09-14-2025, 11:18 AM
Why Post-Roll Over Inspections Are Critical
When an excavator rolls over, even if it rights itself, there can be internal and external damage not obvious to first glance. Components under stress may develop hidden cracks; hydraulic systems may leak; fluid levels may change; safety systems may be compromised. Ignoring these risks can lead to further failures, accidents, or costly downtime. After recent incidents, some companies have reported up to 30-40% increase in maintenance costs when operators restart machines without full rollover checks.
Terminology & Key Concepts
Following a rollover, before you attempt to restart or operate the excavator, perform a full set of inspections. These can be grouped by zones.
Exterior & Structural Inspection
A contractor in the Pacific Northwest had an excavator roll onto its side during a hillside dig. The machine was righted by a crane, but the operator restarted without detailed post-rollover checks. Two weeks later, a hydraulic hose that had been abraded under pressure during the rollover burst, causing a high pressure oil leak. That forced a shutdown for three days, with parts costing over USD 5,000 and labor significant. Had the hose been inspected and replaced immediately, the cost would have been under USD 500.
In another case, a mining operation in Australia mandated post-rollover inspections and found that about 25% of machines that rolled (even slightly) suffered misalignment in the undercarriage or bent boom pins. Their policy reduced downstream failures by nearly 60% over 5 years.
Preventive Measures & Solutions
After a rollover incident, excavator prestart checks must be comprehensive, systematic, and documented. Checking structure, hydraulics, engine, safety systems, undercarriage, cab, fluids, and controls are all essential. With careful attention, many potential failures can be prevented, safety upheld, downtime minimized, and costs dramatically reduced.
When an excavator rolls over, even if it rights itself, there can be internal and external damage not obvious to first glance. Components under stress may develop hidden cracks; hydraulic systems may leak; fluid levels may change; safety systems may be compromised. Ignoring these risks can lead to further failures, accidents, or costly downtime. After recent incidents, some companies have reported up to 30-40% increase in maintenance costs when operators restart machines without full rollover checks.
Terminology & Key Concepts
- ROPS / FOPS: Roll-Over Protective Structure and Falling Object Protective Structure; frames designed to protect operator in rollover or falling debris events.
- Undercarriage / Tracks: The track shoes, rollers, sprockets, idlers and related parts that allow movement on tracked excavators.
- Boom / Stick / Dipper Arm: Sections of the main working arm assembly; “stick” is sometimes “dipper arm.”
- Hydraulic Lines / Cylinders: Pipes, hoses, and working pistons that use pressurized fluid to move boom, bucket, etc.
- Swing Gear / Turret: The mechanism that allows the house / upper structure to rotate.
- Rated Capacity Plate: The identification plate that shows the machine’s load capacities and safety limits.
Following a rollover, before you attempt to restart or operate the excavator, perform a full set of inspections. These can be grouped by zones.
Exterior & Structural Inspection
- Inspect the ROPS and FOPS frame for bends, cracks, weld failures or distortion.
- Check boom, stick, and bucket arms for cracks, bends, or misalignment.
- Examine attachment points and pins / bushings for deformation or damage.
- Inspect the undercarriage: track frame, idlers, sprockets, track shoes. A rollover can shift or damage these.
- Check body panels, side covers, engine hood, top covers: look for dents, twisted mounts.
- Check all hydraulic hoses, lines, couplings, and cylinders for damage, abrasion, or leaks. After a rollover, hoses may rub, kink, or be partially crushed.
- Inspect hydraulic fluid reservoirs: ensure no air pockets, fluid leakage, or signs of contamination (water, dirt).
- Check hydraulic fans, cooler, heat exchangers for dents or blockage.
- Check engine mountings: a hard rollover can loosen mounts or misalign them.
- Inspect radiator, cooling fan blades, belt tension and belts for misalignment or damage.
- Check fuel tank for denting, piping for leaks, fuel lines for damage.
- Inspect the air intake and filter—ingestion can carry debris or water if overturned.
- Ensure battery terminals are secure and undamaged; battery housing not cracked.
- Check all safety switches, emergency stop buttons, seat belts, harnesses, alarms, mirrors, cameras if fitted.
- Inspect lighting and warning systems: head-lights, tail / rear lights, beacons, backup alarms.
- Inspect operator seat anchors; seatbelt latches; seat rails for alignment.
- Check all control levers, pedals, joystick integrity; test neutral positions.
- Verify gauges, instrument panel lights, warning indicators are functioning.
- Check track tension; loose track or twisted final drives may be a result of the machine rolling.
- Inspect track links, rollers, idlers for damage or misalignment.
- For wheeled machines, check axle housings, tires, rims, and differential housings.
- Check engine oil, hydraulic oil, transmission fluid, coolant, fuel, and any additive fluids (for example, DEF / AdBlue). Levels may have shifted or air introduced during rollover.
- Grease all pivot points, pins, bushings. Rollover can force grease out or allow contamination.
- Start the engine in low idle; allow to warm. Listen for unusual noises, vibration, or smoke.
- Operate the boom, stick, bucket, swing and travel functions in no-load conditions. Check for binding, jerky movement, or delayed response.
- Test brakes, slew locking, emergency shutoff, steering (for wheeled machines).
- Check visibility from cab; mirrors, windows, cameras.
- Log the inspection: machine make/model, hour meter; date; who did the check; defects found; corrective actions taken.
- Compare the damage with manufacturer guidelines; consult service manual.
- If cracks or structural damage suspected, hire certified inspection (welding / structural).
- Reassess compliance with rated capacity plate: rollover may shift loads or alter balance, so ensure machine still meets rated specs.
A contractor in the Pacific Northwest had an excavator roll onto its side during a hillside dig. The machine was righted by a crane, but the operator restarted without detailed post-rollover checks. Two weeks later, a hydraulic hose that had been abraded under pressure during the rollover burst, causing a high pressure oil leak. That forced a shutdown for three days, with parts costing over USD 5,000 and labor significant. Had the hose been inspected and replaced immediately, the cost would have been under USD 500.
In another case, a mining operation in Australia mandated post-rollover inspections and found that about 25% of machines that rolled (even slightly) suffered misalignment in the undercarriage or bent boom pins. Their policy reduced downstream failures by nearly 60% over 5 years.
Preventive Measures & Solutions
- Train operators to stop and perform full checks after any rollover, even minor.
- Keep spare parts like hoses, pins, filters, belts on site for quick replacement.
- Use rugged hoses, reinforced undercarriage parts, protective guards.
- Maintain detailed operator manuals; ensure owners & operators have access and understand structural tolerances.
- Use tilt sensors or rollover detection systems to alert supervisors when machine orientation exceeds safety limits.
After a rollover incident, excavator prestart checks must be comprehensive, systematic, and documented. Checking structure, hydraulics, engine, safety systems, undercarriage, cab, fluids, and controls are all essential. With careful attention, many potential failures can be prevented, safety upheld, downtime minimized, and costs dramatically reduced.
