve handle. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 32: Steel Retainer

    5. Clean and inspect all air inlet parts for wear or damage and replace, as necessary. 3.1.8 Steel Retainer 1. On the fronthead, unscrew the nylock nut from the end of the steel retainer pin. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 33 4. Clean and inspect the steel retainer parts. Replace all components worn, cracked, or damaged. Replace the two plastic retainer buffers when the opening and closing action of the steel retainer is slack. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 34: Side Rods

    2. Using a copper mallet, lightly tap the fronthead, and remove it and the chuck from the front of the machine. 3. Withdraw the side rods from the back of the machine. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 35 If the ratchet ring stays in the backhead, it can easily be removed with a “crow foot” bar. 5. Remove the O-ring from the blower port in the back face of the cylinder. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 36: Ratchet Ring & Rifle Bar

    Check the teeth of the ratchet ring and discard if chipped or worn round [more than 1.5 mm (0.059”) radius]. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 37: Piston

    Catch the valve box and piston as they emerge together from the back of the cylinder. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 38 Conversely, if the rocking motion is minimized by the insertion of a new piston, this indicates that the old piston is worn and must be replaced. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 39: Valve Box

    Conversely, if using a new valve has no effect, it indicates that the valve plug is worn and must be replaced. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 40: Cylinder Lug Bushing

    1. To remove the cylinder lug bushing, turn the cylinder on its side. Insert the lug bushing drift tool 5600107 into the bore of the bushing, and strike repeatedly with a copper mallet. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 41 2. To insert a new cylinder lug bushing, place the bushing carefully in position, aligning the location flats on the bushing with the flats on the cylinder lug. Then drive in the bushing using the lug bushing drift tool. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 42: Front Cylinder Assembly

    If metal contact is made, inspection of the cylinder bore, and piston head is required (Section 3.2.11). If both the piston head and the cylinder meet the requirements, then the liner is worn. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 43 Once the liner is pressed into place, remove the piston. Using air, blow out the inside of the cylinder, and install the piston back into the cylinder. Perform the Front Cylinder Liner Test again. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 44: Chuck Insert

    It is important that all parts are correctly aligned in this pressing operation to avoid damage to the chuck. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 45: Rifle Nut

    3.1.16 Rifle Nut 1. Inspect the splines (flutes) of the rifle nut and replace when the splines are worn down to half of their original thickness. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 46: Chuck Nut

    5600044. Remember that these parts are left-hand threaded. 3.1.17 Chuck Nut 1. Inspect the splines of the chuck nut and replace when the splines are worn to half of their original thickness. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 47 2. To remove the chuck nut, 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 the chuck nut remover 5600043. Remember these parts are left hand threaded. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 48: Assembly Procedures

    3. Tighten the spindle nut to give the desired degree of friction between the clevis assembly and the cylinder lug bush. Insert the clevis body spindle into the cylinder lug bush. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 49: Control Handle

    Slip the twist grip onto the end of the control spindle. Work the twist grip left and right to slide it over the friction ring. Fit the control spindle washer and nut. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 50 Gently hammer in with the retract valve assembly tool 5600115. Fit the two springs into the bore of the handle adaptor. 6. Screw the plunger into position. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 51: Water Control & Water Tube

    2. water inlet rubber, 3. thrust washer, 4. water stem, and 5. water stem nut. Tighten the water stem nut. Fit the water inlet cover 5604626 to the water stem to prevent ingress of dirt. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 52: Throttle Valve Assembly

    3. Install the disc spring washer and tighten the throttle valve nut. 4. With a dab of grease, insert the throttle valve plunger and its spring into the hole in the bottom of the backhead. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 53: Steel Retainer

    3.2.6 Steel Retainer 1. To assemble the steel retainer mechanism, insert the steel retainer bushings into the fronthead lug. 2. Hold the steel retainer in position over the fronthead. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 54 3. Insert the steel retainer pin, taking care to align the location flat on the pin and steel retainer. Drive the pin with a copper mallet until fully seated. 4. Tighten the steel retainer nut. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 55: Side Rods & Fronthead

    Even tightening is critical to the life of side rods in service. Working left side/right side, left side/right side, tighten the side rod nuts to a torque of 122 Nm (90 ft-lbs). S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 56: Ratchet Ring & Rifle Bar

    1. Insert the ratchet ring into the cylinder, taking care to align the valve box locating pin grooves. Gently tap the ratchet ring with a copper mallet until fully seated. 2. Assemble the rifle bar parts. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 57 O-ring. Install the backhead into position over the end of the ratchet ring, taking care to engage the valve box locating pin into its groove in the backhead. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 58: Piston

    Place the valve chest assembly tool 5600111 on top of valve box assembly, and gently tap the valve box with a copper mallet until fully seated. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 59: Chapter 4: S250 Stoper Drill Maintenance

    See Sections 3.1 and 3.2. Only those features unique to the stoper are referred to in detail in the following: 1. The latest model of the S250 stoper rockdrill employs a closed-ended nut on the stem end of the operating handle. Unscrew this nut.
  • Page 60 3. Unscrew the twist grip nut and remove the twist grip. 4. Unscrew the pressure release valve and remove the O-ring from the bore. Clean and replace. 5. Unscrew the operating handle from the handle adaptor. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 61 O- rings. 7. Unscrew the side rod nuts and remove. 8. Withdraw the side rods and lift off the thrust leg completely. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 62 10. Unscrew and withdraw the water control valve. The water control valve is the same assembly as used in the jackleg drill, and its service routine is covered in Section 3.1.3 and 3.1.4. 11. Withdraw the water tube. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 63 13. Remove and service the ratchet ring, rifle bar, valve box, piston, cylinder, and chuck parts in exactly the same way as noted in the jackleg drill. Similarly, the fronthead and steel retainer components are covered in Sections 3.1.8 and 3.1.9. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 64: Stoper Air Leg

    3. To replace the bucket seal, pick out the split pin from the small end of the piston rod. Unscrew the bucket spacer and locking ring components from the end of the piston rod. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 65 The lip side of the seal faces outwards from the cylinder. If the end cap bushing must be removed, use service tool 5600100 and strike a series of blows with a copper mallet. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 66 6. Refit the end cap bushing using an assembled piston rod. This ensures correct alignment. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 67: Assembly Procedures

    2. Put the cylinder, complete with piston and valve box assembly, over the fronthead. Insert the ratchet ring and rifle bar assembly in the same way as on the jackleg drill (Section 3.2.8). S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 68 Section 3.2.3. 4. 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. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 69 5. Fit the thrust leg assembly over the backhead cap. 6. Insert the side rods. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 70 (machined) as part of the cylinder lug bushing. Tighten the adaptor nut and control body into the operating handle. 9. Fit the pressure relief valve. Make sure to replace the O-ring prior to installing the relief valve. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 71 10. Fit the twist grip, two washers, and the operating handle nut. 11. Tighten the nut on the end of the control body. 12. The stoper is now complete. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 72: Chapter 5: Critical Part Inspection Criteria

    See Section 3.1.10 step 2. The rifle bar should be replaced when the flutes (splines) are worn to 50% of their original thickness. 5.7 Chuck Insert See Section 3.1.15 step 1 for Chuck Insert inspection S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 73: Chapter 6: Testing Procedures

    Chapter 6: Testing Procedures 6.1 Break-in Period S250 rockdrills will reach maximum performance after a break-in period of approximately 1 hour of usage. 6.2 Start-Up and Lubrication 1. Keep dirt out of the lubricator: When filling or fitting a lubricator bottle, no dirt must be allowed to enter the air passages or the lubricator reservoir.

  • Page 74: Jackleg/Stoper/Sinker Testing

    Drill Torque and Air Leg testers are available on the market to assist in determining when maintenance is required, and to verify performance of rebuilt drills. Please consult the tester manufacturer for test set-up procedures. S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 75: Water Testing

    Water regulating control valves will not work if the water pressure is the same or greater than the air pressure. Ideal air pressure is 620.5 kPa (90 psi); ideal water pressure is 275 ~ 345 kPa (40 ~ 50 psi). S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

  • Page 76: Chapter 7: Troubleshooting Guide

    • • Cuttings not removed from Check water tube. Check plugged drill hole steel. Check water pressure. • • Improper alignment in hole Keep drill steel centred in hole and use S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...
  • Page 77 (Section 6.2 step 5) • • Dirt in drill Check stoppers for front end blow • Plug or cover all openings of the drill when blasting or when storing S250 ROCKDRILL | PARTS & SERVICE MANUAL January, 2021...

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