HLX5 Drifter Failure Guide (Rev3) PDF

Failure Analysis Guide Sandvik HLX5 Drifter
Index
1. Front Head Assembly
a. Front Cover
b. Front Shank Bearing/Bushing
c. Seal Housing
d. Rear Shank Bearing/Bushing
e. Shank bushing
f. Front Head
2. Gearbox Assembly
a. Front Bearing/Bushing
b. Coupling/Driver
c. Rotation Gear
d. Chuck Bushing
e. Rear Bearing/Bushing
3. Percussion Assembly
a. Front Cylinder
b. Front Piston Guide
c. Pilot Cylinder
d. Rear Cylinder
e. Rear Piston Guide
f. Piston
g. Distributor
4. HP Accumulator Assembly
a. Accumulator housing
b. Accumulator housing & insert
5. LP Accumulator Assembly
6. Hydraulic Motor Assembly
a. Geroto & rollers
b. Balance disc
c. Studs
1
Part no: W3899-3085
Part description: 11
Observation: Wear that is predominantly oval in nature.
Probable causes:
✓ Drill steel deviation caused by misalignment of drifter on the cradle or movement of

boom while the drill string is in the rock face.
*When there is normal wear on the rest of the rotation components it can be assumed that
there was a misalignment of the drifter on the cradle which is generally caused by
incorrectly adjusted slides or movement of the boom while the drill string is in the rock face.
This will happen when the boom was not correctly butted against the rock face or if the
hydraulic circuit of the boom is faulty.
Part no: W3899-3085

Part description: Front cover
Observation: Wear that is predominantly oval in nature.
Probable causes:
✓ Drill steel deviation caused by excessive feed being applied which force the drill steel
to flex thus affecting the orientation of the shank in relation to the bearing/bushings
which result in a misalignment between the rock face, drill string and drifter.
*If excessive feed is the cause of abnormal wear, the chuck located inside the rotation
gear will also be worn. When there was inadequate shank lubrication the wear pattern
will be aggressive, rough and usually the affected components will be discoloured as a
result of the friction between the components. There will also be significant and abnormal
wear evident on the thrust faces of the rotation gear and the rear rotation bushing.
2
Part no: W3899-3085
Observation: Wear/damage to the structure of the cover.
Probable causes:
✓ Impact damage caused by physical contact between the drifter and the centraliser
bracket/bushing. Incorrectly configured travelling of the drifter on the feed beam.
*Damages are related to maintenance related shortfalls incorrect settings and alignment
of the feed beam assembly. This is an uncommon failure that is caused by worn or incorrect
components.
Part no: W3899-3085

Observation: Wear on the internal landing into which the bearing/bushing seat
Probable causes:
✓ The internal landing into which the bearing/bushing assembly seat is worn beyond
the allowable wear limits and as a result the required press fit is eradicated. Normal
wear over the operational lifecycle of the component in conjunction with drill string
deviation and inadequate shank lubrication are the main contributing factors to the
failure seen above.
*The bearing/bushing a is a maintenance component and will be replaced regularly during
the operational life cycle of the drifter. As a result of this the tolerances machined into the
front cover will be eradicated over time.
3
Part no: W3899-3085
Observation: Wear on the front face towards the centre of the cover affecting the seal
groove.
Probable causes:
✓ The front face of the cover was damaged and as a result the seal groove was
compromised. It is suspected that the *coupling came into contact with the front
face of the cover during drilling operation.
*Coupling is an internally threaded sleeve designed to connect the shank adaptor to the
drill steel which is then referred to as the drill string. The internal threads are left-handed
thread in order to prevent the uncoupling of the drill string in the rock face.
4
Part no: W3900-3086

Part description: Bearing bushing front cover
Observation: Front face of component severely worn with a crack forming around the seal
groove profile.
Probable causes:
✓ Drill steel deviation caused by excessive feed being applied onto the drill string which
force the drill steel to flex, resulting in the hexagon of the drill steel being in constant
contact with the centraliser bushing. As a result of the cross corners of the hexagon
being in contact with the bushing while it is rotating, an abnormal vibration of the
drill string is caused. This vibration is then resonated via the drill string and shank
adaptor onto the seal housing which is in contact with the bearing/bushing.
*In order for the seal housing to come in contact with front or rear shank bearing bushing
there must be a maintenance or routing shortfall.
Part no: W3900-3086

Observation: Wear that is predominantly oval in nature with clear damaged being caused to
the cup seal.
Probable causes:

boom while the drill string is in the rock face. The misalignment further caused
damage to the sealing arrangement which would have aggravated the failure by
allowing drilling water to enter assembly which will eradicate the shank lubrication
within the assembly.
*When determining what caused the deviation the assessor must also take into to
consideration the wear and the condition of the chuck, rotation gear, rear bearing/bushing
and coupling/driver.
5
Part no: W3900-3086
Observation: Wear that is predominantly oval and has a rough surface.
Probable causes:

*When determining what caused the deviation the assessor must also take into to
consideration the wear and the condition of the chuck, rotation gear, rear bearing/bushing
and coupling/driver.
Part no: W3900-3086

Observation: Consistent but excessive wear across the entire internal bore and as a result
the landing is worn beyond the allowable tolerances.
Probable causes:
✓ Lack of maintenance and failure to replace the shank bushings timeously causing the
bushing to be worn beyond the allowable tolerance which allowed the shank adaptor
to come into contact with the front cover.
*When there was inadequate shank lubrication the wear pattern will be aggressive and
rough.
6
Part no: W3900-3086
Observation: Front face of the component broke off
Probable causes:
*The seal housing assembly fits onto the shank adaptor and as a result the component can
move which will allow contact between the shank bearing/bushings.
Part no: W3900-3086

Part description: Bearing/bushing front cover
Observation: Normal wear
Probable causes:
✓ The wear on the internal landing is even across the entire internal bore.
*The parallel and rotation grooves are dual purpose. It assists with the distribution of
lubrication across the internal bore of the component. Secondly, the grooves are also
wearing indicators which is a visual guide for the wear incurred and operational life left.
7
Part no: W3938-3124
Part description: Seal housing
Observation: The front and rear internal bores are worn oval.
Probable causes:
✓ Worn oval across the bore which affects the sealing arrangement. Misalignment in
relation to the feed beam and cradle and/or failing to replace the guides periodically,
(replacement of slyd rings located inside the housing) affected the alignment of the
seal housing in relation to the shank adaptor. Also contributing to this failure is the
incorrect routing of hoses (hose supplying water to the assembly) which apply strain
onto the assembly forcing it to be misaligned.
*Drill string strain or the misalignment of the drifter will not cause the shank to flex and it
is therefore important to understand that the wear is caused by either a lack of
maintenance by not changing the slyd rings or incorrect routing of the water connecting
pipe.
Part no: W3938-3124
Observation: Location landing worn, and front and rear faces worn.
Probable causes:
✓ Because of drill steel deviation the hex of the drill steel was in constant contact with
the guides resulting in abnormal vibration of the drill string which resonated back
into the unit via the shank adaptor, which caused the seal housing to vibrate
damaging the landing area and the front and rear faces of the seal housing.
*Wear on the landing plane are usually also evident on the corresponding landing plane
on the front head.
8
Part no: W3938-3124
Observation: Threads damaged
Probable causes:
✓ The internal threads on the seal housing water connecting port is damaged.
Operational conditions and/or maintenance practices are usually associated with
damages such as this.
*Depending of the degree of the damage the failure can be attributed to Operational
conditions during which the pipe or the fitting got damaged by falling rock or alternatively,
the threads were damaged as a result of cross-thread the damage was caused by
maintenance shortfalls.
Part no: W3938-3124

Observation: Seal landing groove and plane cracked
Probable causes:
✓ Internal bore is worn slightly oval affecting the sealing arrangement within the
assembly. Very prominent is cracks on the rear shoulder of the seal groove. Failure
to maintain the seal housing (replacement of slyd rings located inside the housing)
caused the component to be misaligned in relation to the shank adaptor and as a
result there was contact between the two components.
* Depending on the severity of the damage sustained to the component the incorrect
routing of hoses (hose supplying water to the assembly) apply strain onto the assembly
forcing it to be misaligned in relation to the shank adaptor. This will accelerate the wear of
the slyd rings and force the seal housing to be in constant contact with the front or rear
shank bearing/bushings.
9
Part no: W3897-3083
Part description: Bearing bushing shank bushing
Observation: Wear that is predominantly oval or to the one side and has a rough surface.
Probable causes:

✓ Drill steel deviation caused by excessive feed being applied which force the drill steel
to flex resulting in a misalignment between the rock face, drill string and drifter.
*Excessive feed is the cause of abnormal wear the chuck located inside the rotation gear
will also be worn. When there was inadequate shank lubrication the wear pattern will be
aggressive, rough and usually the affected components will be discoloured as a result of
the friction between the components.
Part no: W3897-3083

Observation: Consistent wear across the entire internal bore, however, the landing is worn
to the allowable wear tolerances.
Probable causes:
✓ Lack of maintenance and failure to replace the shank bushings and as a result the
bushing is worn beyond the allowable tolerance allowing the shank damage the cup
seal and to come into contact with the front cover.
* When there was inadequate shank lubrication the wear pattern will be aggressive and
rough.
10
Part no: W3897-3083
Observation: Front face of the bearing/bushing broke off.
Probable causes:
*The seal housing assembly fits onto the shank adaptor and as a result the component can
move which will allow contact between the shank bearing/bushings.
11
Part no: W3896-3082
Part description: Shank bushing
Observation: Normal wear across the entire thrust face of the bushing
Probable causes:
✓ Normal wear without any cracks or deep wear patterns indicating that normal wear
took place over the component life cycle.
Part no: W3896-3082

Observation: Worn deep into the thrust face and has a rough surface.
Probable causes:
✓ The component is worn deep into the thrust face with clear *rotational wear evident,
where the shank adaptor and the bushing were in contact during drill string
extraction. The wear pattern would suggest that there was excessive rotation of the
drill string during extraction from the rock face with inadequate shank lubrication
which caused accelerated wear.
*Rotational wear is caused by abnormal rotation of the drill string during extraction from
the rock face. There are various reasons why the drill string will be rotated during the
extraction i.e. friable ground conditions or operator error.
12
13
Part no: W3896-3082
Observation: Severely corroded and damaged on the internal bore
Probable causes:
✓ The shank bushing is severely corroded across the entire front face of the component
which was caused by exposure to *corrosive drilling water. The damage to the
internal bore was caused by the failure of the piston or shank adaptor.
*Corrosive drilling water refers to water with a low pH which causes the water to acidic.
The acidic water is prone to accelerate the corrosion of exposed metal surfaces. Metal with
high carbon content is also more susceptible to corrosion.
Part no: W3896-3082

Observation: Cracks appearing on the thrust face of the bushing.
Probable causes:
✓ *Free percussion causing a *hammering effect within the assembly which causes the
bushing to crack. In severe cases the bushing will break into pieces.
*Free percussion happens when there is no contact between the drill bit and the rock face.
The impact of the percussion piston is a calculated timing process which depends on specific
movements within the assembly. When the drill string is free to move within the assembly
because of low or no feed pressure the timing between the percussion piston and the shank
adaptor will be infringed. This will cause the impact of the two components to be out of
sequence allowing the shank adaptor to hammer into the shank stop or chuck
14
Part no: W4530-3715
Part description: Front head
Observation: Seal housing landing located on the front head is worn.
Probable causes:
✓ Abnormal vibration of the seal housing due to drill steel deviation (excessive feed or
misalignment) causing the seal housing landing to wear abnormally & rapidly.
* Drill Steel Deviation. The drill steel that came into contact with the centralisers and
because the drill steel is hexagon shaped the contact caused a vibration of the drill string
which resonated onto the seal housing resulting in abnormal wear the contact surfaces.
Part no: W4530-3715

Observation: Cracks appearing on the front head.
Probable causes:
✓ Drill steel deviation causing abnormal vibration of the drill string which is then
resonated onto the front head assembly and over time metal fatigue take place.
15
Part no: W4530-3715
Observation: Front internal landings worn oversize.
Probable causes:
✓ Loose front cover bolts will result in movement of the cover assembly inside the front
head which will wear away the required tolerance.
✓ Normal operational & continues maintenance wear away the tolerances over the
lifecycle of the component.
*When selecting loose front cover bolts ensure that the mating faces of the front head and
front cover support the conclusion i.e. the faces will be worn, corroded because of the
movement.
16
Part no: W3917-3103
Part description: Front head bolt
Observation: Damaged integrated washer
Probable causes:
✓ A section of the flat washer that is integrated into the front head bolt broke off. Over
torqueing of the bolt or unevenly worn landing planes on the front head component
are usually associated with this type of failure.
*
Part no: W3917-3103

Observation: Damaged hexagon
Probable causes:
✓ The hexagon is damaged and as a result the component is no longer conducive for
reuse. The damage is directly related to poor maintenance practices, due to the use
of the use of the incorrect or faulty tools (using a punch to loosen the bolt) during the
periodical maintenance of the unit.
17
Part no: W3917-3103
Observation: Damaged hexagon and integrated flat washer
Probable causes:
✓ The hexagon and integrated flat washer are severely damaged and as a result the
component is no longer conducive for reuse. The damage is directly related to poor
maintenance practices, due to the use of the use of the incorrect or faulty tools
during the periodical maintenance of the unit.
Part no: W3917-3103

Observation: Integrity cannot be substantiated
Probable causes:
✓ The integrity of the components could not be verified & substantiated. As a result of
these finding and observations, the components will be replaced accordingly to
ensure that the desired preloads are achieved and maintained
*The front head bolts are crucial for the correct alignment of the front head assembly in
relation to the percussion body. The bolts are subjected to daily/weekly maintenance
during which they are removed and replaced in order to remove the front head. A preload
of 400Nm is applied during this process.
18
Part no: W3917-3103
Observation: Threads are worn and corroded
Probable causes:
✓ The threads are worn and corroded and as a result the component is no longer
conducive for reuse. The condition of the component can be attributed to one of the
following conditions.
✓ Incorrectly torqued (lose) bolts allowing movement between the threads
✓ Over torqued bolts resulting in the seizure of the threads onto each other.
✓ Operational life cycle reached (designed component life)
Part no: W3917-3103

Part description:
Observation:
Probable causes:
19
Part no: W3926-3112
Part description: Gear
Observation: Normal wear on all the wear indicators.
Probable causes:
✓ The front & rear rotation landing as well as the rear thrust face has reached the
allowable wear limits, and as a result the component will be replaced. The wear
pattern is *normal (smooth and even) which is an indication that the wear seen was
as a result of normal operational wear, and that the unit has reached its intended
operational life.
*Normal wear can only be used as a cause when all the related components have the same
or similar wear.
Part no: W3926-3112

Observation: Chuck bushing landing worn.
Probable causes:
✓ The internal landing where the chuck bushing seat is worn to the maximum allowable
wear limit and as a result the correct fitment of the chuck within the assembly will
not be achieved. Normal operational conditions in conjunction with end of
component lifecycle can be attributed to the wear.
*If the chuck was abnormally worn on the thrust face deep indentations or cracked the
wear can be attributed to excessive feed pressure or free percussion which deformed the
chuck causing damage to the mating surface inside the gear.
20
Part no: W3926-3112
Observation: Rear thrust face of the component worn
Probable causes:
✓ The rotation gear is worn beyond the allowable wear indicators on the rear thrust
face. Wear such as this is directly related to inadequate shank lubrication in
conjunction with excessive feed pressure and as a result the shank is thrusted into
the gear assembly.
*When the feed pressure being applied onto the drill string is greater than the rate of
penetration the ration gear assembly is thrusted into the rear rotation bearing/bushing.
Evidence to support this observation will be deep wear marks on the chuck and a
discolouration of the rear spigot section of the rotation gear.
Part no: W3926-3112

Observation: Front & rear rotation landing is worn beyond the allowable wear limits with a
rough texture.
Probable causes:
✓ The front & rear rotation landings have surpassed the allowable wear limits. The
wear is *rough, uneven and a discolouration of the material is evident which is an
indication of inadequate shank lubrication.
*Wear that is rough in in texture refer to a surface with prominent rotational score marks.
Also, evident will be the impregnation of the bearing/bushing material into the score marks
because of the dry wear.
21
Part no: W3926-3112
Observation: Front & Rear rotation landing scored and corroded.
Probable causes:
✓ The front & rear rotation landing as well as the rear thrust face is scored & corroded
with deep pit marks evident. Inadequate shank lubrication during the initial phases
of the operation life caused the wear and *incorrect storage practices caused the
component to corrode.
*Incorrect storage refers to the way and the manner in which a drifter is stored prior or
after it was in operation. Underground conditions are humid and wet. If a unit is stored
underground for a prolonged period, the moisture will affect the exposed components. If
the unit is incorrectly decommissioned the affect will be aggravated.
22
Part no: W3911-3097
Part Description: Coupling/Driver
Observation: Cracked at the base of the internal splines.
Probable causes:
✓ The component is slightly worn on all the wear indicators with small cracks evident
at the base of the internal splines. The cracks are as a result of *excessive torque
being applied onto the drill string because of *friable ground conditions.
*When there is resistance in the movement of the drill string, torque (force) will
immediately be applied onto the coupling/driver via drill string.
Part no: W3911-3097

Observation: Worn on all the wear indicators and the component is also a *first addition
Probable causes:
✓ The component is worn on most of the wear indicators and is also the previous
edition. Base on the wear identified and the fact that the component is a first edition
the component is no longer conducive for reuse. The wear appears normal and can
therefore be attributed to normal operational wear.
*First addition did not have the lubrication slots machined into the front thrust face.
23
Part no: W3911-3097
Observation: External splines damaged.
Probable causes:
1. The external splines are broken in some areas and the component is no longer
reusable. Ingress of foreign matter which infringed between the mating splines and
as a result small pieces of the splines broke away.
Part no: W3911-3097

Observation: Internal splines are broken towards the rear of the coupling
Probable causes:
✓ Rear ⅓ of the coupling splines has all failed and it is suspected that the unit was
operated with a loose front head which allowed the component to float about 12
mm within the rotation gear. As a result of this movement the contact surface
between the splines (coupling/driver and shank adaptor) were reduced by ⅔
resulting in the rear section of the splines failing.
24
Part no: W3911-3097
Observation: Integrity of component cannot be *substantiated
Probable causes:
✓ The component was assessed, and slight wear was measured on all the wear
indicators. The integrity of the components could however not be substantiated and
as a result the component will be discarded and replaced with a new component.
*The component was manufactured by a third party manufacturer and as a result the
component is deemed unfit for reuse because of warranty requirements.
Part no: W3911-3097

Observation: Internal splines pitted on contact surface
Probable causes:
✓ The internal splines are pitted and as a result the component is not conducive for
reuse. It is suspected that there was an ingress of foreign material (metal debris that
originated from the shank bushing) that came between the mating splines of the
coupling/driver and the shank adaptor which caused the damage as seen above.
What could have contributed to the failure is inadequate shank lubrication.
25
Part no: W3911-3097
Observation: External splines worn.
Probable causes:
✓ The coupling is slightly worn on internal splines with more wear evident on the
external splines. Small cracks at the base of the internal splines are also evident and
as a result the component is no longer usable. The cracks are usually caused by
excessive rotational force due to friable ground conditions which collapse onto the
drill string in the rock face and it is believed that the same conditions caused the
wear to the external splines.
Part no: W3911-3097

Observation: Worn on all wear indicators with discolouration evident.
Probable causes:
✓ The coupling is worn on both the internal & external splines as well as the thrust
face. The component is dark in colour which is an indication that there was friction
within the assembly that caused head. The rotation gear was however missing, so
we were not able to assess the condition of the related components. It is suspected
that the drill string deviation contributed to the wear seen on the splines and
inadequate shank lubrication caused friction between the components.
26
Part no: W3911-3097
Observation: Rear face severely scored
Probable causes:
✓ Piston/shank failure caused severe damage to the component because of the metal
fragments which came in between the various rotational landings and thrust faces
of the related components.
Part no: W3911-3097

Observation: Internal splines worn to the allowable wear limit
Probable causes:
✓ The component is worn on both the internal & external splines as well as the front
thrust face. The component has reached the allowable wear limit, and as a result the
item will be replaced. The component is a maintenance item which should be
replaced periodically.
27
Part no: W3911-3097
Observation: Cracked
Probable causes:
The component is worn on both the internal & external splines as well as the front thrust
face. The component has reached the allowable wear limit, and as a result the item will be
replaced. The component is a maintenance item which should be replaced periodically.
28
Part no: W3907-3093
Part Description: Chuck/Drill Sleeve
Observation: Worn on the thrust face with discolouration of the material evident due to heat
Probable causes:
✓ The chuck is a wear component within the assembly. The component is worn on the
thrust face where the shank adaptor & chuck are in contact during drilling operation.
The wear is deep, and the material discoloured which is an indication that there was
inadequate shank lubrication during operation which caused “metal on metal”
contact between the thrust faces.
*Strain was caused by high feed pressure during which the rate of feed exceeded the rate
of penetration.
Part no: W3907-3093

Probable causes:
✓ The wear observed is smooth and even which is associated with normal operational
wear over the operational life cycle of the component.
29
Part no: W3907-3093
Observation: Worn on the thrust face with chip marks on the outer rim
Probable causes:
✓ The chuck is worn on the thrust face where the shank adaptor and the chuck are in
contact during drilling operation. Also evident is chip marks on the outer rim and
internal bore as well as a discolouration of the component. It is suspected that the
chip marks were caused by the piston failure and that the wear and discolouration
was caused by inadequate shank lubrication.
30
Part no: W3911-3097
Part Description: Bearing Bushing
Observation:
Probable causes:
✓ The rear rotation bearing/bushing was worn to such an extent that the rear &
rotational wear indicators are no longer visible. The wear texture is rough and
uneven and is an indication of the thrust wear which took place within the assembly.
There is also a high probability that there was an ingress of foreign material into the
assembly which aggravated the failure.
Part no: W3911-3097

Probable causes:
✓ The wear pattern is even and smooth with the wear indicators worn to their
allowable wear limits. Usually this wear is associated with *normal operational wear
and routine maintenance practices.
* Normal operational wear refers to wear that is even across all the wear indicators with
a smooth texture to the surfaces. This is an indication that the unit was well maintained
and that adequate lubrification was supplied to the various components.
* Maintenance practice refers to the prescribed maintenance as per the OEM guidelines
which dictates time frames in which certain components must be changed.
31
Part no: W3911-3097
Observation: Worn on the rotation landing and rear thrust face.
Probable causes:
✓ Rotation landing and the rear thrust face of the bearing/bushing is severely worn.
The surface texture is rough and pit marks are evident which would suggest that
there was *dry wear during the operational life of the component.
*Dry wear is caused when the unit is operated without the required dosage of shank
lubrification.
Part no: W3911-3097

Observation: Ovality on the rotation landing
Probable causes:
✓ Worn abnormal on the rotation landing with oval wear evident. The rear thrust face
is worn beyond the allowable wear limit. The nature of the wear is uneven which
indicates excessive feed pressure which caused a *misalignment within the assembly
and aggravated by inadequate shank lubrication (*dry wear).
*Misalignment within the rotation assembly of the drifter is caused when the drill string
and feed beam is not in aligned. Failure to maintain the slides on the cradle, movement of
the boom while the drill string is in the rock face and excessive feed pressure are all
contributing factors to misalignment.
32
Part no: W3911-3097
Observation: Access bore and rear thrust face severely damaged.
Probable causes:
✓ The bore through which the piston travel in order to reach the impact zone is
damaged. This is usually caused by the *failure of either the piston or the shank
adaptor, following which metal fragments enter the contact surfaces or infringe on
the clearance between the two components.
*Failure of the components can be as a result of various reasons. Some of the most common
causes will be free percussion, inadequate shank lubrication causing metal on metal
impact, metal fatigue due to over extended life cycles & misalignment between the impact
surfaces due to inadequate maintenance (pre-loads).
Part no: W3911-3097

Observation: Sever ovality on the rotation landing and thrust face wear.
Probable causes:
✓ The rear rotation bearing/bushing is worn to such an extent that the piston was able
to touch the rotation gear assembly as it passed through the access bore on its way
to the impact zone. Misalignment within the assembly, inadequate shank lubrication
and over extended life cycle are all related to failures such as this.
33
Part no: W3911-3097
Observation: Worn oval on the rotational landing
Probable causes:
✓ Abnormal wear (oval) was observed on the rotation landing of the bearing/bushing.
It is believed that there was a severe misalignment of the drifter in relation to the
feed beam, or movement of the boom while the drill string was in the rock face,
which forced the shank adaptor into an off-set position. This caused a misalignment
within the front head and rotation segments.
34
Part no: W3922-3108
Part Description: Rotation shaft
Observation: Rear needle bearing landing worn
Probable causes:
✓ The rear bearing & seal landing plane is worn and as a result the unit is no longer
reusable. The landing was damage as a result of the rear needle bearing that failed
which affected the rotation & seal surface.
Part no: W3922-3108

Observation: Rear seal and bearing landing planes damaged
Probable causes:
✓ The front & rear bearing landings are worn with severe damage visible on the seal &
needle bearing planes. It is suspected that the metal debris from the shank adaptor
failure entered the sealing arrangement which caused intense damage and wear to
the metal surface where the seal seat. The wear seen on the bearing landing was
caused by the needle bearing failure. The wear/damage to the sealing arrangement
must have resulted in an external leakage via the rotation segment.
35
Part no: W3922-3108
Observation: Plane in front of the seal landing is scored
Probable causes:
✓ Front bearing/bushing failure caused the rotation shaft to be misaligned within the
assembly which caused the shaft to touch the rear needle bearing housing.
*The damage could also be caused by the failure of the rear needle bearing but then the
rear bearing landing will be damaged.
Part no: W3922-3108

Observation: The spherical bearing landing plane is cracked
Probable causes:
✓ Misalignment between the hydraulic motor output shaft and the rotation shaft
during assembly/mating of the rotation & percussion segments. Incorrect assembly
practices and poor maintenance practices are directly related to the failure.
36
Part no: W3922-3108
Observation: The front bearing landing severely worn
Probable causes:
✓ Inadequate shank lubrication and/or *prolonged operation of the unit caused the
front needle bearing/bushing to fail. Continues use of the unit after the
bearing/bushing had failed caused severe damage as seen.
*The OEM maintenance guidelines dictates that the bearings within the rotation shaft
assembly should be inspected every 500 hrs or earlier which ever hours that are applicable
to the specific drilling conditions.
Part no: W3922-3108

Observation: The bearing landing is discoloured
Probable causes:
✓ Discolouration of the rear needle bearing landing is evident which is an indication

early stages of bearing failure were taking place. There are score marks in front of
the seal landing plane which was caused by contact between the rear bearing
housing and the rotation shaft.
37
Part no: W5241-4436
Part Description: Button
Observation: Worn on the thrust face
Probable causes:
✓ The button is designed to minimise the movement of the hydraulic motor output
shaft. If the component is worn beyond the allowable wear limits (length) it should
be replaced. Wear across the circumference is less of concern and should only be
considered if the wear is significant.
Part no: W5241-4436

Part Description: Button
Observation: Worn on the circumference
Probable causes:
✓ The component is worn severely across the circumference and as a result the
component will have excessive movement inside the rotation shaft spline area.
Rotation of the button inside the spline area caused the component to wear on the
circumference.
38
Part no: W3946-3131
Part Description: Front needle bearing housing
Observation: Rotational score marks on the outer surface.
Probable causes:
✓ The housing rotated inside the seat which is situated inside the rotation segment.
The rotation worn away the press fit tolerance required for the correct fitment of
the component. The rotation of the housing was caused by either the incorrect
fitment of the housing during the previous repair or because of a bearing/bushing
failure which caused the rotation shaft to seize inside the housing and as a result the
housing rotated inside the rotation segment.
Part no: W3946-3131

Observation: Damaged on the rear face.
Probable causes:
✓ The bearing failure caused debris from the failure to infringe on the clearance
between the housing and the rotation shaft which caused the damage. Bearing
failure will take place when any of the following occurrences take place
✓ Inadequate shank lubrication which caused dry wear. When this is the RCF
the other components within the assembly should have the same
indications.
✓ Failure because of a misalignment within the assembly that was caused by
drill string deviation.
✓ Failure because of prolonged operation.
39
Part no: W3946-3131
Observation: Damaged on the rear face.
Probable causes:
✓ The front bearing housing is severely scored on the outer landing with deep and
prominent lateral score marks, which was caused by the press fit contact between
the landing inside the rotation segment and the bearing housing.
40
Part no: W3749-2935
Part Description: Stud
Observation: Broken on front threads
Probable causes:
✓ There are various reasons for the failure of the stud i.e. operational conditions (falling
rock from the hanging wall, bumping of the drifter against the side or hanging wall) ,
maintenance shortfalls (under or over torqueing of the bolts) and metal fatigue (load
stress due to preloads and percussion frequencies).
*When two or more studs are broken on one side of the drifter the possibility of a
misalignment between the percussion & gearbox segments should be factored into the
assessment of the related components.
Part no: W3749-2935

Part Description: Stud
Observation: Hexagon damaged
Probable causes:
✓ The hexagon on the stud is damaged and as a result the desired preloads will not be
achieved during the assembly of the unit. Due to the damage the component is no
longer fit for reuse. Damage such as this is caused by incorrect or damage tooling
that is used during the refurbishment and/or periodical maintenance of the unit
while in operation.
41
Part no: W3748-2934
Part Description: Cap nuts
Observation: Threads are worn & corroded
Probable causes:
✓ The internal threads are worn & corroded and as a result the component is no longer
conducive for reuse. Maintenance shortfalls (over or under torqued cap nuts will result
in, either the threads seizing onto each other because of excessive preloads or allow
movement between the threads due to lose cap nuts).
✓ Also, probable is the fact that the component has reached the desired operational
life cycle for which the component was designed.
Part no: W3748-2934

Part Description: Cap nuts
Observation: Mating face of cap nuts are worn & corroded.
Probable causes:
✓ The thrust faces of the cap nuts are worn and corroded and as a result the mating
faces are not true. The wear can be as a result of the following conditions.
✓ Uneven mating surface on the gearbox segment.
✓ Lose cap nuts which allowed for movement during operation (there will be
corresponding wear marks on the gearbox mating faces)
✓ If corrosion is the dominant wear indicator the possibility of inadequate
shank lubrication must be included into the RCF.
*The components should be assessed in order to establish whether they can be reworked (surface
grind).
42
Part no: W3919-3105
Part Description: Rear bearing housing
Observation: Scored on the plane in front of the seal groove
Probable causes:
✓ Following the failure of the front needle bearing/bushing, there will be a

misalignment (concentricity) between the front & rear sections of the rotation shaft
which will cause the shaft to come in contact with the bearing housing.
Part no: W3919-3105

Part Description: Rear bearing housing
Observation: Scored on the rear face of the housing.
Probable causes:
✓ The bearing failure caused debris from the failure to infringe on the clearance
between the housing and the rotation shaft which caused the damage. Bearing
failure will take place when any of the following occurrences take place
✓ Inadequate shank lubrication which caused dry wear. When this is the RCF
the other components within the assembly should have the same
indications.
✓ Failure because of a misalignment within the assembly that was caused by
drill string deviation.
✓ Failure because of prolonged operation.
43
Part no: W3768-2954
Part Description: Front Piston Guide
Observation: Worn & Wiped in an *off set position.
Probable causes:
✓ The piston guide is worn (wiped) in an *off-set position. The piston failure depicted
below forced the piston into an asymmetrical position during the impact phase,
which allowed the piston to “break through” the oil filament that is between the
guide and the piston allowing the components to touch.
*Off-set refer to the wear that is opposite each other and is usually associated with a
misalignment within an assembly which causes the components to come in contact with
each other.
Part no: W3768-2954

Observation: Normal operational wear
Probable causes:
✓ The front piston guide located inside the seal housing was assessed and
measurements were obtained, during which it was established that normal wear
took place. The guide is regarded as a mandatory component and will be replaced
and machined to accommodate the new percussion piston.
44
Part no: W3768-2954
Observation: Cavitation near the end plane
Probable causes:
✓ The front piston guide is worn to the allowable wear limit. There is cavitation evident
on the end plane of the guide, which is an indication that there was water present
inside the hydraulic oil, which caused cavitation of the metal surfaces.
Part no: W3768-2954

Probable causes:
✓ The front piston guide located inside the seal housing was assessed and
measurements were obtained, during which it was established that normal wear
took place.
45
Part no: W3768-2954
Observation: Severely scored and wiped
Probable causes:
✓ Due to the piston failure that took place within the percussion circuit the piston guide
was excessively scored which make it exceptionally difficult to determine the actual
cause of the piston failure.
Part no: W3768-2954

Observation: Damaged on the inner face of the guide
Probable causes:
✓ The front piston guide is worn with damage evident on the face of the guide. The
piston was inspected, and it was found that there is a chip mark on the front journal
that protrude forward. It is believed that this high spot touched the guide during
percussion. Ingress of a foreign object into the area that infringed on the required
clearance.
46
Part no: W3905-3091
Part Description: Front Seal Housing
Observation: Internal journal landing plane scored
Probable causes:
✓ The seal housing assembly is severely scored on both the piston guide and valve
journal landing. Based on the condition of the piston guide it can be concluded that
the wear/damage on the piston guide caused the piston to sag to such an extend
that the percussion journal touched the seal housing. This is supported by the fact
that the score marks are only evident on one half of the landing.
47
Part no: W4489-3674
Part Description: Piston
Observation: Strike face fragmented
Probable causes:
✓ Damaged to the strike face of the component is usually caused by the following
conditions or a combination thereof. It is therefore important to assess all the
related components before concluding the RCF. Free percussion causes the piston to
deviate from the desired impact sequence during which the strike face of the piston
will be affected due to the positioning of the components during impact. Another
cause of strike face damage is inadequate shank lubrication in the impact zone which
causes *metal on metal impact between the piston and the shank adaptor.
*Metal on metal contact refer to physical contact between the components because of the
absence of shank lubrification (microscopic oil filament that forms on the metal surfaces of
components) that is required to lubricate the impact surfaces to control friction.
Part no: W4489-3674
Observation: Broken on the front guide/seal landing
Probable causes:
✓ The piston broke on the front guide and seal landing plane. A misalignment within
the percussion segments could have caused an infringement on the required
clearance between the components. This allowed the components to touch each
other during operation. The contact between the components caused *friction, and
as a result both components expanded rapidly, where after the piston seized inside
the guide.
*Friction between components cause heat which affected the integrity of the material and
causes the expansion of materials. In the case of a piston and piston guide different
materials are heated, which will expand at different rates. If the expansion infringed on
the tolerances allowed for free movement the components will seize onto each other.
48
Part no: W4489-3674
Observation: Broken on the rear guide/seal landing
Probable causes:
✓ The piston broke in the rear section between the rear percussion journal and the
rear seal & guide landing. The failure of the piston on the rear section is a common
failure and is caused by the incorrect charge pressure within the LP Accumulator
(high or low pressure) The incorrect accumulator pressure prevents the accumulator
from stabilising the hydraulic oil in the return circuit which causes the percussion
frequencies within the oil to affect the rear section of the piston during the reverse
stroke. This is commonly known as *fishtailing.
*Refers to the uncontrollable curving of metal while in motion caused by an imbalance
resulting in cracks forming causing extreme failure
Part no: W4489-3674

Observation: Corroded on the front section
Probable causes:
✓ The piston is severely corroded on the front face & strike face. This would have
affected the sealing arrangement within the assembly. The corrosion on the front
section and the wear on the strike face was caused by *inadequate shank lubrication
in conjunction with the presence of corrosive mine drilling water. The severity of the
corrosion would further indicate the period that the component was exposed to the
corrosive water.
*The term inadequate shank lubrication is used to describe a variety of shank lubrication
related issues. A comprehensive list of the causes is listed at the end of the failure guide.
49
Part no: W4489-3674
Observation: Scored, pitted and discoloured on front landing plane
Probable causes:
✓ The wear is abnormal and was caused by moisture/water in the hydraulic circuit
which affected the exposed metal during the implosions. The score marks were
caused by contamination inside the hydraulic circuit which infringed on the
clearance between the piston and the guide which caused damage to the piston
landing plane. The discolouration is as a result of friction that was caused by physical
contact between the piston and guide. The contact could have been caused by either
a misalignment between the cylinder assembly or the ingress of foreign matter which
caused the affected area to heat up to very high temperatures resulting in the
hydraulic oil losing its *viscosity because of high heat.
*The term viscosity refers to the oils thickness which determines the ability of the oil to
lubricate under different temperatures.
Part no: W4489-3674
Observation: Pitted & cracked strike face
Probable causes:
✓ The piston is severely pitted on the strike face with small cracks starting to form
across the entire surface area. The damage and wear were caused inadequate shank
lubrication which caused metal on metal impact. The pit marks were caused by water
that emanated either from the front head assembly because of compromised sealing
arrangements or water that was present inside the shank lubrication system. The
compression of the water between the two
*The term inadequate shank lubrication is used to describe a variety of shank lubrication
related issues. A comprehensive list of the causes is listed at the end of the failure guide.
50
Part no: W3903-3089
Part Description: Distributor
Observation: Cavitated on the end plane
Probable causes:
✓ The distributor is severely cavitated on the end plane and score marks are evident
on the rest of the component. Cavitation happens when there is water/air present
inside the hydraulic system and because of a change in pressure within the cavity the
molecules will implode causing severe damage to the metal surfaces within the
vicinity of the implosion.
*Cavitation is a process during which water molecules implodes when it is exposed to
variable pressures inside a hydraulic circuit. Because pressure changes are higher in certain
areas cavitation will be more prominent in those areas.
Part no: W3903-3089

Observation: Cavitated at base of stop journal
Probable causes:
✓ The distributor is slightly scored on the various journals. There is also clear evidence
of cavitation between the valve & stop journals. As a result, the component is no
longer conducive for reuse. The component operates inside hydraulic oil within the
percussion segment of the unit. Wear such as this is directly related to an ingress of
foreign matter (contaminated hydraulic oil & water) during the operational life of
the component.
*Cavitation is a process during which water molecules implodes when it is exposed to
variable pressures inside a hydraulic circuit. Because pressure changes are higher in certain
areas cavitation will be more prominent in those areas.
51
Part no: W3903-3089
Observation: Worn (scored) on the valve journals
Probable causes:
✓ The distributor is worn on and scored on the various journals and as a result the
component is no longer conducive for reuse. The component operates inside
hydraulic oil within the percussion segment of the unit. Wear such as this is directly
related to an ingress of foreign matter (contaminated hydraulic oil) of the
operational life of the component.
52
Part no: W3814-3000
Part Description: High-Pressure & Low-Pressure Accumulators
Observation: Cracked
Probable causes:
✓ When the accumulator is charged incorrectly (too low or no pressure) and is exposed
to this conditions for prolong periods the constant pressure changes inside the
drifter compartments will have a hydraulic hammering effect on the accumulator
housing which will cause metal fatigue and result in cracks forming.
*The effect of incorrectly charge accumulators will be evident on both the High- & Low-
Pressure Accumulators but cracks are more common on the high-pressure side because of
the pressure associated (180–220 bar) within the circuit.
Part no: W3814-3000

Part Description: High Pressure Accumulator
Observation: Accumulator assembly not matching w.r.t. serial numbers.
Probable causes:
✓ The serial number on the insert could not be matched with the accumulator housing
(excessive corrosion on the face of the component), and as a result the assembly is
deemed unfit for future use. The accumulator assembly is regarded as a *pressure
vessel, and as such there are strict guidelines that governs the use of the component.
*Pressure vessel refer to a unit that is designed to contain high pressure and as a result
there is specific legislation guiding the use, inspection and testing of these components. All
pressure accumulators need to be crack tested during assessment. The physical condition
of the unit should also be verified, and any deviation should be addressed. Mismatching of
the housing in relation to the insert is not allowed and thread wear should be measured
using the machined wear indicators.
53
Part no: W4507-3692
Part Description: Hydraulic motor rotor
Observation: Geroto and rollers scored with pit marks evident
Probable causes:
✓ The Geroto assembly (rotor & rollers) were assessed, and it was found that the
rollers and the inner rotor were scored. Also, evident was small pit marks (cavitation)
on the inner rotor. An ingress of water and foreign matter into the rotation hydraulic
circuit, caused the damage seen above.
Part no: W4507-3692

Observation: Geroto splines broken
Probable causes:
✓ The splines located inside the gerotor element of the hydraulic motor is broken
which caused severe damage to the rest of the motor assembly. *Excessive
rotational force and aggressive directional changes and ground conditions are all
contributing factors to this type of failure.
*Operator response to the freeing of the drill string from the rock face during drilling or
drill string extraction. When the ground formation in front of the face is friable the rock
formation around the drilled hole tends to collapse onto the drill string which causes the
drill string to get trapped/stuck inside the drilled hole. In an attempt to rotate or extract
the drill string the operator will apply aggressive movements and directional changes
under high pressure which will damage components in the rotation segments.
54
Part no: W4507-3692
Part Description: Hydraulic motor disc valve
Observation: Scored on the mating face
Probable causes:
✓ For the assembly to operate adequately, the mating faces between the various
components inside the hydraulic motor assembly must seat flush with no
interference or wear on the faces. The only why that the faces could get scored, was
if there was an ingress of foreign matter, which entered the hydraulic motor circuit
via the high-pressure supply side.
Part no: W4507-3692

Part Description: Hydraulic motor balance disc
Observation: Scored on the mating face
Probable causes:
✓ For the assembly to operate adequately, the mating faces between the various
components inside the hydraulic motor assembly must seat flush with no
interference or wear on the faces. The only why that the faces could get scored, was
if there was an ingress of foreign matter, which entered the hydraulic motor circuit
via the high-pressure supply side.
55
Part no: W4507-3692
Observation: Balance plate is scored on contact face.
Probable causes:
✓ The balance plate is scored and severely worn on the face which was in contact disc
valve. It is suspected that there was clearance shortfall between the two
components and as a result the two parts thrusted into each other. The clearance
infringement could have been caused by the ingress of foreign matter into the
hydraulic circuit.
Part no: W4316-3501

Part Description: Hydraulic motor stud
Probable causes:
✓ The hexagon the end of the hydraulic motor stud is worn and as a result the required
preload will not be achieved. Maintenance and or repair practices can be attributed
to the damage.
*Damage to hydraulic motor components such as studs, nuts flanges, rotor and rollers
which are often caused by incorrect maintenance practices or incorrect tooling. It is
important to note that this area of the drifter is seldom opened during routine maintenance
and most of the damages are as a result caused during dismantling or assembly of the unit.
56
Part no: W4316-3501
Part Description: Hydraulic motor stud
Probable causes:
✓ The hexagon the end of the hydraulic motor stud is worn and as a result the required
preload will not be achieved. Maintenance and or repair practices can be attributed
to the damage.
*Damage to hydraulic motor components such as studs, nuts flanges, rotor and rollers
which are often caused by incorrect maintenance practices or incorrect tooling. It is
important to note that this area of the drifter is seldom opened during routine maintenance
and most of the damages are as a result caused during dismantling or assembly of the unit.
57

HLX5 Drifter Failure Guide (Rev3) PDF

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Failure Analysis Guide Sandvik HLX5 Drifter

✓ Drill steel deviation caused by misalignment of drifter on the cradle or movement of

Part no: W3899-3085

Part no: W3899-3085

Part no: W3900-3086

Part no: W3900-3086

✓ Drill steel deviation caused by misalignment of drifter on the cradle or movement of

✓ Drill steel deviation caused by misalignment of drifter on the cradle or movement of

Part no: W3900-3086

Part no: W3900-3086

Part no: W3938-3124

✓ Drill steel deviation caused by misalignment of drifter on the cradle or movement of

Part no: W3897-3083

Part no: W3896-3082

Part no: W3896-3082

Part no: W4530-3715

Part no: W3917-3103

Part no: W3917-3103

Part no: W3917-3103

Part no: W3926-3112

Part no: W3926-3112

Part no: W3911-3097

Part no: W3911-3097

Part no: W3911-3097

Part no: W3911-3097

Part no: W3911-3097

Part no: W3907-3093

Part no: W3911-3097

Part no: W3911-3097

Part no: W3911-3097

Part no: W3922-3108

Part no: W3922-3108

Part no: W3922-3108

✓ Discolouration of the rear needle bearing landing is evident which is an indication

Part no: W5241-4436

Part no: W3946-3131

Part no: W3749-2935

Part no: W3748-2934

✓ Following the failure of the front needle bearing/bushing, there will be a

Part no: W3919-3105

Part no: W3768-2954

Part no: W3768-2954

Part no: W3768-2954

Part no: W4489-3674

Part no: W3903-3089

Part no: W3814-3000

Part no: W4507-3692

Part no: W4507-3692

Part no: W4316-3501

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