How to Extend Rock Drill Machine Life

A hydraulic rock drill represents a significant capital investment, and maximizing its service life is a key objective for any mining or construction operation. The good news is that with the right maintenance practices, it is entirely possible to extend the working life of a rock drill well beyond the average, reducing the total cost of ownership and improving the return on your equipment investment.

This article covers the most effective strategies for extending rock drill machine life, drawing on practical experience from mining operations around the world and the technical knowledge of our team at Forcedrill.

Follow the Manufacturer's Maintenance Schedule

This might seem obvious, but it is worth emphasizing: the single most effective thing you can do to extend the life of a rock drill is to follow the manufacturer's recommended maintenance schedule. These schedules are developed based on extensive testing and field experience, and they specify exactly which components should be inspected and replaced at each service interval.

Many operations fall into the trap of deferring maintenance when machines are running well, reasoning that if it is not broken, there is no need to fix it. This approach almost always results in higher long-term costs, as deferred maintenance allows minor wear to progress to the point where it causes secondary damage to other components.

Service Interval Tracking

Implement a system for tracking operating hours on each machine and scheduling maintenance accordingly. This can be as simple as a spreadsheet or as sophisticated as a computerized maintenance management system (CMMS). The key is consistency — every machine should have a documented service history, and upcoming service intervals should be planned in advance.

Use Quality Hydraulic Oil and Change It Regularly

Hydraulic oil is the lifeblood of a hydraulic rock drill. It transmits power, lubricates internal components, and carries heat away from the machine. Using the wrong grade of oil or allowing oil to become contaminated or degraded is one of the most common causes of premature component wear.

Always use the hydraulic oil grade specified by the manufacturer for your specific machine and operating conditions. In cold climates, a lower-viscosity oil may be required to ensure adequate flow at startup. In hot conditions, a higher-viscosity oil may be needed to maintain adequate film thickness.

Oil Analysis Programs

Regular oil analysis is a cost-effective way to monitor the condition of hydraulic oil and detect early signs of internal component wear. Oil analysis can identify contamination, degradation of the oil's additive package, and the presence of wear metals that indicate which components are wearing. Many mining operations use oil analysis as a standard part of their maintenance program.

Maintain Proper Hydraulic Pressure and Flow

Operating a rock drill outside its specified hydraulic pressure and flow range is a common cause of premature wear and failure. Too little pressure results in reduced percussion energy and increased wear on the percussion mechanism. Too much pressure can cause seal failures and structural damage to hydraulic components.

Check hydraulic pressure and flow settings at every service interval and adjust as needed to maintain the manufacturer's specified operating parameters. If the machine consistently requires pressure adjustments, investigate the root cause — it may indicate wear in the hydraulic pump or control valves.

Protect Against Contamination

Contamination of the hydraulic system is a major cause of premature component wear. Abrasive particles in the hydraulic oil act like sandpaper on precision-machined surfaces, accelerating wear on pistons, cylinders, valves, and bearings. Water contamination can cause corrosion and reduce the lubricating properties of the oil.

• Always use clean containers and funnels when adding hydraulic oil
• Replace hydraulic filters at the specified intervals
• Inspect and replace breather filters regularly
• Check for water contamination in the oil at every service
• Keep hydraulic connections clean when disconnecting and reconnecting hoses

Train Your Operators

Operator technique has a significant impact on rock drill wear and service life. Operators who understand how the machine works and use it correctly will get much longer service life from their equipment than those who do not.

Key Operator Practices

Train operators to avoid collaring at full percussion pressure, as this can cause shock loading on the front head components. Teach them to recognize the signs of a stuck drill string and respond correctly to avoid damage to the rotation motor. Emphasize the importance of maintaining adequate flushing water flow to prevent bit wear and hole deviation.

Operators should also be trained to report any unusual sounds, vibrations, or performance changes immediately. Early detection of developing problems is one of the most effective ways to prevent minor issues from becoming major failures.

Use the Right Drill String Components

The drill string — rods, couplings, and bits — has a direct impact on the wear of the drifter. Using worn or damaged drill string components transfers abnormal loads to the drifter, accelerating wear on the shank adapter, chuck, and front head.

Inspect drill rods and couplings regularly for wear, cracks, and thread damage. Replace worn components promptly. Using the correct rod length and coupling type for your specific application also helps to optimize energy transfer and reduce wear on the drifter.

Source Quality Spare Parts

When replacement parts are needed, always source quality components from reputable suppliers. Using inferior parts may save money in the short term but will result in shorter service intervals and potentially cause damage to other components.

Forcedrill supplies quality spare parts for all major rock drill brands, including Epiroc / Atlas Copco, Sandvik Tamrock, Furukawa, Montabert, and Ingersoll Rand. Our parts are manufactured to OEM specifications and backed by our quality assurance process.

For more information about our spare parts range or to discuss your maintenance requirements, please visit our contact page. Our technical team is available to provide guidance on maintenance best practices and part selection.