Failures of HC-Drifter

For HC155R, HC107R, HC108R, HC109R

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 Striking Piston Failure- 1 - Cracking to piston striking surface -

ƒ Symptom: Cracks on the piston surface are appeared in the very shallow surface
layer. "hair cracks" may happen due to water or oil compression by hitting it between
the shank rod and the piston face
ƒ Possible cause: Entered water from Vaposal flushing, Continuous drilling in seal
leaking condition, Too much Rock Drill Oil flow adjustment

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 Striking Piston Failure- 2 - “Dieseling phenomenon"-

ƒ Symptom: Carbon deposits in the drifter front part

ƒ Possible cause: Continuous drilling in seal leaking condition, Too much Rock Drill Oil
flow adjustment

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 Striking Piston Failure- 3 - Seal leaking due to corrosion -

ƒ Symptom: Premature oil leakage at front head

ƒ Possible cause: Without water separator in the lubrication line for the drifter,
It may enter water condensation to the piston seal area.
ƒ Drifters are shipped through Ocean, and we can imagine that there are big changes in
terms of temperature and air moisture during the trip. This could lead to the problem.

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 Striking Piston Failure- 4A - Damaged Piston, Broken Shank Stop -
ƒ Symptom: Damaged Piston, Broken Shank Stop
ƒ Possible cause: Too much drifter bouncing, Improper maintenance of Shank Stop

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 Striking Piston Failure- 4B - Damaged Piston, Broken Shank Stop -
The surface of Shank Thrust tends to wear prematurely that would result in Over Wear Limit on the surface in case of drilling for
hard rock (Compressive Strength over 1800kg/cm2) and/or drilling for long depth over 15m and/or drilling with large bit
diameter.
If you do not replace it in time (when you used continuously under this condition), since the material on the surface is softer, the
surface will start to break up and could cause other damage to the inside of the front-head assembly.

Instruct the following action to avoid same problem to all of the customers that is working for hard rock ground.
Because we think that this kind of problem may happen with a large bit, a drilling for hard rock, and/or a long hole drilling of the
special drilling application.
"Check or replace the shank thrust (86223492) every 15,000 - 20,000 drilled meters (or 400 - 500 engine hours)."

Please be advised that the shank thrust is a consumable item and critical item to avoid severe damage of the internal
parts of drifter.

(Note: Normally the Shank Thrust will be replaced at 40,000 - 60,000 drilled meter for soft / medium heard rock.)

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 Piston Seal Failure- 5 - Damaged Piston Seal -

ƒ Symptom: Premature seal leaking (especially in hard rock application >1,800kgf/cm2)

ƒ Possible cause: Generating cavitations in Stop piston due to too much vibration by
high reflex that came from the hard rock ground.

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 Stop Piston Failure- 6 - Worn out O.D of Stop Piston -

ƒ Symptom: Seal leaking

ƒ Possible cause: Worn out

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 Rotation Motor Failure- 7 - Damaged O-rings in motor cartridge -

ƒ Symptom: Stalling rotation motor by lacking power due to internal leakage

ƒ Possible cause: Improper maintenance
Long time operation (>3,000hrs) without resealing in the motor housing

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 Rotation Motor Failure- 8 - Scratched Rotor and Side Plate -

ƒ Symptom: Scratched Rotor and Side Plate

ƒ Possible cause: Deforming side plate while drilling for large hole (>4.0 inch)
Too high rotation torque (V4 setting, large hole, long hole…)

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 Rotation Motor Failure- 9 - Crack of Rotation Motor Housing -

ƒ Symptom: Crack of Rotation Motor Housing (@over 6,500hrs)

ƒ Possible cause: Damaged thread of cover due to over torque.
Seizing of the thread of cover when reassembly.

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 Rotation Motor Failure- 10 - Worn out drive shaft spline -

ƒ Symptom: Worn out drive shaft spline

ƒ Possible cause: Too high rotation torque (V4 setting, large hole, long hole…)

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 Accumulator Failure- 11 - Damaged Accumulator Diaphragm -

ƒ Symptom: LP: Excessive return hose vibration

HP: Drill pressure drop
ƒ Possible cause: Fitted without silicone grease inside of the diaphragm.

Others:
Symptom A:
Center area of inner face (gas side) of high-
pressure diaphragm damaged.
Probable cause:
Nitrogen gas leakage by damaged seal
washer due to rough handling of charge valve.

Symptom B:
A mid-area of outer face (oil side) of high-
pressure diaphragm damaged.
Probable cause:
Long time drilling with minimum percussion
pressure.
Too high pressure of a nitrogen gas was
charged.

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 Accumulator Failure- 11a - Damaged Accumulator Diaphragm -

ƒ Symptom: LP: Excessive return hose vibration

HP: Drill pressure drop
ƒ How to find the accumulator diaphragm condition without open the accumulator:

Accumulator condition Engine Speed Rotation Pressure (Mpa) Percussion pressure (Mpa)

LP HP HP at Blank Firing at Blank Firing

X O O Max. 9 to 13 9 to 12

X X O Max. 9 to 13.5 9 to 12

X X X Max. 8.5 to 13.5 8 to 12

O O O Max. 10 to 13 10 to 12

Note:
From this test, we found that there is tendency for the swing of the pressure gage that it
becomes bigger 1Mpa to 2 Mpa than normal when the diaphragm was damaged.
* V2 setting was 12Mpa at the time of this test

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 Accumulator body Failure- 12 - Cracked Accumulator Body -

ƒ Symptom: Heavily hydraulic oil leakage from front head

ƒ Possible cause: Long time operation with damaged HP accumulator diaphragm

15
 Accumulator body Failure- 13 - Cracked Accumulator Body -

ƒ Symptom: Removed accumulator cover due to broken body

ƒ Possible cause:
- Long time operation with damaged HP accumulator diaphragm
- Tightening to excessive of the cover of accumulator;
- Seizing of the thread of cover when reassembly of the accumulator.
- Over pressure in the accumulator who damage the thread.
- Impact to untighten the cover with hammer;

Information:

To eliminate this type of problem,

Montabert has done a modification by
increasing the thickness of the body
of the accumulator.

The modification have been

implemented in February 2005 and
the forging have been changed;
Since November 2005 all the new
parts have been produce with this
new forging.

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 Bronze Nut Failure- 14 - Broken Bronze Chuck Bushing -

ƒ Symptom: Broken Bronze Chuck Bushing

ƒ Possible cause: Lack of lubrication,
Too high rotation torque (V4 setting, large hole, long hole…)
Too much RP operation for long time

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 Stop Piston Failure- 15 - Galling Stop piston -
ƒ Symptom: Galling stop piston and strike piston
ƒ Possible cause: Loosening / Broken of Through bolt
and / or Too low rotation torque & pressure (V4 setting, small hole, single pass)
ƒ Recommended solution: increasing the drifter RPM
ƒ - increasing the feed force
ƒ - increasing the bit diameter
ƒ - changing the bit shape (turn to ballistic)
ƒ - change the rotation cartridge (try a 55 instead of 67) :

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 Stop Piston Failure- 15 - Galling Stop piston -
ƒ Symptom: Galling stop piston and strike piston
ƒ Possible cause: Loosening / Broken of Through bolt
and / or Too low rotation torque & pressure (V4 setting, small hole, single pass)
ƒ Recommended solution: increasing the drifter RPM
ƒ - increasing the feed force
ƒ - increasing the bit diameter
ƒ - changing the bit shape (turn to ballistic)
ƒ - change the rotation cartridge (try a 55 instead of 67) :

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 Slider Failure- 17 - Broken Slider -
ƒ Symptom: Broken Slider (over eng 6,000hrs)
ƒ Possible cause: Metal fatigue of slider
ƒ Recommended solution: You may be better to exchange sliders by 6,000 hrs.

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 Air Check Valve Failure- Others
ƒ Symptom: Erratic motion of Drifter, drifter won’t move to forward
ƒ Possible cause: Worn out internal part of check valve

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