How do you check an excavator before starting work? Daily inspections explained

As a professional excavator operator in New Zealand, performing thorough pre-start checks isn’t just good practice—it’s a legal requirement under the Health and Safety at Work Act 2015. These daily inspections help prevent accidents, extend machine life, and ensure you’re meeting your responsibilities as an operator.

Let’s break down the essential checks you need to perform before starting your workday, explained in a way that makes sense for both new and experienced operators.

Walk Around Visual Inspection

Think of your initial walkaround like checking your car before a long journey, but with more attention to detail. Start at one point (usually the cab) and work your way around systematically. Look for anything obviously wrong – damaged parts, fluid leaks underneath, or structural issues. According to WorkSafe New Zealand guidelines, paying special attention to the excavator’s tracks or wheels, boom, and attachments is crucial.

During your walk-around, inspect the machine’s exterior for any signs of damage or wear that might have occurred since your last shift. Check for loose bolts, cracked welds, or damaged hydraulic hoses. These issues might seem minor, but they can lead to serious accidents if left unattended.

Under the Hood Checks

Just as you check the oil in your car, your excavator needs similar attention. Check all fluid levels, including engine oil, hydraulic oil, coolant, and fuel. Low fluid levels can lead to component failure and potentially dangerous situations.

The engine compartment inspection should include:

• Engine oil level (when cold and on level ground)
• Coolant level in the radiator
• Hydraulic oil level in the sight glass
• Battery condition and connections
• Fan belt tension and condition
• Air filter condition
• Signs of fluid leaks or damage to hoses

Look for any signs of animals that might have made homes in the engine bay overnight; this is particularly important in rural New Zealand, where possums and other wildlife can cause damage to wiring and hoses.

Cab Interior Safety Checks

Imagine getting into your car and finding the seatbelt doesn’t work—that’s not just inconvenient, it’s dangerous. The same applies to your excavator cab, but with more safety features to check. Ensure all controls move freely, gauges work, and safety devices are functional.

In the cab, verify:

• Seatbelt functionality and condition
• All controls return to neutral position when released
• Emergency stops work properly
• Windows are clean, undamaged, and provide clear visibility
• Mirrors are correctly adjusted and secure
• Radio communications equipment (if fitted)
• Horn and other warning devices
• Air conditioning and heating systems
• Windscreen wipers and washers
• A fire extinguisher is present and in date
• The first aid kit is complete and accessible

Attachments and Working Equipment

Checking attachments is particularly important. Think of attachments like tools in your toolbox—you wouldn’t use a damaged hammer, so why use a damaged bucket?

Take extra time to inspect:

• Quick hitch mechanisms (if fitted)—these require special attention
• Bucket teeth and wear patterns
• Hydraulic connections and hose condition
• Safety pins and locks
• Boom and dipper arm condition
• All pivot points and bushings
• Grease points and lubrication levels

Track or Wheel Condition

For tracked excavators, proper track tension is crucial. Think of it like bicycle chain tension—too loose and it could come off, too tight and it causes excess wear. According to industry standards, track sag should typically be between 20 and 30 mm, but always check your manufacturer’s specifications.

Pay attention to:

• Track tension and adjustment
• Sprockets and idler wheels
• Track pad condition
• Drive motors and final drives
• Signs of excessive wear or damage

Documentation and Communication

Before starting work, ensure you have:

• Current operator certification
• Site safety documentation
• Emergency contact information
• Knowledge of site hazards and underground services
• Current site maps and service plans
• Required permits and authorisations
• Communication protocols established

Hazard Identification

WorkSafe requires operators to identify and manage workplace hazards. Look for:

• Overhead power lines (maintain minimum approach distances as per guidelines – typically 4 metres, unless they are high voltage lines)
• Underground services (check before you dig using approved locating methods)
• Ground conditions and stability
• Other workers or public areas
• Weather conditions that might affect operation
• Traffic management requirements
• Environmental hazards and protection measures

Testing and Warming Up

Once visual inspections are complete, start the machine and:

• Check all warning lights and gauges function correctly
• Listen for unusual noises that might indicate problems
• Test all movements at low speed, including full range of motion
• Allow proper warm-up time (especially important in cold weather)
• Check emergency stop functionality
• Verify all operating speeds and functions are normal
• Test tracking in both directions
• Check slew function and brakes.

Why These Checks Matter

Consider this: WorkSafe New Zealand reports that a significant number of excavator-related incidents could have been prevented with proper pre-start checks. Just as you wouldn’t start a long journey in your car without checking it’s roadworthy, you shouldn’t operate an excavator without ensuring it’s safe and fully functional.

Documentation

Keep a record of your checks using a pre-start checklist. This isn’t just paperwork; it’s legal protection and evidence that you’re meeting your obligations under New Zealand health and safety laws. Many companies now use digital forms for this purpose, which can provide instant reporting and tracking of issues.

When to Seek Help

If you find any issues during your inspection, don’t try to be a hero and fix everything yourself. Some problems require qualified maintenance personnel. Operators should only carry out maintenance they’re trained and authorised to perform.

Remember, these pre-start checks aren’t just a box-ticking exercise; they’re about ensuring everyone goes home safe at the end of the day. By following these guidelines and maintaining good inspection habits, you’re not just protecting yourself but also your workmates and your machinery.

A thorough pre-start check might take 15-20 minutes of your day, but it could save lives, prevent expensive repairs, and keep you operating safely and efficiently.

By making these checks part of your daily routine, you’re demonstrating professionalism and commitment to safety that New Zealand employers value. Remember, in the excavator operator’s world, there’s no such thing as being too careful when it comes to safety checks.