Excavators are a worksite must-have for a reason. They’re powerful, versatile, and essential for just about any kind of digging, lifting, or trenching task. But they’re not foolproof. A few wrong moves behind the controls can turn a productive day into a costly delay or worse. Whether you’re new to the seat or have years of experience, avoiding these common mistakes is key to safe and efficient operation.
Here are 9 things every operator should steer clear of.
1. Skipping Pre-Start Checks
This one might sound simple, but it’s where a lot of problems start. Failing to run through the proper operating procedures before getting to work can easily lead to issues like oil leaks, loose hoses, or worn components being missed.
Daily inspections are your first line of defence when it comes to machine health. That includes checking fluid levels, looking over the hydraulic system, and making sure attachments are secure and in good working order. Following the manufacturer’s guidelines for servicing and inspection ensures nothing critical is overlooked.
2. Getting Behind the Controls Without Proper Training
An excavator might look simple from the outside, but efficient operation takes more than just pulling a few levers. Without proper training, it’s easy to fall into improper operation techniques: things like jerky controls, unstable loading, or unsafe movement near other workers.
Investing in comprehensive training means excavator operators know how to handle the machine in a variety of scenarios, understand how attachments work, and follow safety protocols to the letter. It’s not just about protecting the gear, it’s about protecting people too.
3. Ignoring Safety Protocols on Site
Whether operating a mini excavator or a skid steer, there are plenty of common mistakes to avoid, but ignoring safety protocols is one of the worst. These rules exist for a reason. From exclusion zones to two-way communication, each element plays a role in preventing collisions and ensuring safe operation of the machinery for everyone on site.
It’s also essential to wear the right personal protective equipment at all times. High-vis gear, hard hats, safety boots, and hearing protection should be standard issue. And always maintain clear communication with other workers, especially when moving near blind spots or busy zones.
4. Digging Blind Without Locating Underground Utilities
One of the most dangerous excavator mistakes operators can make is failing to check for underground utilities before digging. Striking a gas line, power cable or water main can have serious, and sometimes fatal, consequences.
Before putting bucket to ground, use the proper tools and processes to identify what’s below. Contact relevant authorities for dial-before-you-dig services, and keep a copy of utility plans on hand. It’s always better to check twice than to pay the price.
5. Using the Wrong Attachment for the Job
It might be tempting to make do with what you’ve got on hand, but using the wrong tool, like a digging bucket to shift debris or a ripper to move spoil, can lead to damage and injury. Incorrect bucket usage also places extra strain on your machine, reducing lifespan and increasing the chance of failure.
Choose attachments that are rated and suited for the specific job at hand, and double-check compatibility before hooking them up. Following manufacturer’s guidelines when selecting attachments ensures both performance and safety.
6. Overloading or Poorly Positioned Buckets
Exceeding an excavator’s lifting capacity or failing to follow proper digging techniques puts unnecessary strain on the equipment and can cause it to tip. The same goes for lifting loads with the boom swung to the side instead of straight ahead.
To stay safe, always dig within a 45-degree range of the tracks, use the correct bucket angle, and position loads so the weight is evenly balanced. Overcrowding the bucket might look efficient on paper, but it’s often one of the biggest culprits behind instability and sloppy trenching.
7. Parking Like You’re in a Hurry
When the job’s done, don’t just swing the machine into any old position and call it a day. Parking an excavator safely involves lowering the boom, placing the bucket flat on the ground, and aligning the cab with the tracks to make sure operators can maintain three points of contact when exiting.
Leaving the machine in an awkward or unsafe position not only makes it more likely to get bumped or damaged, it increases the risk of slips, trips, and falls for the next person who hops in.
8. Neglecting Regular Maintenance
An excavator that isn’t maintained is a breakdown waiting to happen. That means downtime, costly repairs, and unhappy clients. Regular maintenance like oil changes, filter replacements, and pin greasing is the backbone of keeping your machine in peak condition.
Don’t wait until something breaks to give your excavator some attention. Set up a schedule based on hours used and stick to it. It’s the best way to protect your investment, reduce the risk of accidents, and keep things running smoothly. Make sure to include regular checks of your hydraulic fluid, as low levels or contamination can lead to serious issues with your hydraulic system, which in turn can compromise both efficiency and safety.
9. Rushing Without a Plan
Whether you’re tackling a new site or a familiar job, planning matters. Without a clear strategy, operators are more likely to cut corners, make poor calls, or waste time reworking bad digs. That’s not just inefficient, it’s unsafe.
Take the time to plan your approach, assess the site, and set up for efficient operation. Know where the dump zones are, check for swing clearance, and confirm that the machine has enough room to manoeuvre without clipping obstacles or people.
Trust Hogan Engineering for Australia’s Best Excavator Attachments
Avoiding excavator fails isn’t about being perfect, it’s about knowing what to look for and working smart. Whether you’re after expert advice, the right tool for the job, or a custom solution that keeps your team productive and safe, we’re here to help.
At Hogan Engineering, we’ve been helping businesses and operators of all shapes and sizes get the most out of their machines for decades. With an extensive range of excavator attachments, such as excavator buckets, excavator rippers, and lifting eyes, as well as the ability to customise attachments to your specific needs, we make it easy to choose the right attachments for your projects and get the most out of your machines. Contact us today to discuss your needs with a member of our team!
