Pre-Start Inspection Signs, Tags & Log Books for Mobile Plant

Under Australian WHS Regulations, a person conducting a business or undertaking (PCBU) has a duty to ensure that plant is without risk to health and safety before it is used. For mobile plant — forklifts, overhead cranes, vehicle hoists and similar equipment — a daily pre-start inspection is one of the most practical ways to meet that duty. The right pre-start inspection signs, Out of Service tags and written log books work together to remind operators, document checks and keep unsafe plant off the floor.

What is a pre-start inspection?

A pre-start inspection is the daily check an operator performs on plant or powered equipment — forklifts, overhead cranes, vehicle hoists, EWPs, mobile plant — before putting it into service for the shift. The operator walks around the machine, checks safety-critical items (controls, brakes, horn, hydraulics, tyres or tracks, attachments, emergency stops), and records the result in a log book or on a tag.

Pre-start inspections are a standard duty under the model WHS Act for any Person Conducting a Business or Undertaking (PCBU) that operates plant. Signage and log books are the system that makes the inspection actually happen: a clear “Pre-Start Inspection Required” reminder at the operator station, plus a place to record the check, plus an “Out of Service” tag if anything fails. This guide covers the signs, tags and log books that make up a compliant pre-start system.

Why Daily Pre-Start Checks Matter

Defects that develop overnight — fluid leaks, worn tyres, faulty brakes, inoperative warning devices — are not always obvious until something fails. A pre-start inspection creates a deliberate pause before the plant enters service, giving the operator the opportunity to catch faults before they become incidents.

Australian WHS Regulations require PCBUs to manage risks associated with plant. Conducting daily inspections is widely recognised as a reasonably practicable control measure. When inspections are signed off in a log book, they also demonstrate due diligence — a documented record that checks were completed and any defects were acted on.

Signage and tags support this system by making the inspection process visible to everyone on site — serving as operator prompts, supervisor cues and an immediate visual indicator when plant has been taken out of service.

What a Pre-Start Inspection Covers

The specific items checked will vary by plant type. Common inspection points across forklifts, overhead cranes and vehicle hoists include:

Forklifts

• Horn, lights and travel alarm operational
• Tyres — condition, inflation and no visible damage
• Mast, forks and tilt mechanism — no cracks, bends or excessive wear
• Hydraulic fluid level and visible leaks
• Seat belt, overhead guard and restraint system intact
• Brakes — service and park brake tested

Overhead Cranes

• Wire rope or chain — no kinks, broken wires or corrosion
• Hook and safety latch — no deformation or cracks
• Limit switches and emergency stop function
• Controls and pendant labelling legible and responsive
• SWL placard visible and matching current rigging configuration

Vehicle Hoists

• Mechanical or hydraulic locks engage correctly
• Arm pads and adapters in good condition
• Hydraulic lines and seals — no visible leaks
• Emergency lowering function tested
• SWL and clear-height limits posted and legible

The Role of Signage and Tags

Signs and tags serve three distinct roles in a pre-start inspection system:

• Operator reminder signs — Posted at the plant's normal parking or charging position, these signs prompt operators to complete a pre-start check before commencing the shift. They are designed to meet mandatory sign conventions with clear instructional language and, where relevant, a reference to the log book location.
• Out of Service / Do Not Operate tags — When an inspection reveals a fault, the plant must be taken out of service immediately. A highly visible Out of Service tag attached to the controls or key signals to every other worker that the equipment is not to be used until cleared by an authorised person. These tags are a critical lock-out and danger communication tool.
• Lock-out reminders — Placed near isolation points, these prohibition signs reinforce that tagged-out plant must not be operated or de-tagged by anyone other than the person who applied the tag or their authorised delegate.

Pre-Start Inspection Log Books

A verbal check is better than nothing, but a written record is what protects your business when something goes wrong. Pre-start inspection log books provide:

• A dated, signed record of every pre-start check, including who conducted it and what was found
• Defect reporting — a structured column or section to document faults and whether the plant was removed from service
• Maintenance triggers — patterns of recurring minor faults that indicate the plant needs attention before a major failure occurs
• Due diligence evidence — can assist in demonstrating that the PCBU has met its duty to manage plant risk if an inspector or insurer requests records

Log books designed specifically for pre-start inspections are available through the SafetySigns.com.au log books range — with dedicated books for forklifts, overhead cranes, vehicle hoists, tippers and more. They are formatted to cover 12 months of daily checks per piece of plant and sized to store conveniently with the equipment. Store completed log books securely on site and retain them as part of your plant maintenance records.

Setting Up a Pre-Start System on Your Site

Rolling out a pre-start inspection system does not require a major overhaul. A practical approach typically follows these steps:

1. Identify all mobile plant on site that requires daily inspection — include hired or contractor-owned equipment where the PCBU controls the work area.
2. Select or develop a checklist appropriate to each plant type. Use manufacturer guidelines and relevant Australian standards as the basis.
3. Install operator reminder signs at each plant's parking or charging bay — reference the log book location on the sign where possible.
4. Issue Out of Service tags and log books with each piece of plant. Keep a small supply of spare tags in the supervisory area.
5. Brief all operators on the process, including how to complete the log book and what to do when a fault is found.
6. Establish a defect review process — a responsible person should check the log books regularly and action any reported faults before the plant is returned to service.

For businesses with multiple vehicles or lifting equipment, custom signs can include your specific plant identification numbers, helping operators and supervisors match each sign to the correct piece of equipment at a glance. See also our guide to warehouse forklift safety signs for broader signage requirements in forklift operating areas, and our loading dock signs guide for the surrounding work zone.

Pre-Start Inspection Checklist