Pre-Start Checks: What to Record for Plant and Forklifts

What should a pre-start check for a forklift or plant item actually cover?

A pre-start check is a quick, structured inspection completed before plant is used each shift, designed to catch defects before they cause an incident. For forklifts, WorkSafe Victoria expects this done in line with the manufacturer's recommendations — at the start of each shift, before first daily use, and whenever the operator changes — covering tyres, forks, mast, chains, hydraulics, attachments, restraints, controls, brakes, steering, warning devices and the power system.

Why pre-start checks matter under Victorian law

Under the Occupational Health and Safety Act 2004 and Part 3.5 of the OHS Regulations 2017 (Vic), employers have a duty to identify hazards associated with plant and eliminate or reduce the risk, so far as reasonably practicable. That duty doesn't stop once plant is purchased and commissioned — it extends to ongoing maintenance and inspection. A documented pre-start check is one of the clearest ways to show you're meeting that duty, and it's often one of the first things checked after an incident involving mobile plant.

What to check before operating a forklift

WorkSafe Victoria's forklift guidance points to these areas before use:

1. Tyres — wear, damage, pressure
2. Forks — cracks, wear, correct positioning
3. Mast and chains — damage, lubrication, smooth operation
4. Hydraulics — leaks, correct function of lift and tilt
5. Attachments — secure fitting, correct operation
6. Restraints — seatbelt and operator restraint systems working
7. Controls — all operating controls functioning correctly
8. Brakes and steering — responsive and effective
9. Warning devices — horn, lights, reversing alarm working
10. Power system — battery, fuel or gas system in safe condition

What to do when a defect is found

If a pre-start check turns up a defect that makes the forklift unsafe to use, WorkSafe Victoria's guidance is clear: it needs to be reported, and there should be a system in place to lock the forklift — or the specific attachment — out of service until it's fixed. Continuing to operate plant with a known defect is a common factor in serious forklift incidents.

What records should you keep?

Inspection and maintenance records should show:

• what requires inspection at each maintenance interval
• what has actually been inspected
• any maintenance that's been carried out
• any defects found, and the rectification work completed
• any pending maintenance still awaiting sign-off or follow-up

A simple pre-start record template

Item	Checked (Y/N)	Defect noted	Action taken
Tyres
Forks
Mast/chains
Hydraulics
Attachments
Restraints
Controls
Brakes/steering
Warning devices
Power system

Keep a copy for each shift or operator change, signed and dated, alongside your broader plant maintenance schedule.

Does this apply beyond forklifts?

Yes. Part 3.5 of the OHS Regulations 2017 sets general duties for employers around plant risk controls, including guarding, operator controls such as emergency stops and warning devices, and installation, maintenance and inspection requirements — covering powered mobile plant more broadly, not just forklifts. The same discipline — checklist before use, lock-out on defect, records kept — applies to other high-risk mobile and fixed plant on a manufacturing floor.

FAQ

How often does a forklift pre-start check need to be done? In line with the manufacturer's recommendations — WorkSafe Victoria's guidance is at the start of each shift, before first daily use, and whenever there's a change of operator.

Who is responsible for keeping pre-start check records? The employer, as part of their broader duty under the OHS Regulations 2017 to identify and control risks associated with plant. In practice, the operator usually completes the checklist, and records are then retained centrally.

What happens if a forklift is used despite a known defect? This is a common factor in serious forklift incidents. Employers should have a lock-out system that takes defective plant out of service immediately until it's repaired, rather than relying on operators to remember not to use it.

If you're not sure your pre-start and plant maintenance records would satisfy a WorkSafe inspector, a safety practitioner can check them alongside the rest of your site — book a site assessment at https://ardmor.com.au/book-audit.

This article is general information for Victorian manufacturers, not legal advice. Last updated: 10 August 2026.