Pre-start Check (Plant/Vehicle)

What is a pre-start check?

A pre-start check is a point-in-time verification that your equipment hasn't degraded to an unsafe state during its downtime or previous shift. In the context of Australian Work Health and Safety legislation, this procedure serves as a fundamental administrative control measure and a critical primary duty for PCBUs and workers alike.

The pre-start check is distinct from scheduled maintenance. While maintenance focuses on long-term preservation through scheduled intervention (oil changes, filter replacements), the pre-start check is a diagnostic pulse-check of the machine's immediate condition. It confirms the asset is fit for purpose in accordance with Original Equipment Manufacturer (OEM) specifications and regulatory standards.

Far from being a bureaucratic exercise, this check represents the practical application of the hierarchy of controls at the administrative level. By enforcing a physical inspection before you turn the key, your organisation introduces a procedural barrier against catastrophic failure.

Industrial machinery is subjected to extreme stresses—vibration, thermal cycling, impact loads, and environmental contaminants. These forces can cause rapid degradation of safety-critical components. A bolt on a crane slewing ring might be secure on Tuesday evening but, due to thermal contraction or vibration, could be loose by Wednesday morning. The pre-start check is the only mechanism capable of capturing this delta in condition.

What equipment requires pre-start checks?

The requirement for pre-start checks extends across the entire spectrum of workplace plant and equipment. It's not limited to heavy yellow machinery—it applies to any equipment where mechanical failure could cause injury.

Equipment requiring pre-start checks includes:

Each asset class requires a tailored inspection protocol derived from the OEM manual, yet the underlying objective remains constant: to verify the machine's energy sources, control systems, and structural integrity are intact before energy is released.

How a pre-start check works

A robust pre-start check is a structured forensic examination, not a casual glance. To be effective, it must follow a logical sequence that ensures you're not exposed to hazards while inspecting the machine. This sequence generally moves from a "cold" static inspection to a "hot" functional test.

Phase 1: The static inspection (the walk-around)

This phase occurs before the engine is started. The machine is effectively inert, allowing you to safely inspect components that would be dangerous or impossible to check while moving.

Structural integrity and ground truth:

Begin by circling the asset. The first indicator of trouble is often found on the ground. Puddles of fluid—whether red (transmission/hydraulic), green (coolant), or black (engine oil)—provide immediate evidence of seal failure or hose rupture. Trace any leak to its source before proceeding.

Tyres, tracks, and undercarriage:

For wheeled plant, inspect tyre integrity for sidewall cuts, bulging, and adequate tread depth. Check wheel nuts for security, often aided by plastic "wheel nut indicators" that visually show if a nut has loosened.

For tracked plant (excavators, dozers), inspect track tension (sag), the condition of idlers and sprockets, and the presence of debris packed into the undercarriage which could freeze or jam the mechanism.

Fluid analysis:

Checking fluids is more than verifying volume—inspect the quality of the fluid on the dipstick. Milky engine oil indicates coolant contamination (head gasket failure); burnt-smelling transmission fluid indicates internal clutch slippage. Check sight glasses on hydraulic tanks to ensure levels are within the operating range.

Ground engaging tools and attachments:

On earthmoving equipment, inspect bucket teeth, cutting edges, and rippers for cracks or missing retention pins. A missing tooth can destroy a crusher downstream or unbalance a machine. Physically verify locking pins on quick-hitches to ensure the bucket cannot detach unintentionally during use—a common cause of fatalities in construction.

Phase 2: Systems and cabin checks

Once the external walk-around is complete, enter the cabin or control station. This phase focuses on your environment and passive safety systems.

Ergonomics and restraints:

The seatbelt is the single most critical safety device in mobile plant. Check the webbing for fraying, the buckle for positive engagement, and the retractor mechanism. The seat itself must be adjustable and secure; a loose seat can cause you to lose control of the pedals during travel.

Visibility aids:

Mirrors must be clean, unbroken, and adjusted to your line of sight. Windshields must be free of cracks that could diffract light or obscure vision. Test wipers and washers to ensure they can clear mud or dust.

Fire suppression and emergency equipment:

Many heavy machines are fitted with fire suppression systems. Check the pressure gauge on the actuator cylinder to ensure it's in the "green" zone. Verify handheld fire extinguishers are secure and charged, and that first aid kits have intact seals.

Phase 3: The functional test (dynamic checks)

Now start the engine. This phase tests the "live" systems of the machine.

Warning systems and diagnostics:

Upon startup, the dashboard undergoes a self-test. Verify that all warning lights (oil pressure, battery charge, temperature, engine fault) illuminate and then extinguish. A light that fails to illuminate suggests a blown bulb, which could mask a critical failure later.

Braking systems:

Parking brake: Engage the parking brake and attempt to gently drive against it. The machine should hold firm.

Service brake: Move the machine slowly and apply the foot brake. The stop should be smooth and immediate, without the machine pulling to one side (indicating a caliper imbalance).

Hydraulics and controls:

Cycle every hydraulic function through its full range of motion. Raise, extend, and slew the boom; crowd and dump the bucket. Listen for hydraulic "screaming" (relief valve actuation), shudders, or hesitation, which indicate air in the system or pump wear. Test steering lock-to-lock to check for play or binding.

Safety interlocks and alarms:

Test critical safety devices. The reverse alarm (beeper/squawker) must be audible. Flashing beacons must rotate. Engage the "deadman" switch or safety lever (on excavators) to ensure controls are isolated when you leave the seat. Activate emergency stops to confirm they kill the engine immediately.

Regulatory framework in Australia

The imperative for pre-start checks isn't merely operational—it's a rigid legal requirement embedded in the Australian legislative framework. Failure to conduct these checks exposes you and your organisation to severe penalties, including fines and imprisonment.

Work Health and Safety Act 2011 (WHS Act)

The WHS Act (harmonised across most Australian jurisdictions) creates a non-delegable duty of care.

Section 19: Primary Duty of Care

Your PCBU must ensure, so far as is reasonably practicable, the health and safety of workers. This explicitly includes the "provision and maintenance of safe plant and structures" and "safe systems of work". You cannot claim to have provided safe plant if you have no mechanism to verify its condition daily.

Section 27: Duty of Officers

Officers (directors, CEOs) must exercise "due diligence." This requires them to have knowledge of safety matters and to ensure the PCBU has appropriate resources and processes for eliminating risks. An Officer must verify that pre-start checks are actually happening—not just assume they are. If an accident occurs because an Officer failed to audit the pre-start system, they can be personally liable.

Section 28: Duty of Workers

You have a duty to take reasonable care for your own safety and to comply, so far as you're reasonably able, with any reasonable instruction given by the PCBU. If your workplace policy mandates a pre-start check, and you "tick and flick" or skip the check, you're in breach of Section 28.

Work Health and Safety Regulations

Regulation 213: Maintenance and Inspection of Plant

This regulation mandates that a person with management or control of plant must ensure that maintenance, inspection, and testing are carried out by a competent person. Crucially, these inspections must be conducted:

1. In accordance with the manufacturer's recommendations; or
2. If there are no manufacturer's recommendations, in accordance with the recommendations of a competent person.

Since virtually every OEM manual for heavy machinery specifies a "Daily" or "Pre-Operational" inspection, Regulation 213 effectively gives the manufacturer's pre-start checklist the force of law. Ignoring the OEM's instruction to check oil levels daily is a breach of Regulation 213.

Regulation 237: Record Keeping

For registrable plant (cranes, lifts), records of all tests, inspections, and maintenance must be kept for the life of the plant. While daily pre-starts for non-registrable plant fall under general record-keeping (typically 5-7 years for liability purposes), Regulation 237 creates a strict archiving requirement for higher-risk assets.

Heavy Vehicle National Law (HVNL) and Chain of Responsibility

For heavy vehicles (over 4.5 tonnes GVM), the HVNL imposes Chain of Responsibility duties. This law recognises that on-road safety isn't solely the driver's responsibility.

The Primary Duty (Section 26C) requires each party in the chain (scheduler, loader, operator, executive) to ensure the safety of transport activities. A pre-start check is the primary control measure for ensuring a vehicle is "roadworthy" before it enters the public road network.

If a truck causes a fatality due to bald tyres, and the investigation reveals the driver skipped the pre-start check (or the fleet manager ignored the defect report), both parties can be prosecuted for a Category 1 offence (Reckless Conduct), which carries multi-million dollar fines and potential jail time. The pre-start logbook is your legal "shield" that demonstrates you checked the vehicle and deemed it safe.

Why pre-start checks matter: business value and compliance

Beyond the threat of prosecution, pre-start checks offer significant operational and financial value.

Asset preservation and predictive maintenance

Machinery rarely fails instantly—it usually gives warning signs. A pre-start check is a condition-monitoring tool. Detecting a weeping hydraulic seal costs $200 to fix (seal replacement). Ignoring it until the hose bursts under load costs $5,000 in oil, cleanup, and hose replacement, plus $20,000 in lost production downtime.

Pre-start checks shift your maintenance curve from "Reactive" (fix it when it breaks) to "Preventative" (fix it before it breaks).

Safety culture indicator

The rigorous application of pre-start checks is a barometer for your wider safety culture. Organisations where operators meticulously check their machines typically have lower incident rates across the board. Conversely, a yard full of machines with unchecked fluid levels and broken mirrors is a leading indicator of a "drift into failure".

Incident defensibility

In the aftermath of an incident, the first question from an investigator is, "Show me the pre-start for that day." A completed, signed, and passed pre-start checklist is powerful evidence that you took all reasonable steps to ensure safety. A missing checklist suggests negligence and systemic failure.

Asset-specific protocols: what to check

Different asset classes have unique risk profiles. The following details critical check items for common plant types.

Earthmoving plant (excavators, loaders, dozers)

Hydraulics: The lifeblood of the machine. Check rams for pitting/leaks and hoses for rubbing. A pinhole leak at 3000 PSI can inject oil into human skin (injection injury), requiring surgical amputation.

Tracks/undercarriage: Check track tension. Loose tracks can de-track on slopes; tight tracks wear out final drives. Inspect for loose track pads.

Safety levers: The "deadman" lever (usually on the left armrest) must physically disconnect the hydraulic controls when raised.

Quick hitch: Verify the safety pin is in place. Unintended bucket detachment is a major killer in this sector.

Material handling (forklifts, telehandlers)

Tines and forks: Inspect the heels of the forks for cracks (where the load is highest). Check locking pins are engaged so tines don't slide off.

Mast chains: Check for equal tension. A slack chain indicates uneven stretching or a seized carriage roller.

Load chart: Ensure the load plate is legible. If you cannot read the capacity, you're guessing.

Gas/battery: For LPG, check the bottle clamp and hose coupling. For electric, check battery water levels and cable insulation.

Elevated work platforms (scissor lifts, boom lifts)

Stability: Check pothole protection bars (scissor lifts) deploy correctly. Inspect outriggers/stabilisers for damage and ensure spreader pads are present.

Controls: Test the "Ground Controls" first (emergency lowering). If you get stuck aloft, the ground crew must be able to lower you.

Harness points: Inspect the lanyard anchor point in the basket for corrosion or damage.

Tilt sensor: Verify the alarm sounds when the machine is on a slope.

Heavy vehicles (trucks)

Air systems: Drain air tanks to check for moisture (which corrodes valves) or oil (indicating compressor failure).

Couplings: Inspect the turntable (fifth wheel) jaws or pin coupling. Visual confirmation that the trailer kingpin is locked is mandatory.

Lights and glazing: All marker lights must work. Heavy vehicles are often wide and long; lighting defines their geometry to other road users at night.

Load restraint: Check straps, chains, and tensioners before leaving the yard.

Common challenges and limitations

Despite their importance, pre-start checks are often the weakest link in the safety chain due to human factors and systemic issues.

The "tick and flick" phenomenon

This is the most pervasive failure mode. You, driven by production pressure or complacency, might rapidly tick "Pass" on every item without looking at the machine. This generates "Safety Clutter"—paperwork that creates an illusion of safety while providing no actual risk reduction.

Repetition breeds blindness. If you check the same machine 500 times and find no faults, you stop expecting to find faults. Lack of consequence also drives this: if you report a broken seat and it isn't fixed for three weeks, you learn that reporting is futile (Learned Helplessness).

Competency gaps

You may be licensed to drive a loader but not competent to inspect it. Training often focuses on control manipulation (digging dirt) rather than technical inspection (identifying hydraulic hose blistering or track wear limits). If you don't know what "excessive play" looks like, you cannot report it.

Paper-based limitations

Paper logbooks are inherently flawed. They're vulnerable to damage (grease/water), loss, and illegibility. Crucially, data in a paper book is "trapped" in the cab. A fleet manager might not see your defect report until the book is full and handed in—weeks after you identified the fault. This latency destroys the ability to react to safety-critical defects in real-time.

Normalisation of deviance

Diane Vaughan's theory of Normalisation of Deviance explains how defects become acceptable. A cracked mirror is reported but not fixed. The machine is used anyway. Over time, the cracked mirror is no longer seen as a "defect" but as a normal part of the machine. The standard of safety slowly erodes until a major failure occurs.

Best practices for implementation

To combat "tick and flick" and ensure compliance, you should adopt the following strategies.

Establish clear "no-go" criteria

Your checklist must clearly distinguish between "Monitor" defects and "No-Go" defects.

Monitor: A torn seat cover or scratched paint. The machine is safe to operate, but maintenance is notified.

No-Go: A hydraulic leak, non-functional brake, or broken seatbelt. The machine is immediately tagged "Out of Service" and the key is removed.

Empowering your operators with a clear list of conditions that mandate stopping work removes ambiguity and pressure.

Implement digital transformation

Transitioning to digital pre-start apps (e.g., iAuditor, MEX, Plant Assessor) addresses the flaws of paper:

Forced workflow: The app can prevent the "submit" button from working until all critical items are checked.

Timestamps and GPS: Verifies when and where the check was done, preventing backdating.

Photo evidence: You can snap a photo of a leak, giving mechanics immediate insight into the problem.

Automation: A "Fail" result can instantly email the maintenance manager and safety officer, closing the loop.

Close the defect reporting loop

A pre-start system fails if your reported defects fall into a black hole. The "Tag Out" procedure is critical:

1. Tag: You attach a yellow/black "Out of Service" tag to the isolation point.
2. Report: Defect is logged (digital or paper).
3. Rectify: Competent person repairs the fault.
4. Remove: Only the competent person or supervisor removes the tag.

Note: Never confuse "Out of Service" tags (Plant status) with "Danger" tags (Personal protection/Lockout). Mixing these can be fatal.

Audit and verify the process

Your supervisors must audit the process by "checking the checker." A supervisor should occasionally observe a pre-start check to ensure you're actually testing the alarms and opening the engine bay. Some organisations place a "dummy fault" (e.g., a zip tie on a dipstick) to see if you find it.

Integrate with journey management

For mobile fleets, the pre-start check is the foundational step of a Journey Management Plan. A JMP assesses the risks of the route (weather, fatigue, remote areas), while the pre-start assesses the vehicle.

You cannot have a safe journey in an unsafe vehicle. Your JMP should require the pre-start ID/number to be entered before the journey is authorised. For remote travel, the pre-start expands to include survival gear (water, satellite phone, EPIRB, dual spare tyres).

References and Further Reading

Work Health and Safety Act 2011 (NSW), Sections 19, 27, and 28 establish the legal framework for duties of care.

Safe Work Australia's Managing the Risks of Plant in the Workplace - Code of Practice (December 2023) provides comprehensive guidance on plant inspection and maintenance requirements.

SafeWork NSW Guide to Inspecting and Maintaining Plant offers practical guidance on inspection frequencies and competency requirements.

Heavy Vehicle National Law (Section 26C) establishes Chain of Responsibility duties for heavy vehicle operations.

Vaughan, D. (1996). The Challenger Launch Decision: Risky Technology, Culture, and Deviance at NASA. University of Chicago Press. This seminal work introduces the concept of "normalisation of deviance" that explains how safety standards gradually erode.

Dekker, S. (2011). Drift into Failure: From Hunting Broken Components to Understanding Complex Systems. Ashgate Publishing. Explains how complex systems fail despite individual component checks appearing adequate.

Pinnacle Software: What is a Pre-start Check? provides industry context on digital pre-start implementation.

SafeWork NSW: Isolation of Plant - Lock-out / Tag-out details the proper use of Out of Service and Danger tags.