Compact machinery, such as mini excavators, skid steers, or dumpers, has become an essential ally for all kinds of construction and urban works. However, misuse 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!
Mistake:
Many operators rely on their previous experience and skip reading the user manual or the specific training for the equipment they are about to use. This may seem like a shortcut, but each model of compact machinery has its own features, functions, and limitations that can go unnoticed if the manufacturer’s instructions are not carefully reviewed.
Why does this mistake happen?
On a daily basis, the pressure to move forward with the project or the belief that “all machines work the same” leads to underestimating the importance of training. However, small differences in the controls, the hydraulic system, or safety protocols can make a big difference in both safety and performance.
Real-life example:
An experienced operator may be used to one 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 even put their own safety and that of their coworkers at risk.
Solution:
Before operating any new machine, take the time to review the user manual. Pay attention to warnings, instructions about the controls, basic maintenance, and load limits. Participate in training sessions offered by the manufacturer or distributor, even if you already have experience. Ask the site manager or supplier about any doubts.
Remember: Training and knowledge are the best tools to prevent accidents and ensure the durability of the machinery. Investing a few minutes in learning can save hours of repair and unnecessary risks in the future.
Mistake:
Getting on the machine without performing a prior check of critical components such as oil, fuel, the hydraulic system, tires or tracks, and detection of possible leaks or damage. This oversight is far more common than it seems and usually happens due to haste or the routine of daily work.
Why does this mistake happen?
Often, the operator assumes that the machine will work perfectly “just like yesterday” and skips those essential minutes of visual inspection. However, wear, small impacts, vibration, and temperature variations can cause unexpected issues overnight—even in new equipment.
Real-life example:
An operator starts the day without checking the hydraulic oil level and, halfway through the job, the machine suffers a major breakdown due to lack of lubrication. Or, a small undetected fuel leak can quickly turn into a fire hazard or an environmental problem.
Solution:
Carry out 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 inadequate pressure.
Look for leaks or drips under the equipment and around components.
Verify that controls and safety systems are working properly.
Always keep a simple log (it can be a daily checklist) to record any anomalies. A five-minute review can prevent costly breakdowns, unexpected downtime, and, above all, personal accidents. Safety and productivity begin before starting the engine.
Mistake:
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 want to speed up progress or maximize equipment use in each work cycle.
Why does this mistake happen?
Sometimes, due to lack of knowledge about the machine’s actual capacity, time pressure on the job site, or simply wanting 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-life example:
A mini excavator trying to lift debris or heavy materials beyond its limit may lose stability and tip over, endangering the operator and anyone nearby. Similarly, an overloaded dumper can suffer failures in the transmission, brakes, or hydraulic system.
Solution:
Always check the machine’s technical specification plate, which indicates the maximum load capacity and operating limits. 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 wear on critical components such as the hydraulic system, axles, structure, and tires or tracks.
If you are unsure about the capacity for a specific task, consult the user manual or ask your supervisor or supplier for guidance. Responsible use within limits guarantees everyone’s safety and extends the service life of the machinery.
Mistake:
Operating the machine without first checking the terrain, slopes, soil firmness, or the presence of obstacles such as cables, trenches, pits, debris, loose materials, or people in the work area. This oversight can result in accidents, equipment damage, or project delays.
Why does this mistake happen?
Often, familiarity with the site or the rush to start work leads operators to skip the inspection of the area. However, the conditions of a construction site can change from one day to the next: new trenches may appear, the ground may soften due to rain, or temporary obstacles may be present.
Real-life example:
An operator begins working without noticing a trench covered by debris and, when passing over it, one track sinks, causing the machine to tip over and halting the entire operation. Likewise, failing to identify the presence of low electrical cables may result in an accident that endangers everyone’s safety.
Solution:
Before starting the machine, walk around the area where you will be working.
Identify and mark hazardous slopes, unstable ground, trenches, or pits.
Detect the presence of overhead cables, surface pipes, or any other hidden risks.
Remove debris, unnecessary materials, and ensure the area is clear.
Always maintain good visibility and communicate with coworkers about the work zone.
If the job requires operating near people, establish a safety perimeter.
The simple habit of inspecting the environment and anticipating hazards drastically reduces the risk of accidents and protects both workers and machinery. Remember: safety begins long before starting the engine.
Mistake:
Making sudden stops, turns, or abrupt movements with the machine. This practice, often the result of haste or lack of experience, can not only damage the hydraulic systems but also significantly increase the risk of accidents on-site.
Why does this mistake happen?
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-life example:
An operator makes a sharp turn at high speed to avoid an obstacle, and the machine loses stability, which could cause a rollover or collision with people, materials, or nearby structures. In addition, sudden braking or sharp turns put unnecessary strain on the hydraulic system, causing premature wear or failures in key components.
Solution:
Always operate smoothly and with foresight.
Use brakes and steering gradually, anticipating every 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.
Familiarize yourself with the machine’s response and the limits of its hydraulic system.
Smooth operation not only protects the integrity of the machine but also increases overall site safety and prolongs the life of components. Remember: in machinery operation, uncontrolled speed is one of the greatest enemies of productivity and safety.
Mistake:
Allowing mud, dust, debris, or foreign materials to accumulate on the machine. Although it may seem minor, dirt can seriously affect the performance and durability of key components.
Why does this mistake happen?
After a long workday, it is common for operators to postpone cleaning until the next day, especially if the equipment seems to be working fine. However, mud, dust, and debris accumulate over time, reaching sensitive areas that are not always visible.
Real-life example:
A radiator covered in mud reduces its cooling capacity, causing overheating and possible engine damage. Dirty filters allow impurities to pass through and affect the hydraulic system. Even small stones or branches can get stuck in moving parts, causing wear or unexpected breakdowns.
Solution:
Clean the machine 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 parts (joints, tracks, wheels, hydraulic arms, etc.).
Remove mud, leaves, stones, and any debris accumulated in critical areas.
Use 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 runs more efficiently, reduces the risk of breakdowns, and makes inspection and maintenance easier. Remember: cleaning is an investment in safety, performance, and machine longevity.
Mistake:
Delaying or skipping periodic checks of oil, filters, belts, lubrication, and other components, often due to work overload, forgetfulness, or underestimating their importance. This mistake can go unnoticed for weeks until a major breakdown stops operations.
Why does this mistake happen?
The routine of the job site, pressure to meet deadlines, and the false sense that the machine “still runs fine” lead to postponing maintenance tasks. However, this oversight dramatically increases the risk of costly failures and compromises both safety and productivity.
Real-life example:
An operator skips an oil change because the machine appears to be running well. Weeks later, the engine suffers a major breakdown 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 respect 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 each task performed and upcoming ones.
Use breaks or shift changes to quickly check oil, filters, levels, and belts.
Use original or manufacturer-recommended spare parts to ensure performance and durability.
Always consult the user manual to know exactly when and how to perform each type of maintenance.
A well-maintained machine is safer, more efficient, and more cost-effective in the long term. Remember: prevention is far cheaper and easier than an urgent repair.