Major service - drill rigs (all makes and configurations)
Estimated duration: 8 - 12 hours • Frequency: every 1,000 engine hours
Equipment Details
| # | Service Action | Type | Done | Notes |
|---|---|---|---|---|
| Engine (carry forward 250-hr and 500-hr tasks) | ||||
| 1 | Drain and replace engine oil (15W-40) | DRAIN/FILL | ☐ | |
| 2 | Replace engine oil filter | REPLACE | ☐ | |
| 3 | Replace primary and secondary fuel filters | REPLACE | ☐ | |
| 4 | Replace outer and inner air filter elements | REPLACE | ☐ | |
| 5 | Flush and replace engine coolant (50/50 mix) | FLUSH/FILL | ☐ | |
| 6 | Inspect and adjust valve clearance | ADJUST | ☐ | |
| 7 | Inspect turbocharger for play, leaks and condition | INSPECT | ☐ | |
| 8 | Check injectors and injection timing | CHECK | ☐ | |
| Hydraulic System | ||||
| 9 | Take hydraulic oil sample from return line (before draining) | SAMPLE | ☐ | |
| 10 | Drain and replace all hydraulic oil | DRAIN/FILL | ☐ | |
| 11 | Replace hydraulic return filter | REPLACE | ☐ | |
| 12 | Replace hydraulic pilot filter | REPLACE | ☐ | |
| 13 | Replace high-pressure filters | REPLACE | ☐ | |
| 14 | Replace suction strainers | REPLACE | ☐ | |
| 15 | Inspect all hydraulic hoses and fittings for leaks | INSPECT | ☐ | |
| Compressor System | ||||
| 16 | Rebuild or replace compressor element / valve assembly | REBUILD | ☐ | |
| 17 | Replace compressor oil and separator element | REPLACE | ☐ | |
| 18 | Test safety relief valve at set pressure | TEST | ☐ | |
| 19 | Check air receiver certification expiry date | CHECK | ☐ | |
| Drill Head and Gearbox | ||||
| 20 | Drain and replace gearbox oil | DRAIN/FILL | ☐ | |
| 21 | Inspect drain plug magnet for metal particles | INSPECT | ☐ | |
| 22 | Inspect gear teeth and bearings through inspection port | INSPECT | ☐ | |
| 23 | Check output shaft seals for leaks | CHECK | ☐ | |
| 24 | Measure gear backlash and compare to specification | MEASURE | ☐ | |
| Mast and Structural | ||||
| 25 | Inspect mast sections, pins and welds for cracks | INSPECT | ☐ | |
| 26 | Dye penetrant test on critical welds (if specified) | TEST | ☐ | |
| 27 | Inspect guy wires or hydraulic mast cylinders | INSPECT | ☐ | |
| 28 | Check mast alignment when raised | CHECK | ☐ | |
| 29 | Inspect ROPS/FOPS structure and mounting bolts | INSPECT | ☐ | |
| Winch and Rope | ||||
| 30 | Inspect winch rope for broken wires, kinks, corrosion | INSPECT | ☐ | |
| 31 | Check sheave grooves for wear and alignment | CHECK | ☐ | |
| 32 | Test winch brake holding capacity | TEST | ☐ | |
| 33 | Test winch clutch engagement | TEST | ☐ | |
| Electrical | ||||
| 34 | Load test batteries (CCA) | TEST | ☐ | |
| 35 | Test alternator output voltage and current | TEST | ☐ | |
| 36 | Clean and tighten all earth straps | CLEAN | ☐ | |
| 37 | Test all emergency stop buttons | TEST | ☐ | |
| 38 | Test safety interlocks (mast lock, drill head guard, rod handler) | TEST | ☐ | |
| Lubrication | ||||
| 39 | Grease all mast pins and pivot points | GREASE | ☐ | |
| 40 | Grease rotary table bearings | GREASE | ☐ | |
| 41 | Grease track/wheel drive points | GREASE | ☐ | |
| Final Checks | ||||
| 42 | Start engine, check for leaks and warning lights | CHECK | ☐ | |
| 43 | Cycle all functions: drill head, mast, winch, compressor, drive | TEST | ☐ | |
| 44 | Walk-around leak check at operating temperature | INSPECT | ☐ | |
Fluid Specifications (General Guide)
| System | Type / Grade | Approx. Capacity |
|---|---|---|
| Engine oil | 15W-40 CI-4 / CK-4 | 15 - 30 L |
| Hydraulic oil | ISO VG 46 or ISO VG 68 | 200 - 400 L |
| Engine coolant | 50/50 ethylene glycol | 30 - 60 L |
| Gearbox oil | EP 80W-90 or manufacturer spec | 5 - 15 L |
| Compressor oil | PAO or mineral (OEM spec) | 10 - 25 L |
| Grease | EP2 lithium complex | As required |
Specifications are general guidelines for typical drill rigs. Always refer to the manufacturer's service manual for your specific make and model. Capacities vary by rig size and configuration.
Parts / Consumables Required
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | Engine oil (15W-40) | 15-30 L | ☐ | |
| 2 | Hydraulic oil (ISO VG 46/68) | 200-400 L | ☐ | |
| 3 | Engine coolant concentrate | 15-30 L | ☐ | |
| 4 | Engine oil filter | 1 | ☐ | |
| 5 | Fuel filters (primary + secondary) | 2 | ☐ | |
| 6 | Air filter elements (outer + inner) | 2 | ☐ | |
| 7 | Hydraulic return filter | 1 | ☐ | |
| 8 | Hydraulic pilot filter | 1 | ☐ | |
| 9 | High-pressure filters | As req. | ☐ | |
| 10 | Compressor oil separator element | 1 | ☐ | |
| 11 | Compressor oil | 10-25 L | ☐ | |
| 12 | Gearbox oil (EP 80W-90) | 5-15 L | ☐ | |
| 13 | EP2 grease cartridges | 4-6 | ☐ | |
| 14 | Oil sample bottles and labels | 2 | ☐ | |
| 15 | Rags, drip trays, waste oil containers | - | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Supervisor / Workshop Manager