Pre-trip inspection
Every shiftDo this walkaround at the start of every shift, machine parked on level ground, work tool flat on the ground, engine off, key out. Don't start the machine until it's done. Anything affecting safe operation gets tagged out and reported before it moves.
Before you approach
- Work area around the machine — people, vehicles, overhead lines and clearances, soft or sloped ground
- Ground under the machine — fresh oil, coolant, fuel or hydraulic puddles
- Grab irons, steps, handholds — secure, clean, free of mud, ice, snow and grease
- Guards, covers, doors, latches — in place, undamaged, closed and latched
- Housekeeping — trash, dirt and grease build-up cleared from the engine bay and undercarriage
Loader arms, work tool and coupler
- Lift arms and cross member — cracks, weld damage, packed debris
- Lift and tilt cylinders — leaks at seals, scored or bent rods, loose pins
- Pins, bushings and retainers — wear, play, retainers in place, greased
- Lift arm support device — present, undamaged, pin accessible and stowed
- Quick coupler — levers fully down and locked, pins engaged, no debris in the plate
- Work tool (bucket, forks, attachment) — wear, cracks, cutting edge, teeth, bent or missing parts
- Auxiliary hydraulic couplers and hoses — leaks, caps in place, chafe, fittings tight
- Grease points on arms and linkage — greased per the lube chart
Undercarriage, tracks and tires
- Rubber or steel tracks — cuts, abrasions, embedded debris, tension, missing lugsIf equipped
- Track rollers, idlers and bogies — leaks, wear, damage, mounting bolts
- Sprockets, rings and sleeves — wear, cracks, retaining nuts tight
- Undercarriage and frame — packed mud and debris, cracks, damage
- Tires — inflation, cuts, cord damage, uneven wearIf equipped
- Rims, wheel nuts, valve stems — cracks, loose or missing nuts, stem caps in place
- Final drives and drive motors — leaks, damage, debris wrapped around the drive
Engine compartment and fluids (engine off)
- Engine oil level — level on dipstick, condition
- Coolant level — level in expansion tank; never open a hot system
- Hydraulic oil level — level in the sight glass, work tool down, engine off
- Chain case oil — level, condition, no leaks at the caseIf equipped
- Fuel level, fuel cap, water separator — enough fuel for the shift, cap sealed, drain water
- DEF level — level, cap sealed, no crystal build-up or debrisIf equipped
- Air cleaner and dust valve — restriction indicator not tripped, dust valve clear
- Belts and hoses — tightness, cracks, leaks, chafe
- Radiator and cooler cores — debris, fin blockage, leaks, fan damage
- Batteries and disconnect switch — secure, terminals clean and tight, no corrosion
Lights, safety devices and exterior
- Work lights and beacon — working, lenses intact and clean
- Windows, glass and door — cracks, clean, unobstructed view, door latches
- Mirrors and camera — intact, clean, adjusted
- Fire extinguisher — charged, mounted, inspection tag currentIf equipped
- ROPS / FOPS, side screens and decals — damage, cracks, loose bolts, labels present and legible
In the cab (before start)
- Seat, seat belt and seat bar — condition, buckle latches, bar lowers and locks, mounting secure
- Controls and armrests — joysticks and pedals in NEUTRAL, controls undamaged and clean
- Cab floor and pedals — clear of tools, mud and debris
- Wipers and washers — working, washer fluid topped upIf equipped
- Heater, defrost, AC — working (visibility in all conditions)
- Emergency exit and hammer — present, accessible, unobstructed
- Manual, inspection log, hour meter — in the cab; hour meter reading recorded on this sheetRecord
Function check (engine running)
- Start-up — no abnormal noise or smoke, warning lights clear after self-test
- Gauges, monitor and warning lights — readings normal, no active fault codes
- Horn, backup alarm, camera — all working
- Operator presence and interlock — drive and hydraulics disabled with the bar raised or belt unbuckled
- Lift and tilt functions — smooth through full range, no drift with the tool raised
- Travel and steering, both directions — tracks or wheels respond evenly, machine tracks straight
- Parking brake and stopping — holds on a grade, machine stops when controls return to neutral
- Leaks after pressure is up — recheck cylinders, hoses, couplers and drive motors
500-hour service
Every 500 hours on the hour meter.
Oil samples
- Obtain engine oil sample
- Obtain hydraulic system oil sample
Engine
- Change engine oil & filter
- Check engine oil level
- Inspect / replace belts
- Inspect / clean engine compartment
Fluid levels & changes
- Check hydraulic system oil level
- Check final drive oil level
- Change final drive oil
- Check drive chain case oil level
Air & cab filters
- Replace / clean engine air filter primary
- Replace / clean engine air filter secondary
- Clean / inspect air cleaner dust valve
Hydraulic filters & breathers
- Replace hydraulic tank breather
Fuel system
- Replace fuel system primary filter / water separator
- Replace fuel system in-line filter
Cooling system
- Check cooling system level
Undercarriage, tracks & tires
- Inspect / adjust track (rubber)
- Inspect / adjust track (steel)
- Inspect track pins
- Inspect track roller and idler
- Inspect bogie and idler
- Inspect sprocket sleeve
- Check sprocket retaining nuts
- Check / adjust drive chain tension
- Check tire inflation
- Tighten wheel nuts
Loader arms & work tools
- Inspect pins and bearings for wear
- Inspect work tool mounting bracket
- Inspect / clean quick coupler
- Check equipment lowering control valve
Hoses & leaks
- Inspect hoses and clamps
- Check hoses and connections for leaks
Cab & safety
- Test backup alarm
- Check all lights and horn
- Inspect seat belt
Lubrication
- Lubricate axle bearings
- Lubricate lift arm and cylinder linkage
- Lubricate tilt cylinder bearings and bucket linkage bearings
- Lubricate work tool
1,000-hour service
Every 1,000 hours. Includes all 500-hour tasks; tasks tagged 1,000 hr are added at this interval.
Oil samples
- Obtain engine oil sample
- Obtain hydraulic system oil sample
Engine
- Change engine oil & filter
- Check engine oil level
- Inspect / replace belts
- Inspect / clean engine compartment
Fluid levels & changes
- Check hydraulic system oil level
- Check final drive oil level
- Change drive chain case / final drive oil1,000 hr
- Check drive chain case oil level
Air & cab filters
- Replace / clean engine air filter primary
- Replace / clean engine air filter secondary
- Clean / inspect air cleaner dust valve
- Replace cab air filters1,000 hr
Hydraulic filters & breathers
- Replace hydraulic tank breather
- Replace hydraulic system oil filter1,000 hr
Fuel system
- Replace fuel system primary filter / water separator
- Replace fuel system in-line filter
Cooling system
- Check cooling system level
Undercarriage, tracks & tires
- Inspect / adjust track (rubber)
- Inspect / adjust track (steel)
- Inspect track pins
- Inspect track roller and idler
- Inspect bogie and idler
- Inspect sprocket sleeve
- Check sprocket retaining nuts
- Check / adjust drive chain tension
- Check tire inflation
- Tighten wheel nuts
Loader arms & work tools
- Inspect pins and bearings for wear
- Inspect work tool mounting bracket
- Inspect / clean quick coupler
- Check equipment lowering control valve
Hoses & leaks
- Inspect hoses and clamps
- Check hoses and connections for leaks
Cab & safety
- Test backup alarm
- Check all lights and horn
- Inspect seat belt
- Inspect ROPS / FOPS1,000 hr
Lubrication
- Lubricate axle bearings
- Lubricate lift arm and cylinder linkage
- Lubricate tilt cylinder bearings and bucket linkage bearings
- Lubricate work tool
2,000-hour service
Every 2,000 hours. Includes all 500 and 1,000-hour tasks; tags show where each task joins the list.
Oil samples
- Obtain engine oil sample
- Obtain hydraulic system oil sample
Engine
- Change engine oil & filter
- Check engine oil level
- Inspect / replace belts
- Inspect / clean engine compartment
- Check / adjust engine valve lash2,000 hr
- Replace engine crankcase breather2,000 hr
Fluid levels & changes
- Check hydraulic system oil level
- Change hydraulic system oil2,000 hr
- Check final drive oil level
- Change drive chain case / final drive oil1,000 hr
- Check drive chain case oil level
Air & cab filters
- Replace / clean engine air filter primary
- Replace / clean engine air filter secondary
- Clean / inspect air cleaner dust valve
- Replace cab air filters1,000 hr
Hydraulic filters & breathers
- Replace hydraulic tank breather
- Replace hydraulic system oil filter1,000 hr
Fuel system
- Replace fuel system primary filter / water separator
- Replace fuel system in-line filter
- Replace fuel tank cap filter2,000 hr
Cooling system
- Check cooling system level
Undercarriage, tracks & tires
- Inspect / adjust track (rubber)
- Inspect / adjust track (steel)
- Inspect track pins
- Inspect track roller and idler
- Inspect bogie and idler
- Inspect sprocket sleeve
- Check sprocket retaining nuts
- Check / adjust drive chain tension
- Check tire inflation
- Tighten wheel nuts
Loader arms & work tools
- Inspect pins and bearings for wear
- Inspect work tool mounting bracket
- Inspect / clean quick coupler
- Check equipment lowering control valve
Hoses & leaks
- Inspect hoses and clamps
- Check hoses and connections for leaks
Cab & safety
- Test backup alarm
- Check all lights and horn
- Inspect seat belt
- Inspect ROPS / FOPS1,000 hr
Lubrication
- Lubricate axle bearings
- Lubricate lift arm and cylinder linkage
- Lubricate tilt cylinder bearings and bucket linkage bearings
- Lubricate work tool
