Common Mistakes When Operating Compact Machinery and How to Avoid Them
Compact machinery, such as mini excavators, skid steers, or dumpers, has become an essential ally for all types of construction and urban work. However, improper use can lead to costly breakdowns, accidents, or loss of productivity. Today we review the most frequent mistakes when operating this type of equipment… and how to prevent them!
1. Not Reading the Manual or Receiving Proper Training
Mistake: Many operators rely on their previous experience and skip reading the user manual or receiving specific training for the equipment they’re going to use. This may seem like a shortcut, but every compact machine model has its own features, functions, and limitations that can go unnoticed if the manufacturer’s instructions are not reviewed carefully.
Why does this happen?
Daily pressure to move the job forward or the belief that “all machines are handled the same” leads to underestimating the importance of training. However, small differences in controls, the hydraulic system, or safety protocols can significantly impact performance and safety.
Real example:
An experienced operator may be used to a certain type of skid steer, but if they use a different model without reviewing the manual, they could activate unexpected automatic functions, damage the equipment, or put themselves and others at risk.
Solution:
Before operating any new machine, take time to review the user manual. Pay attention to warnings, control instructions, basic maintenance, and load limits. Attend training sessions offered by the manufacturer or dealer, even if you already have experience.
2. Ignoring Pre-Operation Inspections
Error:
Getting on the machine without performing a prior inspection of critical components such as oil, fuel, the hydraulic system, tires or tracks, and without checking for possible leaks or damage. This oversight is much more common than it seems and usually happens due to rushing or falling into the routine of daily work.
Why does this error occur?
Operators often assume that the machine will function perfectly “just like yesterday” and skip those essential minutes of visual inspection. However, wear, small impacts, vibration, and temperature changes can cause unexpected issues from one day to the next, even in new equipment.
Real example:
A worker starts their day without checking the hydraulic oil level, and halfway through the job the machine suffers a serious breakdown due to lack of lubrication. Likewise, a small undetected fuel leak can quickly become a fire hazard or an environmental problem.
Solution:
Perform a complete visual inspection before starting the machine each day.
Check oil and fuel levels.
Inspect the hydraulic system: look for loose or damaged hoses and oil stains.
Check tires or tracks for cuts, excessive wear, or improper pressure.
Look for leaks or drips under the equipment and around its components.
Ensure that all controls and safety systems are functioning correctly.
Always keep a simple log (a daily checklist works) to record any anomalies. A five-minute inspection can prevent costly breakdowns, unexpected downtime, and, most importantly, personal injuries. Safety and productivity begin before the machine is even turned on.
Sale of compact machinery for public works
Buy now!3. Overloading the Machine
Error:
Trying to lift, push, or transport loads that exceed the machine’s rated capacity. This practice is more common than it seems, especially when operators try to work faster or get the most out of the equipment in each work cycle.
Why does this error occur?
Sometimes, due to a lack of knowledge about the machine’s real capacity, time pressure on the job site, or simply an attempt to “save trips,” operators take risks by exceeding the limits set by the manufacturer. However, these actions seriously compromise both safety and the integrity of the equipment.
Real example:
A mini excavator trying to lift debris or heavy materials beyond its load limit can lose stability and tip over, endangering the operator and anyone nearby. Similarly, an overloaded dumper may suffer failures in the transmission, brakes, or hydraulic system.
Solution:
Always check the machine’s technical specification plate, where the maximum load capacity and operating limits are indicated. Never exceed these values, even if it seems like “the machine can handle it.” Remember that overloading not only increases the risk of tipping and accidents but also accelerates the wear of critical components such as the hydraulic system, axles, frame, and tires or tracks.
If you are unsure about the machine’s capacity for a specific task, consult the user manual or ask your supervisor or supplier. Using the equipment responsibly and within its limits guarantees everyone’s safety and prolongs the machine’s lifespan.
4. Neglecting the Terrain and Obstacles
Error:
Operating the machine without first checking the terrain, slopes, ground stability, or the presence of obstacles such as cables, trenches, pits, debris, loose materials, or people in the work area. This oversight can lead to accidents, equipment damage, or delays on the job site.
Why does this error occur?
Often, familiarity with the location or the rush to start working leads operators to skip the area inspection. However, a job site can change from one day to the next: new trenches may appear, the ground may soften after rain, or temporary obstacles may be present that weren’t there before.
Real example:
An operator begins work without noticing a trench covered by debris, and as the machine passes over it, a track sinks, causing the equipment to tip over and halting the entire operation. Likewise, failing to identify low electrical cables can result in an accident that endangers everyone’s safety.
Solution:
Before starting the machine, walk through the area where you will be working.
Identify and mark dangerous slopes, unstable ground, trenches, or pits.
Look for overhead cables, shallow pipes, or any other hidden hazards.
Remove debris, unnecessary materials, and ensure the area is clear.
Maintain good visibility at all times and inform your coworkers about the work zone.
If the task requires operating near people, establish a safety perimeter.
The simple habit of inspecting the surroundings and anticipating hazards drastically reduces the risk of accidents and protects both workers and machinery. Remember: safety begins long before the engine is started.
5. Braking or Turning Abruptly
Error:
Making sudden stops, sharp turns, or abrupt movements with the machine. This practice—often the result of rushing or lack of experience—can damage the hydraulic systems and significantly increase the risk of accidents on the job site.
Why does this error occur?
In high-pressure work environments, some operators tend to make quick movements to save time. However, compact machinery, due to its size and center of gravity, is especially sensitive to sudden changes in direction or speed.
Real example:
An operator makes a sharp turn at high speed to avoid an obstacle, causing the machine to lose stability, which could lead to a rollover or a collision with people, materials, or nearby structures. In addition, sudden braking or sharp turns place unnecessary stress on the hydraulic system, leading to premature wear or failure of key components.
Solution:
Always operate smoothly and with anticipation.
Use the brakes and steering gradually, anticipating each movement.
Avoid sudden changes in direction or speed, especially in tight spaces or near other workers.
Reduce speed when approaching corners, slopes, or areas with obstacles.
Become familiar with the machine’s response and the limits of its hydraulic system.
Smooth operation not only protects the integrity of the machinery but also increases safety for everyone on the job site and extends the life of key components. Remember: when operating machinery, uncontrolled speed is one of the biggest enemies of productivity and safety.
6. Not Keeping the Machine Clean
Error:
Allowing mud, dust, debris, or foreign materials to accumulate on the machine. Although it may seem like a minor detail, dirt can seriously affect the performance and durability of key components.
Why does this error occur?
After a long and demanding workday, operators often postpone cleaning until the next day, especially if the equipment appears to be working fine. However, mud, dust, and debris gradually build up, reaching sensitive areas that are not always visible.
Real example:
A radiator covered in mud reduces its cooling capacity, causing overheating and potential engine damage. Dirty filters allow impurities to enter and affect the hydraulic system. Even small stones or branches can get stuck in moving parts, causing wear or unexpected failures.
Solution:
Clean the machinery at the end of each workday, even if it doesn’t look dirty at first glance.
Pay special attention to radiators, air and oil filters, and moving components (joints, tracks, wheels, hydraulic arms, etc.).
Remove mud, leaves, stones, and any debris accumulated in critical areas.
Use the proper tools and products for each part of the equipment (brushes, compressed air, pressure washers, etc.).
Take advantage of cleaning time to detect potential damage or wear that may require maintenance.
A clean machine not only looks better, but also operates more efficiently, reduces the risk of breakdowns, and makes inspections and maintenance easier. Remember: cleanliness is an investment in the safety, performance, and longevity of your equipment.
7. Forgetting Scheduled Maintenance
Error:
Postponing or skipping regular maintenance tasks such as oil changes, filter replacements, belt checks, lubrication, and other component inspections—usually due to workload, forgetfulness, or underestimating their importance. This mistake can go unnoticed for weeks, until a major breakdown suddenly stops operations.
Why does this error occur?
Daily routines on the job site, pressure to meet deadlines, and the false belief that the machine “can keep going a bit longer” lead operators to delay essential maintenance tasks. However, this neglect drastically increases the risk of costly failures and endangers both safety and productivity.
Real example:
An operator skips an oil change because the machine seems to be running fine. Weeks later, the engine suffers major damage due to residue buildup and poor lubrication, resulting in expensive repairs and lost time. Another common case is forgetting to replace hydraulic filters, allowing impurities to damage pumps and valves.
Solution:
Always follow the maintenance intervals recommended by the manufacturer, even if the machine is in constant use or shows no obvious signs of failure.
Keep a record (manual or digital) of every maintenance task completed and the ones coming up.
Use breaks or shift changes to perform quick checks of oil, filters, fluid levels, and belts.
Use original or manufacturer-recommended replacement parts to ensure durability and performance.
Always consult the user manual to know exactly when and how each maintenance procedure should be performed.
A well-maintained machine is safer, more efficient, and more cost-effective in the long term. Remember: prevention is much cheaper and easier than an emergency repair.
Conclusión
Operating compact machinery safely and efficiently is within everyone’s reach. Avoid these common mistakes and prioritize proper training, daily inspections, and responsible maintenance. Your equipment—and your wallet—will thank you!
Common Mistakes When Operating Compact Machinery and How to Avoid Them
Discover the most common mistakes when using compact machinery such as mini excavators, skid steers or dumpers, and learn how to avoid them to improve safety, extend equipment life and reduce costly breakdowns on site.
Main mistakes when operating compact machinery
- Not reading the manual or receiving proper training: every machine has specific controls and limits that must be understood before operating.
- Skipping daily inspections: not checking levels, leaks, tire or track pressure, and hydraulic system condition.
- Overloading the machine: exceeding its capacity compromises stability and increases wear.
- Not reviewing terrain conditions: operating without analyzing slopes, trenches, cables or obstacles puts the operator and equipment at risk.
- Abrupt turns or braking: increases rollover risk and damages the hydraulic system.
- Not keeping the machine clean: mud and debris affect radiators, filters and moving parts.
- Forgetting scheduled maintenance: skipping oil changes, filter replacement or lubrication leads to serious failures.
With good safety practices, daily inspections and regular maintenance, compact machinery can be operated efficiently, productively and without unnecessary risks.
