What is included in a drill rig 250-hour service?

A 250-hour drill rig service is a minor service that includes draining and replacing engine oil (typically 15W-40), replacing the engine oil filter, inspecting the air filter, draining the fuel/water separator, checking coolant level, checking hydraulic oil level, inspecting all hydraulic hoses (especially the high-pressure drill circuit), inspecting the drill head/rotary drive for play, noise and oil level, inspecting the mast/feed system (rails, chains/cables, carriage), checking the hammer/DTH tool (if fitted) including retainer ring and bit condition, inspecting the rod handling system (carousel and clamp), greasing all pivot points (mast tilt, feed, boom if fitted), inspecting tracks or tyres, checking the dust collection system (cyclone, filter, hoses), checking battery and electrical connections, testing emergency stops and safety interlocks, and inspecting the cab and ROPS/FOPS structure. It takes approximately 2 to 3 hours.

How often should a drill rig be serviced?

Drill rigs follow a tiered service schedule based on engine hours. A 250-hour (minor) service covers oil, filters, grease, drill head inspection and basic safety checks. A 500-hour (intermediate) service adds filter replacements, drill head gearbox oil change, compressor oil change, mast cylinder inspection, dust collector filter replacement, hydraulic oil sampling and drill rod thread measurement. A 1,000-hour (major) service adds hydraulic oil change, coolant flush, full compressor overhaul and structural NDT. Daily pre-start checks are performed by the operator before each shift. Always refer to the manufacturer service manual for your specific make and model.

Why is the drill head inspection important at 250 hours?

The drill head (rotary drive) is the primary working component of a hydraulic drill rig. At the 250-hour interval, the technician checks for excessive play in the output shaft, abnormal noise during rotation, and the oil level in the gearbox. Catching early signs of bearing wear, seal failure or gear damage at this stage prevents catastrophic drill head failure that would take the rig out of service for days and cost significantly more to repair than a scheduled gearbox overhaul.

Why is the dust collection system checked at every 250-hour service?

Drilling operations generate significant quantities of respirable dust, including respirable crystalline silica in many ground types. The dust collection system (cyclone, filter, hoses) must be fully functional to protect the operator and nearby workers from harmful dust exposure. A blocked filter, disconnected hose or full collection drum can allow dust levels to exceed workplace exposure standards. Checking the system at every 250-hour service ensures it remains effective and compliant with WHS dust exposure requirements.

Is this drill rig 250-hour service checklist free to download?

Yes, this drill rig 250-hour service checklist is completely free to download as a PDF. No account or signup is required. The checklist covers engine servicing, drill head inspection, mast and feed checks, hydraulic hose inspection, dust collection verification and safety interlock testing. For teams wanting to move beyond paper forms, MapTrack offers a digital version that automates scheduling based on engine hours, sends overdue alerts and stores completed records in the cloud for instant retrieval during compliance audits.

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Free drill rig 250-hour service checklist (PDF-ready). Engine oil, drill head, mast, hydraulics, dust collection and safety interlocks. Download free.

Jarrod Milford

Commercial Director

Updated 3 May 2026

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What is a drill rig 250-hour service procedure?

A 250-hour service is the first tier of scheduled preventive maintenance for a hydraulic drill rig (tracked or wheeled). It is performed every 250 engine hours (or approximately every 4-6 weeks of full-time operation) and is classified as a minor service. The procedure covers engine oil and filter replacement, air filter inspection, fuel system maintenance, hydraulic system checks with particular attention to the high-pressure drill circuit, drill head/rotary drive inspection, mast and feed system checks, hammer/DTH tool inspection, rod handling system check, greasing all pivot points, track or tyre inspection, dust collection system check, electrical checks, emergency stop and safety interlock testing, and cab/ROPS/FOPS inspection. Unlike a daily pre-start check, the 250-hour service involves actual maintenance actions: draining and replacing fluids, replacing filters, greasing components and testing safety systems. It is typically performed by a qualified mechanic or fitter.

Drill rigs operate under extreme conditions, with high-pressure hydraulics driving the drill head through rock and soil while generating significant quantities of respirable dust, including crystalline silica in many ground types. The WHS Regulations 2011, Chapter 5, classify drill rigs as plant that must be maintained so it remains safe for use, and the Safe Work Australia Code of Practice for Managing Risks of Plant in the Workplace requires that safety interlocks and emergency stops are tested regularly. The 250-hour service provides the first line of defence against hydraulic hose burst incidents, drill head bearing failure and dust collection system degradation. Operators working on mining, quarrying and construction drill programmes accumulate engine hours rapidly, often reaching the 250-hour interval in two to three weeks during production drilling. A documented 250-hour service history is critical for demonstrating compliance with WHS obligations, supporting insurance claims and maintaining the rig's residual value when it comes time for trade-in or disposal.

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Benefits of using this drill rig 250-hour service procedure

Reduced breakdowns: regular oil, filter and fluid changes prevent engine and hydraulic failures that cause unplanned downtime on site.
Drill head longevity: checking the rotary drive for play, noise and oil level at every 250-hour service catches bearing wear and seal failure before costly gearbox damage.
Hydraulic system protection: inspecting high-pressure drill circuit hoses prevents burst hoses under drilling pressure, which can cause safety incidents and extended downtime.
Dust system compliance: checking the dust collection system at each service ensures it meets workplace exposure standards for respirable dust.
Compliance: documented service records demonstrate that equipment is maintained to WHS standards, supporting insurance and regulatory obligations.
Resale value: a complete service history with documented 250, 500 and 1,000-hour services increases the rig's value at trade-in or disposal.

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 250-hour service procedure

This drill rig 250-hour service procedure covers 8 key areas:

Engine: drain and replace engine oil (15W-40), replace oil filter, inspect air filter, drain fuel/water separator, check coolant.
Hydraulic system: check hydraulic oil level, inspect all hydraulic hoses (especially high-pressure drill circuit).
Drill head and mast: inspect drill head/rotary drive (play, noise, oil level), inspect mast/feed system (rails, chains/cables, carriage), check hammer/DTH tool (if fitted), inspect rod handling system (carousel, clamp).
Lubrication: grease all pivot points (mast tilt, feed, boom if fitted).
Undercarriage / tyres: inspect tracks or tyres for wear and damage.
Dust collection: check dust collection system (cyclone, filter, hoses).
Electrical: check battery and electrical connections.
Safety devices: test emergency stops and safety interlocks, inspect cab and ROPS/FOPS structure.

How to use this drill rig 250-hour service procedure

Position the drill rig on firm, level ground with the mast lowered, engine shut down and keys removed. Allow the engine to cool before draining oil.: Lower the mast to the transport position and ensure it is secured. Park on firm, level ground clear of the drill hole. Shut down the engine, remove the key and allow at least 15 minutes for cooling before draining oil.
Record the equipment details and current hour meter reading at the top of the service procedure form.: Capture the fleet number, make, model, rig type (top-hammer, DTH, rotary), drill head rating and the current engine hour meter reading. Compare against the previous service to confirm the correct 250-hour interval has elapsed.
Start with the engine section: drain the old engine oil, replace the oil filter, fill with new oil to the correct level, then inspect the air filter, drain the fuel/water separator and check coolant.: Use 15W-40 CI-4 or CK-4 diesel engine oil. Refill to the full mark on the dipstick. Check the air filter primary indicator and replace the element if in the red zone. Drain the fuel/water separator bowl completely. Check coolant level and visually inspect hoses.
Check hydraulic oil level. Inspect all hydraulic hoses, paying particular attention to the high-pressure drill circuit hoses for bulging, abrasion or leaks.: Check the hydraulic oil level on the sight glass with all cylinders retracted. Inspect each high-pressure hose for bulging, cover abrasion, cracking or fitting leaks. High-pressure drill circuit hoses operate at extreme pressures and a burst hose can cause serious injury. Replace any hose showing signs of deterioration.
Inspect the drill head/rotary drive: check for play in the output shaft, listen for abnormal noise, and verify the gearbox oil level. Inspect the mast/feed system (rails, chains or cables, carriage). Check the hammer/DTH tool if fitted. Inspect the rod handling system.: Grasp the drill head output shaft and check for radial and axial play. Any detectable play indicates bearing wear. Check the gearbox oil level through the level plug or sight glass. Inspect mast rails for scoring, feed chains or cables for wear and stretch, and the carriage rollers for flat spots. Check the DTH hammer retainer ring and bit condition.
Grease all pivot points: mast tilt, feed cylinders, boom (if fitted) and any other specified grease points. Inspect tracks or tyres for wear and damage.: Apply EP2 grease to every specified nipple until fresh grease purges. Cover mast tilt pins, feed cylinder mounts, boom pivots and any levelling jack pins. Inspect tracks for pad wear, bolt tightness and roller condition, or tyres for tread depth, pressure and sidewall damage.
Check the dust collection system: cyclone, filter condition and hose connections. Check the battery and electrical connections.: Inspect the cyclone for blockage and empty the collection drum. Check the dust filter element for tears or excessive dust loading. Verify all hose connections are secure and sealed. Inspect battery terminals for corrosion and check that all electrical connections are tight.
Test all emergency stops and safety interlocks. Inspect the cab and ROPS/FOPS structure.: Press each emergency stop button and confirm the engine and hydraulics shut down immediately. Test any safety interlocks (such as mast-up interlock preventing travel). Visually inspect the cab and ROPS/FOPS structure for damage, cracks or modifications. Reset all emergency stops after testing.
Start the engine and check for leaks, abnormal noises or warning lights. Record any defects or recommendations in the notes section.: Run the engine for five minutes and monitor oil pressure, coolant temperature, hydraulic temperature and charge indicators. Walk around the rig checking for fluid leaks. Briefly cycle the mast raise, feed and rotation functions to check for smooth operation. Record all defects with severity and recommended actions.
Set the next service due hours (next 250-hour and next 500-hour intervals). Sign off and update the rig's maintenance log.: Calculate the next 250-hour and 500-hour service due hours from the current reading. Update the service sticker on the rig, the maintenance log and the fleet management system. Obtain sign-off from the service technician.

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How often should you complete this service procedure?

Drill rigs should receive a 250-hour minor service every 250 engine hours, which equates to roughly every four to six weeks of full-time drilling operation. Drill rigs accumulate hours quickly during production drilling, so the interval can be reached in as little as two to three weeks on intensive programmes.

Between scheduled services, the operator must complete a daily pre-start inspection before each shift covering fluid levels, drill head condition, hose condition, dust collection, emergency stops and safety interlocks. The 500-hour intermediate service adds filter replacements, gearbox oil change, compressor oil change, hydraulic oil sampling and drill rod thread measurement. The 1,000-hour major service adds hydraulic oil change, coolant flush, full compressor overhaul and structural NDT.

Frequently asked questions

Applicable regulatory standards

This template aligns with the following regulations and standards:

AS 2294:1997 - Earth-moving Machinery - Protective Structures (ROPS and FOPS requirements)
WHS Regulations 2011, Chapter 5 - Plant and Structures (registration, inspection and maintenance of plant)
Safe Work Australia Code of Practice: Managing Risks of Plant in the Workplace (duty to maintain drill rigs and ensure safety interlocks are functional)

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