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When a hydraulic excavator—commonly referred to as a “trackhoe”—tips onto its side, the consequences extend far beyond cosmetic damage. Fluids shift, components may be stressed or broken, and internal systems can be compromised. Attempting to restart the machine without a thorough inspection can lead to catastrophic engine failure, hydraulic contamination, or even injury.

Immediate Safety Measures

Before any recovery or restart attempt, the following safety steps must be taken:

  • Shut off the engine immediately if it is still running
  • Evacuate the operator safely and assess for injuries
  • Secure the area to prevent further movement or collapse
  • Notify site supervisors and document the incident

In one case, an operator in British Columbia was ejected during a rollover but avoided serious injury thanks to a properly worn seatbelt and a reinforced cab structure. His quick thinking in shutting off the engine prevented oil starvation damage.

Recovery and Uprighting the Machine

The process of righting a tipped excavator should be handled by experienced personnel using appropriate equipment:

  • Use a second excavator, crane, or heavy-duty winch to upright the machine
  • Avoid pulling on the boom or stick unless absolutely necessary
  • Inspect the ground for stability before recovery
  • Ensure all personnel are clear of the danger zone

Improper recovery can twist the frame, damage hydraulic lines, or rupture the cab structure. In one documented case, a rushed recovery attempt led to a cracked swing bearing due to uneven lifting.

Pre-Start Inspection Checklist

Once the machine is upright, a comprehensive inspection is mandatory. Key areas to check include:

  • Engine oil level and condition: Look for signs of overfill, foaming, or diesel dilution
  • Hydraulic oil level: Check for aeration or contamination
  • Fuel system: Inspect for leaks or air intrusion
  • Coolant level: Ensure the radiator and overflow tank are intact
  • Air intake system: Remove the air filter and check for oil or debris
  • Battery and electrical connections: Look for dislodged cables or short circuits
  • Cab structure and ROPS: Inspect for deformation or cracks

If the engine was running during the rollover, oil may have entered the combustion chamber. Attempting to start the engine in this condition can cause a hydraulic lock, bending connecting rods or damaging pistons.

Engine Cranking Procedure

To safely restart the engine:

  • Remove all injectors or glow plugs to relieve compression
  • Manually crank the engine to expel any oil from the cylinders
  • Reinstall injectors and check for proper torque
  • Prime the fuel system if necessary
  • Start the engine at low throttle and monitor for abnormal noise or smoke

In one field case, a Komatsu PC200 was restarted without removing the injectors, resulting in a bent rod and a $12,000 rebuild. The lesson: always assume oil has entered the cylinders after a rollover.

Post-Restart Monitoring

After the engine is running:

  • Let it idle for 10–15 minutes while monitoring oil pressure and temperature
  • Operate hydraulic functions slowly to purge air from the system
  • Check for leaks under load
  • Document all findings and repairs for future reference

Final Thoughts

Recovering and restarting an excavator after a rollover is a high-stakes procedure that demands methodical inspection and mechanical discipline. Rushing the process can turn a minor incident into a major repair. With proper safety protocols, mechanical checks, and patience, many machines can return to service without long-term damage. But as one seasoned operator put it, “The real fix starts with not flipping it in the first place.”

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