Free plant pre-start checklist
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Free plant pre-start checklist (PDF-ready). Covers engine, hydraulics, tracks or tyres, safety systems, controls and general condition for heavy plant.
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See the first part of the plant pre-start checklist below. Download the full version above.
What is a plant pre-start checklist?
A plant pre-start checklist is a structured inspection form completed before operating any item of heavy plant or mobile equipment on a worksite. It covers the engine, hydraulics, undercarriage or tyres, safety systems, operator controls, fluid levels and general condition. Plant includes excavators, loaders, dozers, graders, rollers, dump trucks, cranes and any other mobile or fixed equipment used in construction, mining, civil and industrial operations. The pre-start check ensures the machine is safe to operate and complies with the WHS Act requirement for the PCBU to maintain plant in a safe condition.
Pre-start inspections are the single most effective control for preventing plant-related incidents on worksites. They force the operator to systematically check every critical system before the machine is started, identifying faults that could cause injury, equipment damage or environmental harm. MapTrack digitises plant pre-starts so every inspection is timestamped, geotagged and linked to the plant asset record, giving site managers real-time visibility of which machines have been checked and which are overdue.
Learn more about pre-start inspections in MapTrack.
Benefits of using this plant pre-start checklist
- Operator safety: identifies faults in brakes, steering, hydraulics and safety systems before the operator enters the cab and starts work
- WHS compliance: documented pre-start inspections satisfy the PCBU duty under the WHS Act to maintain plant in a safe condition at all times
- Reduced unplanned downtime: catching fluid leaks, worn components and warning lights early prevents breakdowns during production hours
- Standardised process: a consistent checklist ensures every operator checks the same items regardless of experience level or machine type
- Asset protection: recording operating hours, fluid levels and condition at the start of each shift extends plant life and supports warranty claims
- Site accountability: digital pre-starts linked to operator and machine create a clear audit trail for principal contractor reporting and incident investigation
Benefits of digitising forms in MapTrack
When you digitise plant 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.
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What to include in a plant pre-start checklist
This plant pre-start checklist covers 8 key areas:
- Machine identification: equipment type, make, model, serial number, fleet number and current hour meter reading
- Operator details: name, competency or licence number, date and shift
- Engine and fluids: engine oil level, coolant level, hydraulic oil level, fuel level and any visible leaks
- Undercarriage or tyres: track tension and condition for tracked machines, or tyre pressure and condition for wheeled machines
- Hydraulics: cylinder condition, hose condition, boom stick and bucket operation and no leaks under pressure
- Safety systems: ROPS, FOPS, seatbelt, fire extinguisher, reversing alarm, camera, mirrors and emergency stop
- Operator controls: joysticks, pedals, switches, gauges and warning lights all functional and responding correctly
- General condition: body damage, glass condition, access steps and handrails, clean cab and housekeeping around machine
How to use this plant pre-start checklist
- Walk around the machine: Before entering the cab, complete a full walk-around checking underneath for fluid leaks, inspecting the body for visible damage or loose components, and confirming there are no obstructions or personnel around the machine.
- Check fluids: Verify engine oil, coolant, hydraulic oil and fuel levels are within the operating range marked on each dipstick or sight glass. Top up any low fluids and record the levels. Look for signs of abnormal consumption indicating a developing fault.
- Inspect undercarriage or tyres: For tracked machines, check track tension on both sides, inspect sprockets and idlers for wear and clear any debris from the undercarriage. For wheeled machines, check tyre pressure with a gauge and inspect for cuts, bulges or uneven wear.
- Start the engine and check gauges: With the engine running, check all dashboard gauges and warning lights for normal readings. Listen for unusual noises, excessive vibration or abnormal exhaust smoke that may indicate engine, turbo or exhaust system faults requiring investigation.
- Test safety systems: Verify the reversing alarm sounds when reverse is selected, the camera displays clearly, the horn is audible, the emergency stop cuts all functions immediately, and the fire suppression system gauge reads in the acceptable range.
- Test controls: Operate all hydraulic functions including boom raise and lower, stick in and out, bucket curl and dump, swing left and right, and travel forward and reverse. Confirm smooth, proportional response with no jerking, delay or drift.
- Record the result: Complete the checklist marking Pass, Fail or N/A for every item and noting any defects found. Report safety-critical faults to the supervisor immediately and do not operate until they are rectified.
In MapTrack, you can run digital pre-starts attached to each asset. Each submission is stored as a timestamped PDF against the asset record.
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Back to download formHow often should you complete this checklist?
Plant pre-start inspections should be completed before each use or at the start of each shift. If the operator changes mid-shift, the incoming operator should complete a fresh pre-start. After any maintenance, repair or incident involving the plant, a new pre-start inspection must be completed before the machine returns to service.
The WHS Act does not prescribe a specific inspection frequency but requires the PCBU to ensure plant is maintained so it remains safe for use. Australian Standard AS 2550 for cranes requires daily pre-operational checks and this principle is applied as best practice across all heavy plant categories. Weekly and monthly deeper inspections should supplement the daily pre-start, covering items such as structural integrity, bolt torques and electrical systems. MapTrack can schedule daily, weekly and monthly inspection tiers against each plant asset and alert when any inspection is overdue.
Frequently asked questions
- What is a plant pre-start inspection?
- A plant pre-start inspection is a systematic check of a piece of heavy plant or mobile equipment completed before it is operated each day or shift. It covers engine and fluids, hydraulics, undercarriage or tyres, safety systems, operator controls and general condition. The purpose is to identify any defects that could affect safe operation and to comply with WHS legislation.
- Is a plant pre-start inspection a legal requirement in Australia?
- The WHS Act requires a PCBU to ensure plant is maintained in a safe condition and that risks associated with using plant are managed. While the Act does not prescribe a specific daily inspection form, a pre-start inspection is the accepted standard practice for meeting this duty. Most principal contractors and mining regulators require documented daily pre-starts as a condition of site access.
- Who can complete a plant pre-start checklist?
- The operator who will be using the plant should complete the pre-start checklist. The operator must be competent and, where required, hold the relevant licence or ticket for the class of plant. For high-risk plant such as cranes and forklifts, only operators with the appropriate SafeWork or state regulator licence may operate and inspect the machine.
- Can plant pre-start inspections be done digitally?
- Yes. Digital plant pre-start checklists in MapTrack replace paper forms with mobile-friendly inspections that capture GPS location, timestamps and photos automatically. Completed inspections are linked to the plant asset record and supervisors can see real-time dashboards showing which machines have been inspected and which are overdue.
- What should I do if a plant pre-start finds a defect?
- If the defect is safety-critical the machine must not be operated. Attach a Do Not Use tag, isolate the machine and report the defect to the supervisor and maintenance team. Record the defect on the pre-start form. In MapTrack a linked defect report and work order will be created automatically. For minor defects that do not affect safe operation, record the issue and schedule the repair.
Applicable regulatory standards
This template aligns with the following regulations and standards:
- WHS Regulations 2017 (Part 5.1 Plant)
- WHS Act 2011 (Section 19 - Primary duty of care)
- AS 2550 (Cranes, hoists and winches)
Plant Pre-Start Checklist preview
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