Free NHVR heavy vehicle inspection checklist

• The MapTrack NHVR heavy vehicle inspection checklist contains 25 checks across 9 sections. Sections covered: Brakes, Steering, Tyres & Wheels, Lights & Reflectors, Coupling Equipment, Body & Chassis, Load Restraint, Windscreen & Mirrors, Warning Devices.
• Vehicle and operator details: date, vehicle registration, fleet number, VIN, GVM/GCM, operator name, driver name, licence number and inspection type (pre-start, periodic, annual).
• Brakes: service brake operation and pedal feel, parking brake hold, air system pressure build-up and governor cut-out, low air warning, brake pad or lining condition, brake drums or rotors, air lines and fittings.
• Steering: steering wheel free play within limits, power steering fluid level and operation, tie rod ends, drag link, steering box mounting and king pins.

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• HVNL compliance: documented inspections demonstrate compliance with Section 226 roadworthiness requirements and support due diligence defences under Section 26E.
• Chain of responsibility protection: systematic inspection records show that all parties in the chain took reasonably practicable steps to ensure vehicle safety.
• Defect prevention: identifying worn brakes, damaged tyres, cracked springs and lighting faults before departure reduces the risk of on-road breakdowns and incidents.
• Reduced defect notices: vehicles inspected against NHVR standards are less likely to receive minor or major defect notices during roadside inspections.
• Maintenance planning: trending defect data from completed inspection forms helps maintenance teams forecast parts demand, schedule repairs and optimise workshop throughput.
• Insurance and audit support: a documented vehicle inspection program provides evidence for insurance underwriting, premium negotiations and NHVR compliance audits.

• Vehicle and operator details: date, vehicle registration, fleet number, VIN, GVM/GCM, operator name, driver name, licence number and inspection type (pre-start, periodic, annual).
• Brakes: service brake operation and pedal feel, parking brake hold, air system pressure build-up and governor cut-out, low air warning, brake pad or lining condition, brake drums or rotors, air lines and fittings.
• Steering: steering wheel free play within limits, power steering fluid level and operation, tie rod ends, drag link, steering box mounting and king pins.
• Suspension: springs (leaf and air), U-bolts, hangers, pins, bushings, shock absorbers and air bag condition with no cracks, sag or missing components.
• Tyres wheels and rims: tread depth (minimum 1.5 mm across the full width per ADR), sidewall condition, inflation pressure, wheel nut tightness, rim condition and valve caps present.
• Lighting and reflectors: headlights (high and low beam), tail lights, brake lights, indicators, hazard lights, clearance lights, number plate light, reversing lights and all required reflectors.
• Coupling equipment: fifth wheel, king pin, turntable greased, locking mechanism, safety chains, air and electrical connections between prime mover and trailer.
• Body chassis and load restraint: body and chassis free of cracks, excessive corrosion or structural damage, mudguards secure, load anchor points intact, tailgate and door latches functional.
• Engine exhaust and fluids: engine oil, coolant, power steering and windshield washer fluid levels, belts and hoses, exhaust system secure with no leaks, no excessive smoke.
• Safety equipment: fire extinguisher current, first aid kit, warning triangles, wheel chocks and any additional equipment required by the vehicle operating conditions.
• Overall result: Pass or Fail with defect register, risk rating (minor, major, critical), corrective actions, follow-up dates and driver and inspector signatures.

1. Record the vehicle, operator and inspection details at the top of the form before starting the inspection.

   Enter the date, vehicle registration, fleet number, VIN, GVM/GCM, operator name, driver name, licence number and inspection type. Confirm whether this is a daily pre-start check, a scheduled periodic inspection or an annual roadworthiness inspection. Note the odometer reading and location.

2. Begin the exterior walk-around from the front of the vehicle, inspecting lighting, windscreen, mirrors, tyres, body panels and coupling equipment.

   Work clockwise around the vehicle. Check all exterior lights and reflectors for operation and damage. Inspect the windscreen for cracks in the wiper sweep area. Verify mirrors are secure and properly adjusted. Check each tyre for tread depth (minimum 1.5 mm), sidewall damage, correct inflation and wheel nut tightness. Inspect body panels, mudguards and the chassis for cracks or corrosion.

3. Check under the vehicle: inspect brakes, suspension, steering components, exhaust system, air lines and coupling equipment.

   Where safe to do so, inspect the underside of the vehicle. Check brake pad or lining thickness, drum or rotor condition and air line integrity. Inspect suspension components including springs, U-bolts, hangers, bushings and air bags. Verify steering components are tight and free of excessive wear. Check the exhaust system for leaks, secure mounting and excessive corrosion. For articulated vehicles, inspect the fifth wheel, king pin and safety chains.

4. Open the engine compartment and check fluid levels, belts, hoses and battery condition.

   Verify engine oil, coolant, power steering fluid and windscreen washer fluid levels are within the acceptable range. Inspect belts for wear, cracking or fraying. Check hoses for bulging, cracks or leaks. Confirm the battery is secure, terminals are clean and there is no evidence of acid leakage. Check for any fluid leaks on the ground beneath the engine bay.

5. Start the engine and test brakes, steering, gauges, warning lights, horn, wipers, air system and all interior controls from the driver seat.

   With the engine running, allow the air system to build to governor cut-out pressure. Test the low air warning device. Perform a static leak-down test. Apply the service brake and confirm firm pedal feel with no pull to one side. Set the parking brake and verify it holds. Check steering wheel free play. Test wipers, washers, horn, defrosters and all dashboard warning lights and gauges.

6. Record all findings, assign a risk rating to each defect, document corrective actions, obtain signatures and submit the completed form.

   Document every defect with a clear description, the affected component and a risk rating: minor (schedule repair within 7 days), major (repair before next trip) or critical (vehicle must not be operated). Any critical defect must be corrected before the vehicle is driven. Sign and date the form, then submit it to the fleet manager or maintenance supervisor for review, corrective action tracking and record retention.

Practical answers about the form, record keeping and using MapTrack.

This form is a starting point. Check the current requirements that apply to your equipment, work and location. The form alone does not establish compliance.

• HVNL Section 226 (Obligation not to use defective heavy vehicle)
• HVNL Section 26C (Primary duty to ensure safety of transport activities)
• HVNL Section 26E (Due diligence defence)
• Australian Design Rules (ADRs) for vehicle standards
• NHVR National Heavy Vehicle Inspection Scheme (NHVIS)

• Heavy Vehicle National Law and Regulations (NHVR)

MapTrack publishes this template. The linked authorities publish their own guidance; they haven't endorsed this form.

• Chain of responsibility checklist
• Vehicle pre-start checklist
• Tyre and rim inspection form
• Vehicle defect report form
• Driver daily log sheet
• Inspections and checklists
• GPS and fleet tracking
• Transport and logistics
• Fleet pre-start inspections
• Pricing