Plant and vehicle prestart checklist

Under the Work Health and Safety Act 2011, a PCBU must ensure plant is maintained and safe to use, and operators are the last line of defence before a fault becomes an incident. A prestart check takes a few minutes and catches the failures that maintenance schedules miss between services. This template covers mobile plant and light vehicles, with space to add machine-specific items.

Who it's for: Operators and drivers, transport and depot supervisors, plant managers, and anyone responsible for a fleet or a yard.

Free to use and adapt · Last updated 2026-08-02 · No email required

Machine and operator

Plant or vehicle, and asset or registration number

Operator name

Licence or competency held, and expiry High-risk work licence class where required

Date and shift

Hours or odometer at start

Walk-around, engine off

No new damage, cracks, or deformation to structure, boom, mast or attachments
No fluid leaks under the machine, and none on the machine
Tyres or tracks: pressure, tread, cuts, damage, and wheel nuts secure
Fluid levels: engine oil, coolant, hydraulic, brake, fuel or charge level
Guards, covers and panels present, secure and undamaged
Steps, handholds and walkways clean, undamaged and free of grease
Windows, mirrors and cameras clean, adjusted and undamaged
Lights, beacons and reflectors clean and undamaged
Attachments and quick hitches correctly secured and pins locked
Load-restraint equipment present and in good condition
Fire extinguisher present, charged and in date
First aid kit present and stocked
Operator manual present in the cab
No loose items in the cab that could interfere with controls

Function checks, engine running

Gauges and warning lights behave correctly at start-up, with no faults remaining lit
No unusual noise, vibration, smoke or smell
Service brake and park brake both effective, tested at low speed in a clear area
Steering responds correctly with no excessive play
Hydraulics operate smoothly with no drift when held
Horn works
Reversing alarm and any travel alarm work
Beacon, work lights, head, tail, brake and indicator lights work
Seat belt latches, retracts and is undamaged
Seat adjustment and operator presence system work correctly
Emergency stop works, and the operator knows where it is
Cameras, proximity sensors and other safety devices function
Two-way radio or communications device works, and the correct channel is set

Machine-specific checks

Add the items that matter for this class of plant. Keep the list short enough that operators complete it honestly.

Item	Pass	Fail	Comment

Operator fitness and conditions

Operator is fit for duty, not fatigued, and not affected by alcohol, drugs or medication
Operator holds the current licence or competency for this machine
Operator is familiar with this specific machine and its controls
Ground conditions, slopes, edges and underfoot hazards assessed for today's work
Overhead and underground services identified, with clearances agreed
Exclusion zones and pedestrian separation in place
Weather and visibility suitable, with stop conditions understood
Communications with spotters or ground crew agreed and tested

Defects and stop conditions

Any fault affecting brakes, steering, guards, safety devices, structure or load-bearing components means the machine does not operate. Tag it out and report it. Nobody should have to argue this in the moment.

Defect found	Safe to operate (Y/N)	Action taken	Reported to	Time	Tagged out (Y/N)

Declaration

I have completed this prestart check. Any defect found is recorded above and has been reported. I have not operated the machine with a defect that makes it unsafe.

Operator signature and time. Supervisor review signature and time.

How to use it

Getting the most out of this template

Keep the book with the machine, not in the office. A prestart completed at a desk is not a prestart.
Make the stop conditions explicit and back operators who use them. One overruled operator teaches everyone that the check is theatre.
Review completed sheets weekly. Recurring minor defects usually indicate a maintenance interval that is too long.
Tag out and physically immobilise anything unsafe, rather than relying on a note.
Add machine-specific items after any incident or near miss with that class of plant.

This template is general information, not legal advice. Requirements differ by jurisdiction and industry; check the guidance published by Safe Work Australia and your state WHS regulator and seek advice for your specific circumstances.

Questions

Frequently asked

Is a prestart check legally required?

The duty under the Work Health and Safety Act 2011 is to ensure plant is safe and properly maintained, and a documented prestart check is the accepted way of demonstrating the daily part of that. Specific regulations and standards for particular plant classes may set more detailed requirements, so confirm what applies to your fleet with Safe Work Australia and your state WHS regulator.

Who is responsible if a defect is missed?

Responsibility is shared. The PCBU must provide maintained plant, a workable system and the authority to stop. The operator must complete the check honestly and report what they find. Where an operator was pressured to run a defective machine, the failure sits with the system, not the operator.

How long should prestart records be kept?

Keep them at least as long as your record-keeping policy requires, and longer for plant involved in an incident. They are the evidence that the machine was checked and that reported defects were acted on, and they will be requested after any serious plant incident.

Can we do prestart checks electronically?

Yes, and a photo requirement for defects tends to improve honesty and speed up the repair. Make sure the electronic system still works when there is no signal in the yard, and that a failed check actually blocks the machine rather than just logging it.

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The template covers the paperwork. Duress covers the response.

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