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Pre-Shift Inspection — Excavators & Skid Steers

MA 2A Hoisting License · Module 3, Session 1

OSHA Basis & Timing

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Regulatory Requirement

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Two OSHA standards together form the basis for pre-shift inspections:

  • •29 CFR 1926.20(b)(2): Employers must provide "frequent and regular" inspections of job sites, materials, and equipment by a competent person.
  • •29 CFR 1926.600(b)(1): Equipment left unattended at night must be visually inspected before use. Equipment in use must be inspected by a competent person.

    • 230 CMR 6.00 (Massachusetts regulation) requires written pre-shift inspection records for hoisting machinery, kept with the machine and available for OPSI review.

    "Competent person" for inspections: A person knowledgeable about the equipment's safe operation who can identify hazards and has the authority to take corrective action.

    When to Inspect

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    Inspect before:

  • •The first use each shift
  • •Each time the machine is relocated to a different area on the same day
  • •After any maintenance or repair

    • Inspect after:

  • •Rain, flooding, or significant weather change
  • •Any incident or near-miss involving the machine
  • •Operating in unusually harsh conditions (deep mud, rocky terrain, demo work)

    • Time required: A thorough pre-shift inspection takes 10–15 minutes. Shortcuts lead to missed defects. Research consistently shows each minute of inspection time prevents approximately 60–90 minutes of unplanned downtime — plus the human cost of an injury from an undetected defect.

    Best conditions: Inspect on level ground, engine cold, all implements lowered.

    Removal-from-Service vs. Documented Defect

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    Not all defects require immediate shutdown. Use this decision framework:

    🔴 Remove from service immediately (no exceptions):

  • •Active hydraulic leak from any hose or fitting
  • •Non-functional seat belt
  • •Damaged or modified ROPS/FOPS structure
  • •Structural crack in boom, stick, bucket mounting ears, or frame
  • •Non-functional brakes or steering
  • •Non-functional backup alarm (when rear view obstructed)
  • •Missing or discharged fire extinguisher
  • •Engine oil leak (active drip — not just residue)
  • •Track partially derailed or missing shoe(s)

    • 🟡 Document and notify supervisor (restricted operation may be permitted):

  • •Non-critical light burned out (not backup light)
  • •Wiper not functioning (clear weather only)
  • •Minor cosmetic damage with no structural concern
  • •Low but not empty fluid level (check rate of consumption)

    • ✅ Record and monitor (continue operation):

  • •Normal wear within specification (tooth wear, cutting edge wear)
  • •Fluid levels within acceptable range
  • •Fluids showing early degradation but not at change threshold

    • Step 1 — 360° Walk-Around

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    The Walk-Around Method

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    Start at a fixed reference point (e.g., front-left corner of the machine) and move consistently in one direction around the entire machine without backtracking.

    Why this method: Random spot-checks miss items. The consistent walk-around ensures every surface, component, and zone gets checked in every inspection.

    During the walk-around, check:

  • ☐Fluid puddles under the machine — location tells you the source (hydraulic, oil, coolant, fuel, DEF)
  • ☐Ground conditions — stable and level; no undermining near edges or drop-offs
  • ☐Structural integrity — visible cracks in frame welds, boom base, bucket mounting
  • ☐Guards and covers — all in place, secured, undamaged
  • ☐Fasteners — missing or visibly loose bolts, pins, retaining clips
  • ☐Hoses — visible routing; no hoses contacting moving parts, no obvious damage
  • ☐Access steps and handholds — secure and undamaged
  • ☐Lights and beacons — present and unbroken (test function later in cab)

    • Step 2 — Fluid Levels (Engine Off)

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    Fluid Inspection Checklist

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    Check all fluids with the engine OFF and the machine on level ground. Checking on a slope gives inaccurate dipstick and sight gauge readings.

  • ☐Engine oil: Pull dipstick, wipe clean, reinsert fully, pull again. Level between MIN and MAX marks. Color: should be amber to brown — not milky (coolant contamination) and not black with heavy deposits.
  • ☐Coolant: Check overflow reservoir level. Coolant should be visible in the reservoir, within the MIN-MAX marks. If the reservoir is empty, do not open the radiator cap on a warm engine — risk of steam burns. Color: check for oily sheen (head gasket failure) or unusual cloudiness.
  • ☐Hydraulic oil: Sight gauge or dipstick depending on machine. Level within operating range. Check color: amber = good; milky = water contamination; dark = oxidation; metallic sheen = internal wear.
  • ☐Fuel: Check level. Plan refueling before work begins to avoid a mid-shift stoppage.
  • ☐DEF/AdBlue (Tier 4 Final engines): Low DEF triggers engine derate (reduced power), then shutdown. Check level daily.
  • ☐Air filter restriction indicator: Most machines have a yellow/red service indicator visible without removing the filter. Service when in red zone.

    • Step 3 — Undercarriage (Excavators)

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    Undercarriage Inspection Checklist

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  • ☐Track sag: Measure at midpoint between front idler and nearest carrier roller. Compare to manufacturer spec (typically 20–30 mm for mid-size machines). Adjust with track tensioner grease fitting if outside spec.
  • ☐Sprocket teeth: Run eye or gloved hand along tooth profile (engine off). Sharp-pointed, asymmetric, or broken teeth require replacement.
  • ☐Idler wheels: Should rotate freely. Check for flat spots, bearing play (rock side-to-side — detectable looseness = bearing wear), and seal weeping (oil at the seal face).
  • ☐Track rollers (bottom): Roll the machine slightly to expose all roller surfaces. Check for flat spots, cracking, and seal leaks.
  • ☐Carrier rollers (top): Should rotate freely. Check for flat spots and seal integrity.
  • ☐Track shoes: No broken or missing grouser plates. Bolts must be tight. When bolt heads are flush with the grouser face, the shoe is worn to its service limit.
  • ☐Track chain: No broken links, pins seated flush (no migration out of bore), proper alignment on idler and sprocket.
  • ☐Mud packing: Clear any compacted mud or debris from track voids — packed mud overloads the undercarriage and affects track tension.

    • Step 4 — Boom, Stick & Bucket

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    Structural & Attachment Checklist

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  • ☐Boom base welds: Inspect the weld at the boom foot (where it attaches to the upperstructure). This is the highest-stress point. Any crack visible to the naked eye = remove from service.
  • ☐Stick welds: Check boom-tip-to-stick joint and cylinder mounting welds. Cracks at these points are removal from service.
  • ☐Pin and bushing play: Rock each joint by hand with the machine stationary. Detectable lateral movement indicates worn bushings. Audible clunking during operation confirms worn bushings.
  • ☐Bucket mounting ears: Visually inspect the pin holes and surrounding steel for cracks. Cracks at mounting ears = remove from service.
  • ☐Bucket teeth: All teeth present and locked in adapters. No cracked or broken shanks. Teeth worn beyond the indicator line need replacement before the next hard digging shift.
  • ☐Cutting edge: Even wear, no cracking, no missing sections.
  • ☐Hydraulic cylinder rods: Smooth surface — no chrome pitting, scoring, or flaking. Seals not weeping (an oily film is normal lubrication; steady drip = seal failure).
  • ☐Hydraulic hoses (boom/stick/bucket): No bulges, abrasion, kinking, or leaking fittings. Hose routing clear of moving surfaces.
  • ☐Quick coupler (if equipped): Refer to Quick Coupler inspection procedure. Verify secondary locking.

    • Steps 5–6 — Cab, Safety Devices & Startup Test

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    Cab & Safety Device Checklist

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  • ☐ROPS/FOPS: Inspect the structural members and welds. No cracks, bends, or deformation from prior impact. All mounting fasteners present and tight.
  • ☐Seat belt: Latch engages positively (firm click, does not release under tension). Webbing not frayed, cut, or worn through.
  • ☐Cab windows: No cracks that impair visibility. Front window guard in place if demolition or debris hazard exists.
  • ☐Mirrors: Clean, properly angled, not cracked. Replace cracked mirrors — distorted reflection creates blind spots.
  • ☐Wipers and washers: Operational. (May allow reduced service for dry-weather operations with supervisor approval.)
  • ☐Horn: Test — must be audible at a distance.
  • ☐Backup alarm: Test in reverse — must be audible above ambient noise. Non-functional alarm on a machine with obstructed rear view = remove from service.
  • ☐Fire extinguisher: Present in its mount, pin intact, gauge needle in green zone, accessible without removing obstacles.
  • ☐First aid kit: Present.

    • Engine Startup Test

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    After completing all pre-shift checks and addressing or documenting all findings:

  • ☐Start engine — listen during warmup. No unusual knocking, rattling, or misfiring. Smoke color: light gray/white is normal on a cold start; persistent blue smoke (oil burn) or black smoke (rich fueling) needs investigation.
  • ☐Gauge check — all must show normal within 30 seconds of startup:
  • •Oil pressure: rises within 5 seconds (very slow rise = low oil or failing pump — shut down immediately)
  • •Coolant temperature: begins rising toward normal operating range
  • •Hydraulic temperature: begins rising from ambient
  • •Fuel level: confirms what you measured in Step 2
  • ☐Warning lights: all should clear after engine stabilizes. Any persistent warning light = investigate before operating.
  • ☐Function test — slowly cycle all functions:
  • •Boom up/down
  • •Stick extend/retract
  • •Bucket curl/dump
  • •Swing left/right
  • •Travel forward/reverse

    • Listen for abnormal noises, feel for hesitation or binding, observe for unexpected drift when joystick is released.

  • ☐Quick coupler test lift (if equipped): Raise the attached tool 2–3 feet and apply sideways force. No movement at the coupler.

    • Documentation

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    230 CMR 6.00 requires written inspection records maintained with the machine and available for OPSI inspection.

    Minimum documentation:

  • •Date and time of inspection
  • •Machine ID or serial number
  • •Operator name
  • •Items inspected (or reference to inspection form)
  • •Defects found and action taken (repaired, supervisor notified, machine removed from service)
  • •Operator signature

    • Record retention: Maintain at least 12 months of inspection records. Records are required during OSHA and OPSI inspections.

    Tip: Use a standardized inspection form (paper or digital) — it ensures consistency and provides a defensible record. A blank form with "all ok" written in is not an inspection.

    Skid Steer — Additional Inspection Points

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    Skid Steer-Specific Checks

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    In addition to the general checklist above, skid steers require these additional checks:

  • ☐Scissor point guards: Inspect guards at all scissor points (where lift arms meet the machine frame). Guards must be in place and undamaged before operating.
  • ☐Lift arm pins and pivot bolts: Check the main pivot points of the lift arms for play, loose fasteners, or cracked mounting brackets.
  • ☐Attachment quick-attach plate: Clean the mounting surface. Check the locking bar or wedge for wear. Ensure the locking mechanism fully engages around both attachment pins before use.
  • ☐Tires (rubber-tired skid steers): Check pressure and condition. Uneven tire pressure causes the machine to pull to one side and increases rollover risk on slopes. Inspect for cuts, bulges, or missing tread.
  • ☐Drive chains or belt (if applicable): Some smaller skid steers use chains or belts to transfer power. Check tension and condition if accessible.
  • ☐Load capacity plate: Verify it is present and readable. If the plate is missing or unreadable, the machine must be removed from service.

    • Exam Quick-Reference

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    OSHA inspection basis: 29 CFR 1926.20 and 1926.600
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    Inspect after relocation: Yes — before resuming work at new location
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    Active hydraulic leak: Remove from service — no exceptions
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    Seat belt non-functional: Remove from service — no exceptions
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    ROPS damage: Remove from service — no exceptions
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    Discharged fire extinguisher: Remove from service
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    Track sag (mid-size excavator): 20–30 mm (0.8–1.2 in) — measure at midpoint
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    Inspection time: 10–15 minutes for thorough check
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    Record requirement: Written records, kept with machine, per 230 CMR 6.00
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    Oil pressure after startup: Must rise within 5 seconds — slow rise = shut down