Diagnosing a Hydraulic Failure in a Drill Rig – A Step-by-Step Field Guide

Hydraulic systems are the beating heart of modern drill rigs. Whether you’re using top hammer, down-the-hole (DTH), or rotary rigs, virtually every function—from mast raise to rotation and feed—is powered by high-pressure hydraulic circuits. When one of these systems fails, productivity stops cold.

Industrial & Mining Services (IMS) specializes in the diagnosis and repair of hydraulic failures in drill rigs across the Southeastern U.S. With mobile technicians, diagnostic tools, and real-world drilling experience, IMS quickly restores function and prevents repeat failures.

The Importance of Hydraulic Diagnostics in Drill Rigs

Hydraulic failures account for over 60% of unexpected drill rig downtime in mining and construction operations. Without proper diagnostics, these failures can lead to:

• Costly replacement of good parts
• Extended machine downtime
• Lost drilling footage and production delays
• Operator safety risks
• Long-term damage to pumps and motors

Common Causes of Hydraulic Failures in Drill Rigs

• Contaminated hydraulic fluid
• Overheated systems
• Damaged hydraulic hoses and fittings
• Cylinder leaks and seal failures
• Pump cavitation
• Solenoid or pilot valve failure
• Accumulator failure
• Aeration in hydraulic lines

Case Study: Drill Rig Failure in North Georgia

A quarry in North Georgia contacted IMS regarding a failing Epiroc SmartROC T40. Operators reported:

• Loss of feed pressure
• Inconsistent rotation speed
• Audible cavitation noise
• Slow mast raise
• Oil pooling near the stabilizer

Tools Used by IMS

• Infrared thermometer
• Hydraulic gauges and flow meters
• Fluid contamination sampling kit
• OEM diagnostic laptop (CANBus-compatible)
• Ultrasonic leak detector
• Mobile crimping and welding tools

Step-by-Step: Diagnosing the Hydraulic Failure

Step 1: Safety Lockout and Walkaround

Lockout/tagout was completed. Inspections revealed hot hydraulic cylinders and visible dampness at the left stabilizer.

Step 2: Fluid and Filter Check

• Fluid temp: 185°F
• Water contamination: 1%+
• Return filter failed Beta rating

Step 3: Pressure Testing Circuits

• Feed pressure: 1,800 psi (low)
• Rotation: unstable (2,000–2,400 psi)
• Pilot pressure: intermittent
• Charge pressure: unstable

Step 4: Cylinder Isolation and Rebuild

• Scored rod and damaged seal
• Rod reconditioned
• New seals installed
• Upgraded fittings used

Step 5: Valve and Electrical Diagnostics

• Tested all solenoids
• Found one sticking valve
• Replaced solenoid and re-flashed system

Step 6: System Flush and Recharge

• Flushed with filtered ISO VG 46
• Filters replaced
• Tank cleaned
• System bled and recharged

Results Summary

Metric	Before Repair	After IMS Fix
Feed Pressure	1,800 psi	2,600 psi
Rotation Stability	Unstable	Stable
Fluid Condition	Contaminated	Clean
Temperature	185°F	140°F
Repair Time	—	7.5 hours

IMS Hydraulic Services for Drill Rigs

• Onsite diagnostics
• Flow and pressure testing
• Cylinder rebuilds
• Pump and valve service
• Fluid flushing and monitoring
• Preventive maintenance plans

Drill Rigs We Service

• Epiroc (Atlas Copco)
• Sandvik
• Furukawa
• Driltech
• Schramm
• Ingersoll Rand
• Ditch Witch

Field Safety Protocols

• MSHA-certified techs
• Lockout/tagout used
• PPE and spill kits onsite
• Fire watch during welding

Targeted SEO Keywords

• drill rig hydraulic failure repair
• hydraulic diagnostics for drill rigs
• feed pressure loss in drill rig
• SmartROC T40 hydraulic issue
• mobile hydraulic service Georgia
• contaminated hydraulic oil fix
• solenoid valve troubleshooting drill
• rig rotation motor repair
• hydraulic cylinder leak detection
• field pump diagnostics drill equipment
• hydraulic system flushing for drills
• drill rig maintenance partner GA
• drill rig repair onsite georgia
• down the hole drill repair
• rotary drill hydraulic service
• Epiroc field service southeast
• drill rig downtime reduction
• high pressure hose replacement drill
• rig oil filtration system repair
• hydraulic rotation circuit fix
• preventive hydraulic service mining
• hydraulic seal rebuild drill rig
• Georgia mobile mining repair
• hydraulic pressure testing onsite
• hydraulic field repair contractor

Client Testimonial

“We were down to half production and feared we’d lose the rig for a week. IMS diagnosed the issue, rebuilt the stabilizer, replaced the solenoid, and had us back online the same day. These guys know hydraulics inside and out.”
– Drill Supervisor, Quarry Site, Georgia

Call IMS for Drill Rig Hydraulic Troubleshooting

If your rig is showing hydraulic symptoms like slow feed, inconsistent rotation, or system overheating, call IMS today. We provide onsite hydraulic diagnostics and repairs for mining and drilling operations across Georgia and the Southeast.

Contact Industrial & Mining Services to schedule a field visit or enroll in a preventive hydraulic maintenance program today.