Quick answer: A plant pre-start checklist is a structured form completed by the operator before using a piece of plant — such as an excavator, forklift, or crane — at the start of each shift. It confirms the plant is in a safe and serviceable condition before work begins.
Last reviewed: June 2026 by the BlueSafe Technical Team. Reflects current Model WHS framework.
If you operate plant and equipment on a worksite in Australia, a pre-start checklist is one of the simplest and most effective controls you can have in place. It takes only a few minutes to complete, but it can be the difference between catching a brake fault before it causes a serious incident and finding out about it the hard way.
This guide explains what a plant pre-start checklist is, what it covers, who completes it, and what your business should do when a defect is identified.
What is a plant pre-start checklist?
A plant pre-start checklist is a structured inspection form completed by the operator before operating a piece of plant at the start of each shift — or before a new operator takes over mid-shift. It is a systematic walk-around and functional check designed to confirm that the plant is in a safe, serviceable condition before it is put to work.
"Plant" in WHS terms covers a broad range of equipment — excavators, forklifts, elevated work platforms (EWPs), cranes, rollers, loaders, tractors, compactors, and any other powered mobile or stationary machinery used on a worksite.
Pre-start checklists are sometimes called pre-operational checks, pre-shift inspections, or daily plant inspection forms. Whatever the name, the purpose is the same: verify the plant is safe before the shift starts.
What does a plant pre-start checklist cover?
A thorough pre-start checklist will cover the following areas.
Fluids
The operator checks engine oil, coolant, hydraulic fluid, brake fluid, and fuel levels. Low or contaminated fluids can indicate a leak or an impending mechanical failure. Hydraulic leaks in particular create both a fire risk and a loss-of-control risk.
Tyres and tracks
For wheeled plant, this means checking tyre condition, inflation, and any signs of damage such as cuts, bulges, or embedded objects. For tracked plant, the operator checks track tension, wear, and whether any rollers or sprockets show signs of damage or leakage.
Guards and safety covers
Belt guards, PTO guards, rotating part covers, and access panels should all be in place and secure. Missing or damaged guards are a direct exposure to entanglement and struck-by hazards.
Lights and warning devices
All headlights, work lights, reverse lights, and beacon lights should be operational. Poor visibility is a leading cause of collisions on worksites — particularly during early-morning starts, in tunnels, or in dusty conditions.
Alarms and beepers
Reverse alarms, travel alarms, load alarms, and any other audible warning devices must be functional. The operator tests these during the pre-start check so that any worker in the vicinity has the warning they are entitled to expect.
ROPS and FOPS
Rollover protection structures (ROPS) and falling object protection structures (FOPS) should be inspected for physical damage, missing mounting bolts, cracks, or any modification that could compromise their integrity. A damaged ROPS or FOPS does not provide the protection it is rated for.
Controls
All operating controls — steering, braking, lifting, lowering, tilt, swing, and any auxiliary controls — should be checked for correct operation, no unusual resistance, and no unexpected play. The operator should also confirm that the operator restraint system (seatbelt or lap bar) is functional.
Leaks
The operator conducts a visual inspection under and around the machine for signs of hydraulic, fuel, coolant, or oil leaks. Even a slow leak warrants reporting — it will worsen under load and can create a fire or ground contamination risk.
Attachments
Any attachments fitted to the plant — buckets, forks, blades, augers, jib arms — should be checked for secure mounting, visible cracking or wear, and correct function. Quick-couplers should be inspected to confirm the attachment is locked correctly.
Fire extinguisher
Most worksites and many plant hire agreements require a serviceable fire extinguisher to be mounted on the plant and within easy reach of the operator. The pre-start check confirms it is present, within its service date, and fully charged.
What is the purpose of a plant pre-start checklist?
A plant pre-start checklist serves three connected purposes.
First, it verifies the plant is safe to operate before each shift. An excavator that worked fine yesterday may have developed a hydraulic leak, a flat tyre, or a faulty reverse alarm overnight. The pre-start check catches these issues before anyone is exposed to the resulting risk.
Second, it creates a record that demonstrates your maintenance and inspection obligations are being met. Under the Model WHS Regulations, a PCBU has duties in relation to plant — including ensuring plant is inspected, maintained, and operated safely. A completed pre-start checklist is evidence that those obligations are being taken seriously. It is the kind of record a WHS inspector, principal contractor, or insurer will ask for after an incident.
Third, it catches developing faults before they become serious failures. A small hydraulic weep may not affect the machine's performance today, but if it is recorded and monitored, a maintenance decision can be made before it becomes a burst hose and a sudden loss of control. Pre-start checklists are a front-line maintenance tool as much as a safety tool.
Who completes a plant pre-start checklist?
The operator — the person who will be using the plant during that shift — completes the pre-start checklist. This is important: the person best placed to notice something unusual about the machine's condition is the person who uses it regularly.
The operator should be trained in how to perform a pre-start inspection, what they are looking for, and what action to take if they find a defect. This training should be documented.
On sites where multiple operators use the same piece of plant across shifts, each operator completes a separate check at the beginning of their shift, or when they take over from the previous operator.
What to do when a defect is found
If the pre-start check identifies a defect — whether it is a fluid level outside the normal range, a damaged guard, a faulty alarm, or any other issue — the following steps apply.
- Do not operate the plant. A plant with a known defect that creates a risk must be taken out of service.
- Tag out the plant. Apply a danger or out-of-service tag to the controls so that no other worker starts the machine.
- Report the defect immediately. The operator must report the defect to their supervisor or the plant manager. The defect should be recorded on the pre-start checklist and in any maintenance log.
- Arrange assessment and repair. A competent person — a qualified mechanic or the manufacturer's authorised repairer — should assess the defect and carry out any required repairs before the plant is returned to service.
- Do not remove the tag until the repair is verified. Only the person who applied the tag, or a person authorised by the PCBU, should remove it — and only once the plant has been confirmed as safe to operate.
Sample plant pre-start checklist items
The following are examples of the types of items typically included on a plant pre-start checklist. Exact items will vary depending on the type of plant.
| Check item | Satisfactory | Defect noted | Action taken |
|---|---|---|---|
| Engine oil level within normal range | |||
| Coolant level within normal range | |||
| Hydraulic fluid level within normal range | |||
| Fuel level adequate for shift | |||
| No visible fluid leaks under machine | |||
| Tyres/tracks in serviceable condition | |||
| All guards in place and secured | |||
| Headlights, work lights, reverse lights operational | |||
| Reverse alarm/travel alarm functional | |||
| ROPS/FOPS structure — no damage or cracks visible | |||
| Seatbelt/operator restraint operational | |||
| All controls operate correctly | |||
| Attachments — secure mounting, no visible damage | |||
| Fire extinguisher present, within service date | |||
| Windscreen/mirrors clean and undamaged |
Operator name: ________________ Date: _________ Shift: _________
Plant ID/Registration: ________________ Hourmeter/Odometer: _________
Defects noted: __________________________________________________
Supervisor notified: Yes / No Plant tagged out: Yes / No
Related resources
If you are setting up plant safety documentation for your business, the pre-start checklist works alongside two other important documents:
- What Is a Plant and Equipment Register? — a central record of all plant your business owns, hires, or operates, including registration, service history, and inspection due dates.
- Plant and Equipment Safety Checklist — a broader inspection checklist used for periodic plant safety reviews, complementing the daily pre-start check.
Frequently asked questions
Is a plant pre-start checklist a legal requirement in Australia?
WHS regulations require PCBUs to ensure plant is without risk to health and safety, which includes having maintenance and inspection processes in place. While the regulations do not prescribe a specific form called a "pre-start checklist," completing and recording pre-start checks is widely recognised as evidence that a PCBU has met their duty to manage plant risks. Many principal contractors, plant hire companies, and industry codes of practice also require pre-start checks as a condition of operation.
Who is responsible for completing a plant pre-start checklist?
The operator using the plant at the start of each shift is responsible for completing the pre-start checklist. The PCBU is responsible for ensuring the check is carried out, that the operator has been trained to perform it, and that a process exists for reporting and acting on any defects identified.
What happens if a defect is found during a pre-start check?
If a defect is found, the plant should be taken out of service immediately — tagged out or locked out — until the fault is assessed and repaired by a competent person. The defect must be reported to the supervisor or plant manager. Plant must not be operated when a known fault creates a risk to health and safety.
How long should completed pre-start checklists be kept?
There is no single prescribed retention period across all jurisdictions, but keeping completed pre-start checklists for at least two to five years is common practice. They may be required as evidence in the event of an incident investigation, insurance claim, or WHS inspection. Check any applicable industry codes, principal contractor requirements, or your insurer's expectations for your specific situation.
Ready to manage your plant documentation?
BlueSafe Online gives you access to ready-to-use WHS document templates including plant pre-start checklists, plant and equipment registers, and plant safety inspection forms — designed for Australian small business and built to satisfy worksite and audit requirements.
This guide provides general information only. Requirements will depend on the nature of your plant, applicable legislation, industry codes of practice, and any contractual obligations.