Free roller / compactor pre-start checklist
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Free roller compactor pre-start checklist (PDF-ready). Covers cab, ROPS, drums, vibration system, brakes, steering and safety devices. Download free.
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 roller / compactor pre-start checklist?
A roller compactor pre-start check is a documented inspection completed by the operator before the machine is started or moved each shift. It systematically checks mechanical condition, fluid levels, safety systems, and structural integrity to confirm the roller is fit for operation. Pre-start inspections are a requirement under the Australian Model Work Health and Safety (WHS) Regulations for plant and equipment, and most site safety management plans specify that no plant is to be operated without a completed daily pre-start. Roller compactors operate in dynamic environments, compacting asphalt, aggregate base, and earthworks where drum faults, brake issues, or vibration system failures can cause serious incidents. A thorough pre-start is the first line of defence. AS 4024 (Safety of machinery) and ISO 6165 (Earth-moving machinery) provide additional guidance on guarding, safety systems and inspection requirements. During asphalt paving operations, the water spray system and drum scrapers require particular attention as hardened asphalt residue can damage drum surfaces and affect compaction quality.
Under the WHS Act 2011 and WHS Regulations 2017 (Part 5.1 Plant), a Person Conducting a Business or Undertaking (PCBU) has a duty to ensure that plant capable of causing injury is inspected and maintained so it remains safe for use. Roller compactors present specific hazards including whole-body vibration, rollover on sloping ground, and entrapment between the drum and fixed objects. The documented pre-start checklist provides contemporaneous evidence that the duty holder has taken reasonably practicable steps to manage these risks. On civil and road construction projects, principal contractors routinely require completed pre-start records before any roller is permitted to operate on site, and insurers increasingly expect a verifiable digital inspection trail.
Learn more about pre-start inspections in MapTrack.
Benefits of using this roller / compactor pre-start checklist
- Identify faults before operation: catch drum damage, hydraulic leaks, or brake faults early before they cause breakdowns or injuries.
- WHS compliance: demonstrate duty of care and meet work health and safety obligations under Australian legislation.
- Reduced downtime: prevent costly breakdowns and unplanned maintenance by catching issues before they escalate.
- Insurance and warranty protection: documented pre-starts support insurance claims and manufacturer warranty requirements.
- Operator accountability: signed records confirm who inspected and operated the roller each shift.
- Maintenance planning: trend data from pre-starts helps schedule servicing before failures occur, particularly for vibration systems and drum scrapers.
Benefits of digitising forms in MapTrack
When you digitise roller 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 roller checklists.
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What to include in a roller / compactor pre-start checklist
This roller / compactor pre-start checklist covers 5 key areas:
- Cab & ROPS: ROPS/FOPS structure, seatbelt and operator restraint, mirrors, horn, backup alarm, gauges and instruments, fire extinguisher.
- Engine & Fluids: engine oil, coolant, hydraulic oil, fuel level, DEF/AdBlue where applicable, air filter restriction indicator, battery, leaks and hoses.
- Drums & Vibration System: drum surface condition, scraper blade condition and adjustment, vibration system engagement (amplitude/frequency selector), drum bearing condition, water spray system (asphalt rollers).
- Brakes & Steering: parking brake function, service brake response, steering operation (articulated joint, cylinder, linkages), hydraulic steering pressure.
- Lights & Safety Devices: headlights, work lights, rotating beacon, reverse alarm, emergency stop, seat-activated safety interlock, walk-around for fluid leaks or ground hazards.
How to use this roller / compactor pre-start checklist
- Walk-around inspection: Before starting, walk around the roller checking underneath for fluid leaks, inspecting drum surfaces for damage or flat spots, and confirming there are no objects or personnel near the machine.
- Check fluid levels: With the engine off, check engine oil, coolant, hydraulic oil, fuel and the water spray tank level if fitted. Top up any low fluids and record the levels on the checklist form.
- Inspect cab and controls: Check ROPS/FOPS structural integrity for cracks or deformation, fasten the seatbelt and tug to test the retractor, position mirrors correctly and test the horn and dashboard gauges before starting.
- Start engine and check instruments: Observe that all warning lights illuminate during self-test then extinguish at startup. Confirm oil pressure and coolant temperature gauges read within normal range and verify the backup alarm sounds correctly.
- Test brakes and steering: At slow speed in a safe area, apply the parking brake and confirm the roller holds stationary. Test the service brake for firm pedal response and check articulated steering for smooth operation without play.
- Test vibration system: Engage the vibration system at low speed and confirm both amplitude and frequency selectors respond correctly. Listen carefully for abnormal noise from drum bearings or the eccentric shaft that may indicate wear.
- Complete the form: Mark Pass, Fail or N/A for every item and record detailed notes for any failed item. Sign, print your name and date the form. Do not operate the roller until all failed items are rectified or escalated.
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 roller / compactor pre-start checklist as a PDF.Back to download formHow often should you complete this checklist?
A roller compactor pre-start check must be completed before first use at the start of each shift or each working day. If the roller is used across multiple shifts, each operator must complete their own pre-start before taking control of the machine. For hired or shared plant, additional end-of-shift handover walkarounds are recommended. In addition to daily checks, follow the manufacturer's scheduled maintenance intervals (typically at 250, 500, 1000 hours) and any requirements set by your site safety management plan or principal contractor. During asphalt paving works, the water spray system and drum scrapers should also be checked at the start of each paving session.
Frequently asked questions
Applicable regulatory standards
This template aligns with the following regulations and standards:
- WHS Regulations 2017 (Part 5.1 Plant)
- AS 4024 (Safety of machinery)
- ISO 6165 (Earth-moving machinery)
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<div style="max-width:480px;font-family:system-ui,-apple-system,'Segoe UI',Roboto,sans-serif;border:1px solid #E5E7EB;border-radius:12px;padding:20px;background:#ffffff;">
<p style="font-size:12px;font-weight:700;letter-spacing:0.05em;text-transform:uppercase;color:#0E7490;margin:0;">Free template</p>
<p style="font-size:18px;font-weight:700;color:#071D49;margin:6px 0 0;">Roller / compactor pre-start checklist</p>
<ul style="margin:12px 0 0;padding-left:18px;color:#374151;font-size:14px;line-height:1.6;">
<li style="margin:4px 0;">Cab &amp; ROPS: ROPS/FOPS structure, seatbelt and operator restraint, mirrors, horn, backup alarm, gauges and instruments, fire extinguisher.</li>
<li style="margin:4px 0;">Engine &amp; Fluids: engine oil, coolant, hydraulic oil, fuel level, DEF/AdBlue where applicable, air filter restriction indicator, battery, leaks and hoses.</li>
<li style="margin:4px 0;">Drums &amp; Vibration System: drum surface condition, scraper blade condition and adjustment, vibration system engagement (amplitude/frequency selector), drum bearing condition, water spray system (asphalt rollers).</li>
<li style="margin:4px 0;">Brakes &amp; Steering: parking brake function, service brake response, steering operation (articulated joint, cylinder, linkages), hydraulic steering pressure.</li>
<li style="margin:4px 0;">Lights &amp; Safety Devices: headlights, work lights, rotating beacon, reverse alarm, emergency stop, seat-activated safety interlock, walk-around for fluid leaks or ground hazards.</li>
</ul>
<p style="font-size:13px;color:#6B7280;margin:14px 0 0;padding-top:12px;border-top:1px solid #E5E7EB;">Free <a href="https://www.maptrack.com/templates/roller-compactor-pre-start-checklist" style="color:#071D49;font-weight:600;text-decoration:none;">Roller / compactor pre-start checklist</a> by MapTrack</p>
</div>Please keep the “by MapTrack” attribution link in the snippet.
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