How to conduct a pre-use check on a mobile elevated work platform

Mobile elevated work platforms (MEWPs), including boom lifts, cherry pickers and scissor lifts, place workers at height for construction, maintenance and inspection tasks. A pre-use check confirms that the machine is suitable, safe and ready for the planned operation. It also gives the operator time to identify defects before the platform rises, reducing risks to workers, pedestrians and people below.

The check forms part of a broader safety system. Australian employers must comply with the applicable work health and safety laws, while Safe Work Australia model codes provide national guidance on work at height and mobile plant. Site-specific risks, manufacturer instructions and the condition of each machine still determine what must be inspected before use.

Know the machine and inspection boundary

Begin by identifying the exact machine. Check the model, serial number, data plate, rated working load, maximum platform height and any platform or reach limitations. The correct operator manual and inspection instructions should be available. A generic checklist cannot replace the manufacturer’s requirements for a particular boom lift or scissor lift.

The operator’s pre-use inspection is separate from the formal maintenance inspection completed by a competent person. The shift check looks for obvious faults, missing components and unsafe conditions, but it does not authorise the operator to repair machinery or certify complex repairs. A current inspection and maintenance status, defect history and service records must also be available.

Before starting, review the task-specific risk assessment, safe work method statement (SWMS) or job safety analysis (JSA). Confirm the required working height, load, travel route, ground conditions and emergency arrangements. The operator should be authorised, trained and familiar with the controls for that model. Any uncertainty about the machine’s condition or suitability should stop the work.

Inspect the chassis and working structure

Walk around the machine before operating it. Look for damage to the chassis, access steps, guards, counterweights and wheel arches. Check tyres for cuts, bulges, embedded objects and correct inflation, and inspect wheel nuts and steering components. Hydraulic, fuel or coolant leaks, damaged hoses and loose fasteners require investigation before use.

Inspect the elevating structure according to its type. For boom lifts, examine the boom sections, pivot pins, locking devices, cylinders, hoses and any visibly cracked or corroded welds. For scissor lifts, check the base, crossed arms, pivots, locking pins and platform underside. Look for distortion, unusual movement, damaged retaining pins and signs that a component has been modified without approval.

Check the work platform carefully. Guardrails, midrails, toe boards, gates and the platform floor must be secure and free from holes or sharp edges. Inspect access ladders and platforms, manufacturer-specified anchor points and required emergency equipment. Warning labels must remain legible. Missing labels, structural damage or absent safety components mean the machine is not ready for use.

Assess the ground and work area

The machine must stand on firm, stable ground that meets the manufacturer’s slope, load-bearing and surface requirements. Check for potholes, soft soil, standing water, loose gravel, mud, ramps and uneven paving. Where outriggers or stabilisers are required, position them as specified and use suitable pads on weak surfaces. Wheel chocks and any edge-protection system should also be installed where the risk assessment requires them.

Australian worksites present varied ground conditions. Melbourne’s inner-city loading lanes and distribution depots often provide little separation from traffic, while Brisbane sites can have clay that softens after rain. Newcastle port and heavy-industry operations bring congestion, port vehicles and changing wind conditions. Around Perth and Fremantle, long travel routes, dust and heat can expose tyres, batteries and hydraulic components before a machine reaches the work area.

Survey the entire operating area before raising the platform. Identify pedestrians, public traffic, excavations, drop zones, access routes and nearby structures. Treat overhead power lines as energised and maintain the exclusion distance required by the relevant electricity safety rules, network operator and site plan. Use a trained spotter and physical barriers where needed, and ensure that no person can enter beneath the platform.

Test controls and protective systems

Use the manufacturer’s start-up sequence and test the machine in a clear area. Confirm that the emergency stop operates before beginning the inspection. Check that ground and platform controls respond correctly, that the controls return to their neutral position and that the horn, lights, reversing alarm and other fitted devices operate as intended. Travel, steering and braking should be tested at low speed.

Raise and lower the boom or scissor mechanism through its permitted range. Movement should be smooth, without unusual noise, vibration or sudden movement. Test emergency lowering and other emergency functions only as directed by the operator manual. Where overload protection, tilt sensing, platform limits or cut-out devices are fitted, confirm that they activate in the specified sequence rather than forcing or bypassing them.

Keep personnel out of the platform’s travel path and away from its movement during functional checks. A failed control, warning device, overload system, emergency stop or emergency lowering function requires the machine to be taken out of service. Safety devices must never be taped over, disconnected or replaced with non-approved components. Record the defect rather than attempting an unauthorised adjustment.

Verify access, load and fall protection

Check the rated working load and the platform load chart before loading equipment, materials or personnel. Calculate the combined weight, including tools, leads, fixtures and any suspended loads. Keep the load within the machine’s rating, distribute it as the manufacturer directs and secure it against movement. Items must not create a contact risk for the operator or exceed the platform’s structural limits.

The operator should inspect the required personal fall-protection equipment before use. Check the full-body harness, lanyard, shock-absorbing pack, connectors and attachment points for cuts, chemical damage, worn webbing, failed stitching and distorted hardware. Fit and connect the equipment exactly as specified by the manufacturer. Where the risk assessment and operating instructions require a harness to be attached, this must happen before the platform is raised.

Keep the gate closed while operating, and never stand on guardrails, toe boards or an improvised ledge. Use approved access and egress arrangements, tether tools where necessary and establish a safe exclusion zone below. The work plan must also address rescue. Operators and nearby personnel should know how to contact the responsible person, lower a person safely and prevent the machine being operated while someone is in danger.

Record defects and control the machine

Complete the pre-use record before the machine enters service. The record should identify the machine, date, checker, operating hours and any defects found. Use the hire company’s inspection sheet where one is supplied, and keep the completed record with the machine or the approved digital system. A consistent record shows that the inspection occurred and creates an early warning of recurring problems.

When a defect is found, park and secure the machine, remove it from service and notify the supervisor or hire provider. Depending on the fault, isolate the controls, retain the key or apply the site’s out-of-service tag. Examples include structural cracks, fluid leaks, damaged tyres, missing platform components, failed controls, defective emergency lowering and illegible safety labels. Repairs should be completed by an authorised competent person.

Where elevated work supports process operations, align the machine check and stop-work signal with the site’s control room emergency procedures. Clear coordination helps prevent an unexpected shutdown, restart or isolation while workers are in a platform. Any defect that could affect the wider work area should be communicated before the task begins.

Make the check part of every shift

A dependable routine has four stages: prepare, walk, operate and secure. Preparation confirms the task, manual and operating area. The walkaround checks the machine’s visible condition and structural components. Operational testing confirms that controls and safety systems work, and the final stage records the result or isolates a defective machine. Allowing enough time for each stage reduces the temptation to rush.

The Australian rental market includes common brands such as JLG, Genie and Skyjack, but the model and supplier still dictate the inspection requirements. Before accepting a hire unit, verify its identification, load chart, inspection status and service information, then conduct the operator’s check regardless of the supplier’s delivery inspection. Rental arrangements do not transfer responsibility for identifying unsafe conditions before use.

Strengthen competence by training operators to recognise defects, follow the correct test sequence and make safe stop-work decisions. HCF Catch offers hands-on industrial training in a live-process-plant environment, along with facility tours and room hire for conferences, meetings and training events. Contact the centre to discuss course availability, practical training options and arrangements for your next team safety briefing.