Heavy Equipment Inspection Checklist

Regular Inspections vs In Depth Inspections

In this guide, we will provide two comprehensive heavy equipment inspection checklists to make sure that you cover all of your bases and check all of your machines' components. This will ensure they are working safely and correctly.

Regular Inspections

Experienced operators know you should inspect your machine before and after each use. In most commercial settings, these will be daily inspections. This usually consists of doing a quick visual and audible check of a machine's main components. From checking batteries to testing the brakes, frequent heavy equipment inspections are the key to keeping your employees safe on the job and your machine well maintained.

A daily checklist will help keep you and your team organized during inspections and ensure you cover all areas, including critical and non-critical points. If anything seems out of place or unusual it should be flagged for further investigation or diagnosis. You can purchase daily inspection forms from common suppliers like Grainger, ULine, or even Amazon. At a high level those daily inspection forms should cover:

1. [ ] Exterior condition

2. [ ] Handles and steps

3. [ ] Lights and mirrors

4. [ ] Cab (seat, horn, glass, air)

5. [ ] Engine (startup, no visible smoke, no unusual noises, battery)

6. [ ] Hydraulics (smooth operation, no unusual noises, no leaks)

7. [ ] Fluid levels (oil, coolant, hydraulics)

8. [ ] Lines (oil and hydraulic lines are clean and dry)

9. [ ] Tire or tracks in good condition

10. [ ] Attachments are secure and undamaged

Increasingly, companies are relying on technology platforms to ensure regular inspections are completed and that issues are surfaced to management or service teams. Providers like Tenna, Fast Field Forms, Record360, are a few options to consider if you're looking to implement a tech solution for your team.

Daily inspections will help identify potential issues early and avoid more expensive repairs. More importantly, it keeps you and your employees safe on the job.

In-Depth Inspections

In depth inspections cover what to look for when buying a machine or when a machine is being evaluated for service. For some machines like cranes, an certified third party inspection needs to be performed regularly in order to be compliant with safety regulations. Regardless, it's good to do an in-depth inspection on a regular basis following either the manufacturer's recommendations.

If the machine is being serviced, it should be evaluated by a qualified mechanic. If you're looking to buy a machine you'll want to look at the following:

1. [ ] Do a thorough visual inspection of the machine to check for any signs of leaks or pooling fluid underneath. If so, you'll need to find the source of the leak and have it repaired.

2. [ ] Check the undercarriage, rims, and tires for excessive wear, accumulated mud or dirt, and other signs of damage. This could pose a safety risk and affect how well the machine performs.

3. [ ] Check all fluids: coolant, fuel, engine oil, hydraulic oil, and diesel exhaust fluid, to ensure they are all at optimal levels. As the lifeblood of your machine, having insufficient fluids will affect its performance and lead to excessive damage and expensive repairs.

4. [ ] Check the radiator and other engine components for mud, debris, and dirt, to ensure that all of the engine parts have the space to move, breathe, and cool correctly.

5. [ ] Look at all filters, including oil, fuel, and air; check for leaks or other damage. Though issues with filters are relatively easy to fix, the damage caused by problems that were undetected or ignored can be costly.

6. [ ] Inspect smaller components such as the alternator, fan, and belts for signs of excessive wear or damage. These issues are easy to repair if caught early, and ignoring them will eventually lead to costly repairs and downtime.

7. [ ] Ensure all high-friction areas are sufficiently greased to avoid excessive wear and damage.

8. [ ] Inspect the hydraulic connections, coupling structure, and pressure, being sure to release pressure when removing the attachments.

9. [ ] Check all ground tools, including teeth and buckets, to check for cracks, breaks, and other signs of damage that could limit productivity, pose a safety risk, damage the machine, and impact fuel efficiency.

10. [ ] Check the attachment mount-up and make sure electrical connections, hydraulic hoses, and the coupler are all connected properly and securely.

11. [ ] Do a quick visual inspection of the machine's exterior to point out any signs of damage, wear, and other areas of concern.

12. [ ] Inspect the cab and be sure that all operator controls, lights, and other safety features, such as the rear camera and backup alarm, are in working order.

13. [ ] Check all mirrors and ensure that they offer optimal visibility.

If you don't feel confident evaluating a machine yourself you can utilize a trusted dealer like Boom & Bucket or a local OEM to inspect the machine for you.

Digging Deeper

No matter how different machines are, some aspects are relevant no matter which type of heavy equipment you inspect.

One indicator of further issues is a blow-by on the engine. A blow-by happens when a mixture of air-fuel or combustion gasses leak between the pistons and cylinder wall into the crankcase. While some blow-by is normal, excessive amounts can indicate damage to the components, abnormal engine wear, or poor equipment maintenance.

If most or all of the cylinders are leaking, you must inspect the condition of the pump because the pressure is most likely much too high. Even if only a few cylinders are leaking, chances are that the others are only a little behind unless the root of the problem is fixed.

Finally, one of the best indicators of the condition of a machine is how it sounds when it is running and operating. Hydraulics have a distinct sound, so when something is off, you will be able to clearly hear the difference. If you notice the sound of your machine changing, you may want to take an oil sample to find out what is going on.

Oil Samples

It's a good idea to get an oil sample analyzed regularly as a preventative measure or if you see smoke at any point while the engine is running. This can surface potentially serious issues before they become expensive or cause long term damage.

Boom and Bucket utilizes Polaris Labs (www.polarislabs.com) for the oil samples we perform. To take a sample:

Warm up the engine for a few minutes to prepare the machine for a thorough inspection. Once the engine has had time to warm up, you're ready to take an oil sample.

Be sure that the tools you use to take your oil sample, such as the hose, are in a plastic bag until you are ready to use them; this prevents the oil from being contaminated by dust and debris that could affect the outcome of your test. Once you've prepared the sample bottle, cut the hose to the length of the dipstick so that it is long enough to get oil out but not so long that it reaches too deep into the engine.

Being careful not to get dirt on the hose in the process, slide the hose into the engine until you feel it reach the oil. Carefully begin extracting some oil until it reaches about the third line on the sample bottle. Once you've filled the sample bottle, remove the hose from the engine and place the cap on the bottle so it is ready to be shipped off.

Sometimes the fuel will find its way past the injectors and into the engine, so you may want to consider smelling the oil sample to see if you can detect any diesel fuel. If you can, you will want to note that for your report. Additionally, the viscosity of the oil gets thinner as it heats up. After collecting the oil sample, you can do a visual inspection to see how thin it is. If it is abnormally thin, this may indicate an issue that should be investigated.

Code Readers

If your machine, specifically an on-highway truck, is showing warning lights or error codes you should investigate farther. There's a number of readers you can buy online to help evaluate codes or surface past codes. This typically works better for on-highway machines as many OEMs now require special software to read their machines.

Conclusion

Regularly inspecting your fleet will help you identify potential issues early on and prevent costly repairs and premature replacements. The work environment, frequency of use, and seasonal weather will all impact how often your equipment needs to be maintained. Be sure to document your maintenance records, make notes during inspections, and take photographs as you check each component of your machines. The above checklists will help make sure you don't overlook any components and will help you anticipate issues and understand some of the pain points on each piece of equipment.