What is included in a drill rig 500-hour service?

A 500-hour drill rig service is an intermediate service that carries forward all 250-hour tasks (engine oil and filter, grease points, drill head inspection, safety interlock tests) and adds fuel filter replacement, air filter replacement, hydraulic return filter replacement, drill head gearbox oil change, compressor oil change (if on-board compressor), mast cylinder inspection (seals and rod condition), winch wire rope check (if fitted), water pump service (injection system), dust collector filter replacement, full electrical check (wiring, sensors, pressure switches), hydraulic oil sampling for analysis, drill rod thread measurement, mast alignment check and centraliser/guide bush inspection. It takes approximately 4 to 6 hours.

What additional items does a 500-hour drill rig service include compared to a 250-hour service?

Beyond the 250-hour service, the 500-hour interval adds: replacing the fuel filter, air filter and hydraulic return filter, changing drill head gearbox oil, changing compressor oil (if on-board), inspecting mast cylinders for seal leaks and rod condition, checking winch wire rope (if fitted), servicing the water pump/injection system, replacing the dust collector filter, performing a full electrical check (wiring, sensors, pressure switches), taking a hydraulic oil sample for laboratory analysis, measuring drill rod thread wear, checking mast alignment and inspecting centraliser/guide bushes.

Why is drill rod thread measurement important at 500 hours?

Drill rod threads are subject to high torque loads and cyclic stress during drilling operations. Measuring thread wear at the 500-hour interval quantifies how much material has been lost and whether the rod is approaching rejection limits. Worn threads can lead to rod separation during drilling, which can result in lost rods down the hole (an extremely costly event), drill string failure or safety incidents. Regular measurement establishes a wear trend that helps predict replacement timing.

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Yes. Download and use the drill rig 500-hour service procedure for free. Open the file and use your browser's Print, then Save as PDF. No MapTrack account required. If you later want digital service procedures linked to each rig with scheduling by hours, cost tracking and alerts, we would be happy to show you MapTrack.

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Free drill rig 500-hour service checklist

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A step-by-step 500-hour (intermediate) service procedure for hydraulic drill rigs, tracked or wheeled. This service carries forward all 250-hour tasks and adds filter replacements, drill head gearbox oil change, compressor oil change, mast cylinder inspection, winch wire rope check, water pump service, dust collector filter replacement, full electrical check, hydraulic oil sampling, drill rod thread measurement, mast alignment check and centraliser/guide bush inspection. Includes fluid specifications, parts list and technician sign-off. This page explains what the service involves, how to perform it, and offers a free PDF-ready form you can download straight away.

Last updated: 2026-03-26 · MapTrack

Jarrod Milford

Commercial Director

Updated 26 March 2026

How to use: Complete the 250-hour service first, then work through these additional 500-hour items. Tick Done as each task is completed. Record measurements and part numbers used. Set the next service due hours and sign off.

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What is a drill rig 500-hour service?

A 500-hour service is the second tier of scheduled preventive maintenance for a hydraulic drill rig (tracked or wheeled). It is performed every 500 engine hours and is classified as an intermediate service. The procedure carries forward all 250-hour tasks and adds filter replacements (fuel, air, hydraulic return), drill head gearbox oil change, compressor oil change, mast cylinder inspection, winch wire rope check, water pump service, dust collector filter replacement, full electrical check, hydraulic oil sampling for laboratory analysis, drill rod thread measurement, mast alignment check and centraliser/guide bush inspection. It is performed by a qualified mechanic or drill rig technician.

Benefits of scheduled drill rig servicing

Drill head protection: changing gearbox oil at the 500-hour interval removes wear metals and maintains proper lubrication of gears and bearings, extending drill head life.
Rod thread safety: measuring drill rod threads at the 500-hour interval catches wear before threads strip under load, preventing lost rods down the hole.
Hydraulic system health: oil sampling detects contamination, wear metals and moisture before they damage the high-pressure drill circuit pumps and valves.
Dust compliance: replacing the dust collector filter at 500 hours ensures the system meets workplace exposure limits for respirable crystalline silica.
Compressor reliability: changing compressor oil prevents overheating and bearing failure, which would halt drilling operations until repaired.
Reduced downtime: catching mast cylinder seal leaks, worn centralisers or electrical faults at the 500-hour interval prevents unplanned failures during production drilling.

Benefits of digitising forms in MapTrack

When you move from paper or static PDFs to digital forms 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.
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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).

Book a demo to see digital service procedures and hour-based scheduling in MapTrack.

Service actions included in the 500-hour procedure

This service includes all 250-hour tasks plus 14 additional service actions across 8 system areas:

Engine (additional): replace fuel filter, replace air filter.
Hydraulic system (additional): replace hydraulic return filter, take hydraulic oil sample for analysis.
Drill head and gearbox (additional): change drill head gearbox oil, measure drill rod thread wear.
Compressor (additional): change compressor oil (if on-board compressor).
Mast and cylinders (additional): inspect mast cylinders (seals, rod condition), check mast alignment, inspect centraliser/guide bushes.
Winch (additional): check winch wire rope condition (if fitted).
Water injection and dust collection (additional): service water pump (injection system), replace dust collector filter.
Electrical (additional): full electrical check (wiring, sensors, pressure switches).

Fluid specifications

General fluid specifications for hydraulic drill rigs (tracked and wheeled). Capacities vary by rig size and manufacturer.

System	Type / Grade	Approx. Capacity
Engine oil	15W-40 CI-4 / CK-4	15 - 25 L
Hydraulic oil	ISO VG 46 (AW 46)	100 - 200 L (system)
Coolant	50/50 ethylene glycol	20 - 30 L
Drill head gearbox oil	Per manufacturer specification	Varies
Compressor oil	Per manufacturer (if on-board)	Varies
Grease	EP2 lithium complex	As required

Specifications are general guidelines. Always refer to the manufacturer's service manual for your specific make and model.

Parts and consumables

Have the following parts and consumables ready before starting the 500-hour service (includes 250-hour items):

Engine oil (15W-40 CI-4/CK-4) - 15-25 litres
Engine oil filter - 1
Fuel filter element - 1
Air filter element - 1
Hydraulic return filter - 1
Drill head gearbox oil - as required
Compressor oil - as required
Dust collector filter - 1
Fuel/water separator element - 1
EP2 grease cartridges - 2-4
Oil sample bottle (hydraulic) - 1
Coolant (pre-mixed or concentrate) - as required
Rags, drip tray and waste oil container

Look up part numbers in the manufacturer's parts manual for your specific make and model before ordering.

How to perform a drill rig 500-hour service

Complete the full 250-hour service procedure first. All 250-hour tasks carry forward to the 500-hour interval.
Replace the fuel filter, air filter and hydraulic return filter.
Drain and replace the drill head gearbox oil per the manufacturer's specification. If the rig has an on-board compressor, drain and replace the compressor oil.
Inspect mast cylinders for seal leaks and rod condition. Check mast alignment. Inspect centraliser/guide bushes for wear.
Check winch wire rope condition if the rig is fitted with a winch. Service the water pump (injection system).
Replace the dust collector filter. Perform a full electrical check covering wiring, sensors and pressure switches.
Take a hydraulic oil sample from the designated sampling port. Label the bottle with the rig ID, hours and date. Send to the laboratory for analysis.
Measure drill rod thread wear using a thread gauge or calliper. Record measurements and compare against rejection limits.
Record all measurements, defects and recommendations in the notes section. Set the next service due hours (next 500-hour and next 1,000-hour intervals). Sign off and update the rig's maintenance log.

In MapTrack, you can schedule services based on hour meter readings, get automatic reminders, complete service procedures on mobile and link every record to the rig. Book a demo to see how.

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Drill rig service interval hierarchy

Drill rig maintenance follows a tiered schedule where each level includes all tasks from the level below. This is called carry-forward or cumulative servicing.

250 hours - Minor service

Engine oil and filter, grease points, drill head inspection, safety interlock tests. Estimated 2-3 hours.

500 hours - Intermediate service (you are here)

All 250-hour tasks plus filter replacements, drill head gearbox oil change, compressor oil, mast cylinder inspection, dust collector filter replacement and hydraulic oil sampling. Estimated 4-6 hours.

1,000 hours - Major service

All 500-hour tasks plus hydraulic oil change, coolant flush, full compressor overhaul and structural NDT. Estimated 8-12 hours.

2,000 hours - Overhaul service

All 1,000-hour tasks plus drill head rebuild assessment, mast structural inspection, hydraulic pump and motor inspection. Typically 2-3 days.

In MapTrack, you can configure service schedules by engine hours and receive automatic alerts when each interval is due.

Frequently asked questions

What is included in a drill rig 500-hour service?: A 500-hour drill rig service is an intermediate service that carries forward all 250-hour tasks (engine oil and filter, grease points, drill head inspection, safety interlock tests) and adds fuel filter replacement, air filter replacement, hydraulic return filter replacement, drill head gearbox oil change, compressor oil change (if on-board compressor), mast cylinder inspection (seals and rod condition), winch wire rope check (if fitted), water pump service (injection system), dust collector filter replacement, full electrical check (wiring, sensors, pressure switches), hydraulic oil sampling for analysis, drill rod thread measurement, mast alignment check and centraliser/guide bush inspection. It takes approximately 4 to 6 hours.
What additional items does a 500-hour drill rig service include compared to a 250-hour service?: Beyond the 250-hour service, the 500-hour interval adds: replacing the fuel filter, air filter and hydraulic return filter, changing drill head gearbox oil, changing compressor oil (if on-board), inspecting mast cylinders for seal leaks and rod condition, checking winch wire rope (if fitted), servicing the water pump/injection system, replacing the dust collector filter, performing a full electrical check (wiring, sensors, pressure switches), taking a hydraulic oil sample for laboratory analysis, measuring drill rod thread wear, checking mast alignment and inspecting centraliser/guide bushes.
Why is drill rod thread measurement important at 500 hours?: Drill rod threads are subject to high torque loads and cyclic stress during drilling operations. Measuring thread wear at the 500-hour interval quantifies how much material has been lost and whether the rod is approaching rejection limits. Worn threads can lead to rod separation during drilling, which can result in lost rods down the hole (an extremely costly event), drill string failure or safety incidents. Regular measurement establishes a wear trend that helps predict replacement timing.
Is the template free to use without MapTrack?: Yes. Download and use the drill rig 500-hour service procedure for free. Open the file and use your browser's Print, then Save as PDF. No MapTrack account required. If you later want digital service procedures linked to each rig with scheduling by hours, cost tracking and alerts, we would be happy to show you MapTrack.

Need digital service procedures scheduled by engine hours?

Register every drill rig in MapTrack. Set up 250, 500 and 1,000-hour service schedules, complete procedures on mobile, track parts and costs, and get automatic alerts when the next service is due.

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