What is included in a drill rig 1000-hour service?

A 1,000-hour drill rig service is a major service that carries forward all 500-hour tasks and adds: replacing the inner air filter element, checking injectors, inspecting the turbocharger and exhaust manifold, draining and replacing the full hydraulic oil system, replacing the hydraulic suction strainer, inspecting hydraulic pumps, draining and replacing compressor oil, inspecting compressor valves and separator, flushing and replacing coolant, measuring rotary head backlash and feed chain wear, performing a detailed mast structural weld inspection, servicing the winch gearbox, inspecting wire rope, and testing all safety interlocks and emergency stops. It typically takes 8 to 14 hours.

What regulations apply to drill rig maintenance in Australia?

Drill rig maintenance must comply with the WHS Act 2011 and WHS Regulation 2017 Part 5.1, which require that plant is maintained in a safe condition with documented records. Rigs operating on mine sites must also comply with WHS (Mines) Regulations, which are state-specific (for example, NSW WHS Mines Regulations 2022). Safe Work Australia Code of Practice for Managing Risks of Plant provides further guidance. Wire rope inspection must follow AS 2759. Documented service records at each interval demonstrate compliance during mine safety audits and incident investigations.

How often should drill rig mast welds be inspected?

Mast welds should receive a visual check at each 500-hour service and a detailed structural inspection at the 1,000-hour major service. Rigs subjected to high vibration, frequent mast raising and lowering, or transport over rough terrain may need more frequent inspections. Any suspected cracks must be verified by NDT methods such as magnetic particle or dye penetrant inspection before the rig returns to service.

Should a 1000-hour drill rig service be done in a workshop or on site?

A workshop or hardstand is preferred due to the large fluid volumes (200 to 600 litres of hydraulic oil, compressor oil, coolant, winch gearbox oil), the need for specialist mast inspection and safety device testing, and better containment of waste fluids. If the rig cannot be relocated, a field service is possible with adequate containment, a service truck and access equipment for mast inspections.

What compressor maintenance is done at 1000 hours on a drill rig?

At 1,000 hours the compressor oil is fully drained and replaced, the inlet and discharge valves are inspected, the oil separator element is checked or replaced, and the aftercooler and moisture separator are inspected. Compressor oil capacity ranges from 15 to 60 litres depending on the compressor model. The minimum pressure valve operation is also verified. For DTH and RC drilling rigs, compressor reliability is critical to production.

Is this drill rig service checklist free to download?

Yes. Download and use this drill rig 1,000-hour service checklist for free. Print or Save as PDF from your browser. No MapTrack account required. For digital service records linked to your fleet register with automated scheduling and work order management, book a MapTrack demo.

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Free drill rig 1000-hour service checklist (PDF-ready). Hydraulic oil, mast, rotary head, compressor and structural inspections. Download free.

Jarrod Milford

Commercial Director

Updated 3 May 2026

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What is a drill rig 1000-hour service checklist?

A drill rig 1,000-hour service is a major scheduled preventive maintenance event performed every 1,000 engine hours, or approximately every 4 to 6 months of full-time drilling operation. It is the third tier of the cumulative service model and carries forward all 250-hour and 500-hour tasks before adding the most significant fluid replacements and structural assessments. The 1,000-hour service includes draining and replacing the full hydraulic oil system, flushing and replacing the engine coolant, replacing compressor oil (on rigs with onboard air compressors), draining and replacing winch gearbox oil, performing a detailed mast and derrick structural inspection including weld checks, measuring rotary head and feed chain wear, testing all safety interlocks and emergency stops, replacing the inner air filter element, and checking or servicing injectors. This service typically takes 8 to 14 hours depending on the rig type and configuration.

Drill rigs operate under extreme mechanical loads, vibration and dust exposure. Under the WHS Regulation 2017 Part 5.1, the WHS (Mines) Regulations and relevant state mining safety legislation, drill rig owners have an obligation to maintain plant in accordance with the manufacturer maintenance schedule and to keep documented records of all service activities. The 1,000-hour major service produces the evidence required for statutory inspections, insurance renewals and incident investigations. Neglecting this milestone allows hydraulic contamination, mast structural fatigue, rotary head wear and compressor degradation to progress unchecked, creating serious safety and productivity risks.

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Benefits of using this drill rig 1000-hour service checklist

Hydraulic system longevity: replacing the full hydraulic oil removes contamination, moisture and degraded additives that cause pump, valve and cylinder wear in the high-pressure drilling circuit.
Mast structural integrity: a detailed weld inspection at 1,000 hours detects fatigue cracking in the mast, derrick and substructure before it compromises rig stability during drilling.
Compressor reliability: replacing compressor oil and inspecting valves, separators and coolers prevents air supply failures that halt DTH (down-the-hole) or RC (reverse circulation) drilling operations.
Compliance with mining regulations: documented 1,000-hour service records satisfy WHS (Mines) Regulations and state mine safety requirements for plant maintenance.
Reduced unplanned downtime: catching rotary head wear, feed chain stretch and hydraulic pump degradation at a scheduled service prevents costly mid-programme breakdowns.
Resale and hire value: a drill rig with documented 250, 500 and 1,000-hour service records commands a higher price at sale and meets hire company compliance requirements.

Benefits of digitising forms in MapTrack

When you digitise drill rig service procedures in MapTrack, you get:

Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
Automatically get alerts when faults are identified.
Link every form digitally as a PDF to the relevant asset, location or person.
Receive a digital PDF copy with every submission to your email.
Ability to share forms digitally.
Build conditional logic (show or hide questions based on answers).
Take pictures or attach photos. Not possible with a paper-based form.
Electronic signatures.
Edit forms later without reprinting.
Restrict permissions (who can view, complete or approve).
Build forms with AI (describe what you need and MapTrack suggests the form).
Trigger work orders automatically when a fault is logged during an inspection.
Track service intervals by hours, kilometres or calendar date in one place.
Attach supplier invoices and parts receipts to each maintenance record.

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What to include in a drill rig 1000-hour service checklist

This drill rig 1000-hour service checklist covers 8 key areas:

Engine: replace inner air filter element, check or send injectors for testing, inspect turbocharger for shaft play and oil leaks, inspect exhaust manifold and gaskets.
Hydraulic system: drain and replace full hydraulic oil (ISO VG 46 or VG 68), replace hydraulic suction strainer, inspect all hydraulic pumps for noise, pressure and wear, check all high-pressure hose assemblies for age and condition.
Compressor (if fitted): drain and replace compressor oil, inspect inlet and discharge valves, check oil separator element, inspect aftercooler and moisture separator.
Rotary head and feed system: measure rotary head gearbox backlash, inspect feed chain or cable for stretch and wear, check feed motor and gearbox oil.
Cooling system: drain, flush and replace coolant (50/50 ethylene glycol), pressure test the cooling system, replace thermostat if due per manufacturer schedule.
Mast and derrick: detailed visual inspection of all mast welds, inspect mast pivot pins and bushes, check mast locking pins and safety catches, inspect guy wire attachments (if fitted).
Winch and hoisting: drain and replace winch gearbox oil, inspect wire rope per AS 2759, check brake bands and adjustment, test winch load limiting device.
Safety devices: test all emergency stops, test safety interlocks (mast raise/lower lockout, rotation lockout), verify fire suppression system (if fitted), inspect ROPS/FOPS.

How to use this drill rig 1000-hour service checklist

Complete the full 500-hour service procedure first (which includes all 250-hour tasks). Use the 500-hour service checklist as the starting point.: Verify all 250-hour and 500-hour items are completed and defects documented before starting the 1,000-hour specific tasks. This ensures the cumulative service model is properly followed and no items are missed.
Replace the inner air filter element. Check or send injectors for testing. Inspect the turbocharger for shaft play and oil leaks. Inspect the exhaust manifold and gaskets.: Handle the inner element carefully to prevent debris entering the intake manifold. Drill rigs in dusty environments may require the inner element more frequently. Inspect injector nozzles for carbon buildup. Check turbo shaft play by gripping the compressor wheel and testing for radial and axial movement.
Drain the full hydraulic oil system. Replace the hydraulic suction strainer. Refill with fresh hydraulic oil per manufacturer specification. Inspect all hydraulic pumps for abnormal noise or pressure drop.: Drill rig hydraulic systems can hold 200 to 600 litres depending on the rig size. Drain the tank, cylinders and hoses as thoroughly as possible. Clean the suction strainer housing before fitting the new element. Bleed air from the system by cycling all functions slowly at idle before applying drilling loads.
Service the onboard compressor: drain and replace compressor oil, inspect valves, check the oil separator element and inspect the aftercooler and moisture separator.: Compressor oil capacity varies from 15 to 60 litres depending on the compressor model. Use the manufacturer-specified oil grade. Check the minimum pressure valve operation. Inspect the aftercooler fins for blockage and the moisture separator drain for correct operation. Record compressor running hours separately if the rig has a dedicated compressor hour meter.
Drain, flush and replace the coolant. Pressure test the cooling system. Replace the thermostat if due. Inspect the rotary head gearbox and feed chain for wear.: Flush the cooling system until the discharge runs clear. Refill with pre-mixed 50/50 coolant. Pressure test at the radiator cap rating and hold for 10 minutes. Measure rotary head backlash and compare against the manufacturer specification. Measure feed chain pitch to check for elongation beyond the service limit.
Perform a detailed mast and derrick structural inspection. Inspect all welds, pivot pins, bushes, locking pins and safety catches.: Focus on high-stress weld areas at the mast foot, pivot points, crown block mounts and pullback cylinder attachment points. Use a strong light and magnifying glass for visual inspection. Any suspected cracks must be verified by NDT (magnetic particle or dye penetrant) before the rig returns to service. Check mast locking pins for wear and correct engagement.
Service the winch: drain and replace gearbox oil, inspect wire rope per AS 2759, check brake bands and test the load limiting device. Test all safety interlocks and emergency stops.: Inspect the wire rope for broken wires, corrosion, kinking and diameter reduction. Measure diameter at three points minimum. Test each emergency stop from every station on the rig. Verify that mast raise/lower interlocks and rotation lockouts function correctly. Check fire suppression system pressure gauges and activation circuits if fitted.
Start the engine and cycle all functions. Check for leaks, abnormal noises or warning lights. Record any defects and set the next service intervals.: Run the engine to full operating temperature. Cycle all hydraulic functions, engage the rotary head at low RPM, raise and lower the mast through a partial range (if safe to do so), and run the compressor under load. Walk around the rig checking for new fluid leaks. Record next 250, 500 and 1,000-hour service due hours.

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How often should you complete this service procedure?

A 1,000-hour major service should be performed every 1,000 engine hours, which typically equates to every 4 to 6 months of full-time drill rig operation. This service carries forward all 250-hour and 500-hour tasks. For rigs operating in highly abrasive or dusty conditions such as mineral exploration, quarry blast-hole drilling or hard-rock RC drilling, consider shortening the hydraulic oil change and compressor service intervals. Always follow the manufacturer service schedule and WHS (Mines) Regulations for your specific rig type. In MapTrack, set up meter-based maintenance schedules with automatic work order generation as each drill rig approaches its next service threshold.

Frequently asked questions

What is included in a drill rig 1000-hour service?: A 1,000-hour drill rig service is a major service that carries forward all 500-hour tasks and adds: replacing the inner air filter element, checking injectors, inspecting the turbocharger and exhaust manifold, draining and replacing the full hydraulic oil system, replacing the hydraulic suction strainer, inspecting hydraulic pumps, draining and replacing compressor oil, inspecting compressor valves and separator, flushing and replacing coolant, measuring rotary head backlash and feed chain wear, performing a detailed mast structural weld inspection, servicing the winch gearbox, inspecting wire rope, and testing all safety interlocks and emergency stops. It typically takes 8 to 14 hours.
What regulations apply to drill rig maintenance in Australia?: Drill rig maintenance must comply with the WHS Act 2011 and WHS Regulation 2017 Part 5.1, which require that plant is maintained in a safe condition with documented records. Rigs operating on mine sites must also comply with WHS (Mines) Regulations, which are state-specific (for example, NSW WHS Mines Regulations 2022). Safe Work Australia Code of Practice for Managing Risks of Plant provides further guidance. Wire rope inspection must follow AS 2759. Documented service records at each interval demonstrate compliance during mine safety audits and incident investigations.
How often should drill rig mast welds be inspected?: Mast welds should receive a visual check at each 500-hour service and a detailed structural inspection at the 1,000-hour major service. Rigs subjected to high vibration, frequent mast raising and lowering, or transport over rough terrain may need more frequent inspections. Any suspected cracks must be verified by NDT methods such as magnetic particle or dye penetrant inspection before the rig returns to service.
Should a 1000-hour drill rig service be done in a workshop or on site?: A workshop or hardstand is preferred due to the large fluid volumes (200 to 600 litres of hydraulic oil, compressor oil, coolant, winch gearbox oil), the need for specialist mast inspection and safety device testing, and better containment of waste fluids. If the rig cannot be relocated, a field service is possible with adequate containment, a service truck and access equipment for mast inspections.
What compressor maintenance is done at 1000 hours on a drill rig?: At 1,000 hours the compressor oil is fully drained and replaced, the inlet and discharge valves are inspected, the oil separator element is checked or replaced, and the aftercooler and moisture separator are inspected. Compressor oil capacity ranges from 15 to 60 litres depending on the compressor model. The minimum pressure valve operation is also verified. For DTH and RC drilling rigs, compressor reliability is critical to production.
Is this drill rig service checklist free to download?: Yes. Download and use this drill rig 1,000-hour service checklist for free. Print or Save as PDF from your browser. No MapTrack account required. For digital service records linked to your fleet register with automated scheduling and work order management, book a MapTrack demo.

Applicable regulatory standards

This template aligns with the following regulations and standards:

WHS Regulation 2017 Part 5.1 (Management of Risks of Plant in the Workplace)
WHS (Mines) Regulations (state-specific, e.g. NSW WHS Mines Regulations 2022)
Safe Work Australia CoP: Managing Risks of Plant in the Workplace
AS 2759 (Steel Wire Rope, Use, Operation and Maintenance)
WHS Act 2011 (General duty of care)
WHS Regulations 2011, Chapter 5 - Plant and Structures

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