A plant pre-start checklist is a daily check an operator completes before using mobile plant, such as an excavator, loader or roller, to confirm it is safe to operate and to report any defects before work starts.
Plant Pre-Start Checklist: Safer Machines, Faster Fixes, Better Records
Mobile plant is some of the highest-risk equipment on any site. A split hydraulic hose, a quick hitch that has not locked, or a reversing alarm that has stopped working can turn an ordinary shift into a serious incident. A daily pre-start is the operator’s chance to find those problems first.
DIGI CLIP is an Australian-built mobile checklist and inspection platform. Operators complete plant pre-starts on a phone or tablet, defects are captured with photos, and repairs move into the Action Log where they are assigned, resolved and verified.
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What to include in a plant pre-start checklist
Start with the manufacturer’s daily checks for each machine, then make sure your checklist covers these areas.
| Area | Checks | What good looks like |
|---|---|---|
| Walk-around | Tracks or tyres, undercarriage, body damage, guards, steps and handrails | No cracks, missing parts or loose fittings; tracks correctly tensioned |
| Hydraulics and fluids | Hoses, cylinders, fittings, engine oil, coolant, hydraulic and fuel levels | No leaks, bulges or chafing; levels within range |
| Cab and controls | Rollover and falling object protection, seatbelt, controls, gauges, mirrors and cameras | Structure undamaged, seatbelt working, controls responding correctly |
| Safety devices | Reversing alarm, beacon, horn, lights, fire extinguisher, isolation switch | All working, extinguisher present and in date |
| Attachments and quick hitch | Bucket, teeth, pins, quick hitch locking mechanism and indicator | Attachment locked and confirmed; pins secure; no cracks |
| Operational test | Brakes, steering, boom and arm functions, slew and travel | Smooth, controlled movement with no unusual noises |
For forklifts, lifting gear, ladders and workshop equipment, see our equipment inspection checklist template.
How to complete a plant pre-start
- Check the area: look for overhead power lines, unstable ground, people and other plant nearby.
- Walk around the machine: check tracks or tyres, hoses, guards, attachments and leaks.
- Check fluids: engine oil, coolant, hydraulic oil and fuel, as the manufacturer recommends.
- Get in safely and check the cab: seatbelt, controls, gauges, mirrors and cameras.
- Start up and test: alarms, lights, brakes, steering and each hydraulic function.
- Record and escalate: answer “No” with a comment and photo for any defect, and tag the machine out if safety is affected.
A completed checklist shows a task happened. It doesn’t show what happened next.
If you're choosing software, our guide to inspection checklist apps covers offline use, audit trails and evaluation criteria. For excavators, loaders and other earthmoving plant, see our heavy equipment inspection app.
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Adjusting the checklist by machine
| Machine | Extra items to add |
|---|---|
| Excavators | Quick hitch lock and indicator, slew lock, boom and dipper pins, track tension |
| Wheel loaders and backhoes | Articulation joint, bucket linkage, tyre condition and pressure, stabilisers |
| Skid steers and compact track loaders | Lap bar or door interlock, lift arm support, attachment locking |
| Rollers and graders | Drum and scrapers, vibration controls, blade and circle wear |
| Telehandlers | Boom sections, load chart, stabilisers, load moment indicator |
| Tractors | Rollover protection, PTO guard, three-point linkage, implement hitching |
In DIGI CLIP you can keep one form per machine type, or one form with smart fields that show the right questions for each machine.
Plant pre-starts and WHS
Under work health and safety laws, businesses must manage the risks of plant, including how it is inspected and maintained. Safe Work Australia’s model Code of Practice: Managing the risks of plant in the workplace explains how to do this. In South Australia, SafeWork SA’s mobile plant guidance also covers traffic management, exclusion zones and operator competency.
A consistent pre-start record, with defects followed through to verified repairs, can help show that these controls are working day to day.
Example scenario: from a leaking hose to a verified repair
This is an illustrative scenario showing how DIGI CLIP is designed to work. It is not a specific customer case study.
A civil contractor runs excavators and loaders across several sites. Pre-starts are on paper, and when an operator notes a weeping hydraulic hose, the sheet stays in the site shed until the end of the week. With DIGI CLIP configured for their fleet:
- Find it: the operator marks the hydraulics item “No”, adds a photo and flags the machine for assessment.
- Fix it: an action is created in the Action Log, assigned to the fitter with a due date, and escalated by email if it goes overdue.
- Prove it: the fitter records the repair, a supervisor verifies close-out, and the record links back to the original pre-start.
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Related DIGI CLIP guides
- Equipment Inspection Checklist Template
- Pre-Start Checklist Template
- Pre-Operational Checklist App
- DIGI CLIP vs SafetyCulture for Plant Machinery Maintenance
- Action Log
About DIGI CLIP Mobile Forms
DIGI CLIP is an Australian-built mobile checklist and inspection platform. Inspections. Actions. Evidence. Teams complete checks on a phone or tablet, turn defects into assigned actions, and keep the proof that each one was fixed and verified.
Learn more about DIGI CLIP mobile forms or view DIGI CLIP pricing.
Frequently asked questions
What is a plant pre-start checklist?
It is a daily check an operator completes before using mobile plant, such as an excavator, loader or roller, to confirm the machine is safe to operate and to report any defects before work starts.
Who should complete the plant pre-start?
The operator who will use the machine should complete it before the shift, and again if the machine changes operator or attachment during the day.
What should happen if a defect is found?
If the defect affects safety, the machine should be tagged out and not operated until it is repaired and checked. In DIGI CLIP, a failed item can create an action in the Action Log so the repair is assigned, tracked and verified.
Can we use one checklist for different machines?
Yes. You can keep a form for each machine type, or use one form with smart fields that show the right questions for the machine being checked.
Can operators complete pre-starts without mobile coverage?
Yes. Pre-starts can be completed in the DIGI CLIP app without coverage and submitted with a tap once the device is back online.
How long should plant pre-start records be kept?
Keep them in line with your own obligations, contracts and maintenance needs. Many businesses keep inspection and maintenance records for several years. DIGI CLIP stores submitted forms in the cloud with search by form, person, date range and keyword.
Conclusion: pre-starts that end in a fix
A plant pre-start is only as useful as what happens after a defect is found. When operators complete checks on mobile, capture defects with photos, and repairs are assigned and verified, you get safer machines, less downtime and a record you can stand behind.
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This page is general information, not legal or engineering advice. Always follow the manufacturer’s instructions and the WHS requirements that apply in your state or territory.