Forklift Pre-Start Checklists: What Operators Must Check Every Single Day

The pre-start check is the most important five minutes in a forklift operator’s day. It is the point at which equipment defects that developed overnight, during the previous shift, or during delivery are identified before they become safety incidents. It is also one of the clearest examples of a legal obligation under WHS legislation that has a direct, documented safety benefit.

In workplaces across Sydney and NSW, Mars Forklifts sees what happens when pre-start checks are skipped or performed superficially. Defects that would have taken ten minutes to identify at the start of the shift turn into breakdowns, damage incidents, and in the worst cases, injuries. Keeping equipment in safe operating condition is a shared responsibility between the operator, the site, and the equipment provider.

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The Legal Basis for Pre-Start Checks

Under the Work Health and Safety Act 2011 (NSW) and the Work Health and Safety Regulation 2017, persons conducting a business or undertaking (PCBUs, which includes employers and businesses that use plant) have a duty to ensure that plant used at the workplace is without risk to health and safety. This duty includes ensuring that plant is maintained, inspected, and operated safely.

For forklifts specifically, the duty to maintain plant in safe condition is supported by the requirement that operators hold a valid High Risk Work Licence (HRWL) for the relevant forklift class. In NSW, the LF licence class covers counterbalance forklifts with a rated capacity up to 10,000 kilograms. Operators working with machines in excess of 10,000 kilograms capacity may require the LO licence class.

Daily pre-start inspections are the practical mechanism through which the duty to maintain plant in safe condition is fulfilled on a shift-by-shift basis. They are not optional, and the absence of a pre-start inspection record is a significant indicator of WHS non-compliance in the event of an incident investigation.

⚠️  Non-compliance carries real consequences: Operating a forklift without a valid HRWL, or operating a forklift that has a known defect, exposes both the operator and the PCBU to significant WHS penalties. Defects identified during a pre-start check that have not been acted upon before the machine was used are a serious aggravating factor in any post-incident investigation.

The Pre-Start Checklist: Every Item That Matters

Fluid levels

• Engine oil (LPG and diesel forklifts): check level using the dipstick with the engine cold. Low oil level can cause engine damage within a single shift and is often a sign of a developing leak
• Hydraulic oil: check the hydraulic oil reservoir level. Hydraulic oil below minimum level affects lift capacity and system pressure, creating unpredictable load behaviour
• Coolant level (applicable to water-cooled engines): check coolant reservoir or radiator level. Low coolant risks engine overheating and damage
• Fuel level (LPG or diesel): confirm the machine has adequate fuel for the shift. For LPG, check the cylinder is secured and the valve connection is tight and undamaged
• Battery condition (electric forklifts): check battery charge level and confirm it is adequate for the shift. Check battery hold-down security and inspect for visible damage to the battery or cable connections

Tyres and wheels

• Inspect all tyres for cuts, damage, embedded objects, and visible wear. Solid tyres should have adequate wear material remaining. Pneumatic tyres should be checked for inflation pressure
• Check that all wheel nuts are in place and visually appear tight
• Inspect for any oil or grease contamination on the tyre surfaces, which can reduce traction

Forks and fork carriage

• Fork inspection: examine both forks for cracks, particularly at the heel (the right-angle bend where the fork blade meets the shank) and at any weld points. Cracks at the heel are a critical defect and the machine must be withdrawn from service immediately
• Fork tip wear and symmetry: forks should be within 10% of each other in height when positioned on a flat surface. Uneven forks create unbalanced loads. Tips worn to a sharp edge require replacement
• Fork latch: confirm that the fork positioning latch (the hook that holds the forks in position on the carriage bar) is in place and functional. Loss of a fork during operation is a major safety incident
• Fork carriage: inspect the carriage side shifts (if fitted) and confirm they move freely. Check for cracks in the carriage plate

Mast and lifting system

• Mast chains: inspect both lift chains for missing, broken, or bent links. Check chain lubrication: dry chains accelerate wear and increase the risk of chain failure under load
• Mast rollers and channels: confirm the mast moves freely throughout its range, including tilt, without catching or grinding. Inspect rollers for flat spots or damage
• Hydraulic cylinders and hoses: check for hydraulic oil weeping or leaking from cylinders, hose connections, or control valves. Hydraulic leaks worsen rapidly under operating pressure
• Load backrest extension: confirm the load backrest is in place, undamaged, and properly secured. The backrest prevents loads from falling backward onto the operator

Safety systems and controls

• Overhead guard: inspect the overhead guard for structural integrity. The overhead guard must be intact and properly attached. Operating a forklift without a compliant overhead guard is a critical safety violation
• Operator restraint system (seat belt or lap bar): confirm the operator restraint is present, undamaged, and functional. If the machine overturns, the restraint is what keeps the operator inside the protective overhead guard zone rather than being thrown from the machine
• Horn: test the horn. It must sound clearly. Horn failure means the operator cannot audibly warn pedestrians or other vehicles
• Lights and flashers: where fitted, test headlights, tail lights, and flashing warning lights. Check that they are operational
• Reversing alarm: confirm the reversing alarm sounds when reverse gear is engaged (where the alarm is fitted)
• Brakes: test the parking brake (it must hold the machine on any slope the forklift will operate on) and the service brake (it must stop the machine smoothly and without pulling to one side)
• Steering: confirm steering moves freely through its range without notchy or binding points. Check for excessive play in the steering wheel
• Controls and pedals: confirm hydraulic lift, tilt, and side shift controls operate smoothly and return to neutral when released. Confirm pedals operate correctly and are not slipping or sticking

Placards and documentation

• Data plate and capacity chart: confirm the machine’s rated capacity chart (load diagram) is fitted, legible, and in place. Operators must be able to reference the capacity chart during operations
• Safety warning labels: confirm safety warning labels are in place and legible. Faded, missing, or illegible labels require replacement before operation
• Hour meter: record the hour meter reading. This supports scheduled maintenance tracking and is part of the maintenance record

💡  Document everything: A pre-start check that is not documented is a pre-start check that cannot be proven. Most workplaces use a physical or digital pre-start checklist form that is signed by the operator and retained as a site record. In the event of an incident, the checklist records are among the first documents reviewed by investigators and insurers.

What to Do When You Find a Defect

The purpose of the pre-start check is not to find defects: it is to identify defects before they cause an incident. When a defect is identified, the correct procedure is:

1. Record the defect clearly on the pre-start checklist form
2. Tag the machine as out of service and ensure it cannot be started or moved by other workers until the defect is assessed and cleared
3. Report the defect to the supervisor or maintenance contact immediately
4. Do not operate the machine until the defect has been assessed, repaired, and the machine has been cleared for return to service by an authorised person

For machines on hire, contact Mars Forklifts’ maintenance and repair team as soon as a defect is identified. We will assess the defect and, where repair or replacement is required, arrange the appropriate response as quickly as possible to minimise your operational disruption.

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Our team provides fast response for forklift defects and breakdowns. Call 1300 736 231 for repair assistance.

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Frequently Asked Questions

Is a daily forklift pre-start check required by law in NSW?

Yes. Under the Work Health and Safety Act 2011 (NSW) and the Work Health and Safety Regulation 2017, PCBUs have a duty to ensure that plant used at the workplace is maintained in safe condition. Pre-start inspections are the standard mechanism for meeting this obligation. Failure to conduct or document pre-start checks is a significant WHS compliance issue. For current regulatory requirements, refer to SafeWork NSW at safework.nsw.gov.au.

Can an operator refuse to use a forklift that has a defect?

Yes. Workers have the right under WHS legislation to cease or refuse to carry out work that they reasonably believe would put themselves or others at risk of serious harm. An operator who identifies a defect that they believe makes the machine unsafe to operate has both the right and the obligation to decline to operate the machine until the defect has been assessed and cleared.

How long should a forklift pre-start check take?

A thorough pre-start check for a standard counterbalance forklift typically takes five to ten minutes when done correctly. Operators who are familiar with their machine will complete the check efficiently. The check should never be rushed to the point that items are skipped or given only superficial attention. Contact Mars Forklifts if you need advice on pre-start procedures for specific machines in your hire fleet.

Safety note
This article provides general educational information about forklift pre-start inspection practices. It does not constitute WHS advice and does not replace formal safety training, site-specific WHS procedures, or compliance with applicable legislation. All forklift operators in NSW must hold a valid High Risk Work Licence (LF class) issued by SafeWork NSW. Consult SafeWork NSW at safework.nsw.gov.au for current regulatory requirements.