Free haul truck inspection checklist
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Free haul truck daily pre-start inspection checklist (PDF). Covers brakes, tray body, steering, tyres, hydraulics, lights and safety systems.
Commercial Director
Updated 3 May 2026
How to use: download the PDF, print or complete digitally on any device.
- PDF format, ready to print or fill on screen
- Use as-is or customise to suit your operation
- Go digital in MapTrack for photos, alerts and audit trails
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What is a haul truck inspection checklist?
A haul truck inspection checklist is a structured daily pre-start form used to verify the operational safety and mechanical condition of rigid-body and articulated haul trucks before each shift on mine sites, quarries and large civil earthworks projects. It covers the engine and drivetrain, braking system (service, secondary and park brake), tray body and tailgate, steering and suspension, tyres and rims, hydraulic hoist system, electrical system, lights, mirrors, reversing camera and alarm, fire suppression system, cabin and operator controls, and all safety devices including seatbelts and ROPS. Each item is marked Pass, Fail or N/A with space for defect notes and corrective actions.
Haul trucks are among the highest-risk mobile plant on any site due to their size, mass, limited operator visibility and the haul road conditions they operate on. Under the WHS Act 2011 and WHS Regulations 2011, the PCBU must ensure that plant is inspected before use each shift by a competent operator. State mining regulations, including the Mining and Quarrying Safety and Health Act 1999 (Qld) and NSW WHS (Mines and Petroleum Sites) Regulation 2022, impose specific obligations for mobile plant pre-start inspections on mine sites. A documented daily pre-start checklist ensures operators identify brake fade, tyre damage, hydraulic leaks, inoperative cameras and other defects before they lead to runaways, collisions or tyre bursts, and creates an auditable inspection record for regulators and insurers.
Learn more about pre-start inspections in MapTrack.
Benefits of using this haul truck inspection checklist
- Brake safety: verify service, secondary and park brake performance before operating on steep haul roads and ramps.
- Tyre integrity: identify cuts, bulges, embedded objects and inflation issues before they lead to tyre failures at speed.
- Visibility assurance: confirm reversing camera, mirrors, lights and audible alarm are functional, reducing the risk of collisions with personnel and light vehicles.
- Fire risk reduction: verify fire suppression system charge, nozzle coverage and automatic activation before operating in dusty, high-temperature environments.
- Regulatory compliance: documented daily inspections satisfy WHS Regulations 2011 and state mining regulation requirements for plant pre-start checks.
- Fleet condition tracking: every defect is logged, creating a maintenance history that helps identify recurring issues and supports capital planning decisions.
Benefits of digitising forms in MapTrack
When you digitise haul truck checklists in MapTrack, you get:
- Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
- Automatically get alerts when faults are identified.
- Link every form digitally as a PDF to the relevant asset, location or person.
- Receive a digital PDF copy with every submission to your email.
- Ability to share forms digitally.
- Build conditional logic (show or hide questions based on answers).
- Take pictures or attach photos. Not possible with a paper-based form.
- Electronic signatures.
- Edit forms later without reprinting.
- Restrict permissions (who can view, complete or approve).
- Build forms with AI (describe what you need and MapTrack suggests the form).
- Auto-schedule pre-start forms so operators are prompted before every shift.
- Flag overdue pre-starts on the dashboard so nothing leaves the yard unchecked.
- Link each pre-start to the asset record for a complete inspection history.
Book a demo to see how MapTrack handles haul truck checklists.
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What to include in a haul truck inspection checklist
This haul truck inspection checklist covers 11 key areas:
- Truck and operator details: truck number, make, model, serial number, payload capacity, operator name, competency reference, date, shift and site location.
- Engine and drivetrain: engine oil level, coolant level, fuel level, air filter indicator, exhaust condition, transmission fluid, drive shafts, differentials and cooling fans.
- Braking system: service brake pedal travel and response, secondary (retarder) brake function, park brake engagement and hold, brake cooling system (if fitted), air pressure or hydraulic pressure readings.
- Tray body and tailgate: tray body condition (cracks, wear plates, liner), tailgate pins and latches, hoist cylinder mounting, body pivot pins and wear.
- Steering and suspension: steering response, power steering fluid, steering linkage, suspension cylinders or springs, shock absorbers and ride height.
- Tyres and rims: tyre condition (cuts, bulges, tread depth, embedded objects), inflation pressure, rim condition, lug nuts and valve caps. Note tyre position numbers for any defects.
- Hydraulic hoist system: hydraulic fluid level, hoist cylinders, hoses, fittings, control lever function and body-up indicator or alarm.
- Lights, mirrors and visibility aids: headlights (high and low beam), tail lights, brake lights, clearance lights, rotating beacon, reversing camera, side mirrors and rear-view mirror.
- Safety devices: fire suppression system (gauge, tags, nozzles), seatbelt, ROPS certification plate, emergency steering (if fitted), horn, reversing alarm and first aid kit.
- Cabin and controls: seat adjustment, air conditioning, gauges (oil pressure, coolant temperature, voltmeter, tachometer, payload indicator), windscreen wipers, washers, defroster and two-way radio.
- Defect register and sign-off: item, description, severity, corrective action, responsible person, due date, operator signature and supervisor acknowledgement.
How to use this haul truck inspection checklist
- Record truck identification and operator details at the top of the form.: Note the truck number, make, model, serial number, payload capacity, site location, date, shift and your name and competency reference. Confirm you hold the required authorisation to operate the truck class. Record haul road conditions including wet, dry, dusty or icy and any visibility limitations.
- Walk around the truck starting at the front left and inspect tyres, rims, body, hydraulics and external condition.: Walk clockwise around the truck inspecting each tyre for cuts, bulges, tread depth and embedded objects. Check rim condition and lug nuts. Inspect the tray body for cracks, worn liners and tailgate pin condition. Check underneath for hydraulic, oil and coolant leaks. Inspect the hoist cylinders, hoses and fittings. Verify fire suppression nozzle coverage and system pressure gauge.
- Check all fluid levels, engine compartment, filters and the cooling system.: Open the engine access panels and check engine oil, coolant, transmission fluid and hydraulic fluid levels. Inspect the air filter restriction indicator. Check belts, hoses and cooling fans for wear and damage. Inspect the battery terminals and electrolyte level. Top up all fluids to the correct levels and record any abnormal consumption that may indicate a developing fault.
- Enter the cabin and test all brakes, steering, controls, gauges and visibility systems.: Start the engine and allow gauges to stabilise. Check oil pressure, coolant temperature, voltmeter and payload indicator readings. Test the service brake pedal for travel and response. Engage the park brake and confirm the truck does not roll. Test the retarder (secondary brake) if fitted. Test steering in both directions. Check the reversing camera display, adjust all mirrors and test headlights, tail lights, brake lights, rotating beacon, horn and reversing alarm.
- Test the fire suppression system indicator, seatbelt, radio and all safety devices.: Confirm the fire suppression system gauge is in the acceptable range and the inspection tag is current. Fasten and adjust the seatbelt. Test the two-way radio on the site frequency. Verify the ROPS certification plate is present and legible. Check the first aid kit contents and fire extinguisher charge. Test the windscreen wipers, washers, defroster and air conditioning.
- Record all defects, determine the overall result and sign off the form.: Document every failed item with a description, severity rating and corrective action. Any safety-critical defect, such as brake failure, inoperative fire suppression, major tyre damage or non-functional reversing camera, means the truck must not operate until the defect is rectified. Attach a Do Not Operate tag and notify the supervisor and maintenance team. Sign the form and submit it to the site supervisor for review and retention.
In MapTrack, you can run digital pre-starts attached to each asset. Each submission is stored as a timestamped PDF against the asset record.
Get the free templateEnter your email above to download the full haul truck inspection checklist as a PDF.Back to download formHow often should you complete this checklist?
A haul truck daily pre-start inspection must be completed before the first operation of each shift. If the truck operates across day and night shifts, each shift operator must complete their own pre-start check before commencing haulage. This is a requirement under the WHS Regulations 2011 and applicable state mining regulations for mobile plant.
In addition to the daily pre-start, a more detailed periodic inspection should be carried out at intervals specified by the truck manufacturer and the site maintenance management plan, typically every 250, 500 and 1000 engine hours. Tyres should be inspected and pressure-checked daily, with a detailed tyre assessment by a competent tyre fitter at regular intervals. Fire suppression systems require monthly visual checks and semi-annual servicing by an authorised technician. After any collision, brake event, tyre failure, fire or operational incident, a targeted inspection must be completed before the truck returns to service. In MapTrack you can schedule daily, hourly-interval and calendar-based inspections per truck and track compliance across your haul fleet.
Frequently asked questions
Applicable regulatory standards
This template aligns with the following regulations and standards:
- WHS Act 2011 (Duty to ensure health and safety of workers)
- WHS Regulations 2011 Part 5.1 (Management of risks of plant)
- Mining and Quarrying Safety and Health Act 1999 (Qld)
- NSW WHS (Mines and Petroleum Sites) Regulation 2022
- AS 1418 Cranes, hoists and winches (for hoist system components)
Need to run digital pre-starts attached to each asset?
Register every haul truck in MapTrack, attach digital forms, and get a complete history of every inspection, service and compliance record.
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