Heavy Machinery and Industrial Equipment Safety Checklist

Date: 2025-11-20

Inspector: [INSPECTOR NAME]

Location/Area: [LOCATION/AREA]

Department: [DEPARTMENT]

Purpose

To ensure the safe operation of heavy machinery and industrial equipment by identifying potential hazards and verifying safety measures are in place.

Instructions for Use

1. Inspect all items on the checklist prior to operating any heavy machinery or industrial equipment.
2. Mark each item as either 'Pass' or 'Fail' based on the verification criteria.
3. If an item fails, immediately take corrective action and document the issue.
4. Ensure all documentation is completed and filed appropriately.

Frequency

This checklist should be completed: Daily before operation

Safety Checklist

Pre-Operation Inspection

Item	Pass	Fail	Comments
Visually inspect all vehicles and heavy equipment for any malfunctions that could affect safe operation. [6] Check: No visible defects, damage, or leaks are present. All components are in good working order. If failed: Correct all defects before the equipment is placed in service. [1593(d), 1597(j), and 3664(a)(7)]			_________________
Check that seat belts are in good working order on all vehicles and heavy equipment. [6] Check: Seat belts are present, not frayed or damaged, and latch securely. If failed: Replace damaged seat belts immediately. [1596(g) and 1597(g)]			_________________
Verify that Roll-Over Protection Structures (ROPS) are provided on vehicles and heavy equipment. [6] Check: ROPS are securely installed and show no signs of damage. If failed: Ensure ROPS are properly installed or replace if damaged. [1596(a)]			_________________
Ensure the windshield and powered windshield wipers are intact and operable. [3] Check: Windshield is free of cracks and wipers function correctly. Defogging or defrosting equipment is operable. If failed: Repair or replace damaged windshields and wipers. [1591(a) and 1597(d)]			_________________
Check that all vehicles and heavy equipment have two operating headlights and two operating taillights. [3] Check: All headlights and taillights are functioning correctly. If failed: Replace any non-functioning lights before operation. [1591(g) and 1597(b)]			_________________
Verify that brake lights are working on all vehicles and heavy equipment. [3] Check: Brake lights illuminate when the brake pedal is pressed. If failed: Repair or replace faulty brake lights. [1591 and 1597(c)]			_________________
Ensure that haulage vehicles have a cab shield or canopy to protect the driver from falling materials. [3] Check: Cab shield or canopy is securely in place and in good condition. If failed: Repair or replace damaged cab shields or canopies. [1591(e)]			_________________
Confirm that the vehicle or equipment has a working back-up alarm that can be heard 200 feet away. [6] Check: Back-up alarm sounds clearly when the vehicle is in reverse. If failed: Repair or replace the back-up alarm. [1592(a) and (b)]			_________________

Work Area Assessment

Item	Pass	Fail	Comments
Check for warning signs, barricades, or flaggers to keep people out of the equipment operating area. [2] Check: Warning systems are in place and properly positioned. If failed: Install or reposition warning systems as needed.			_________________
Assess the presence of overhead obstructions, like power lines or trees. [2] Check: Adequate clearance from obstructions is maintained. If failed: Ensure proper clearance or use a spotter.			_________________
Inspect temporary covers for conduits, trenches, and manholes. [1] Check: Covers are secured against displacement and can carry at least twice the maximum intended load. If failed: Secure or replace inadequate covers. [1597(k)]			_________________
Verify that the area is free from holes and ruts that may affect the safe operation of vehicles and equipment. [7] Check: Roadways are well-maintained and safe for vehicle operation. If failed: Repair any hazardous road conditions. [1590(a)(3)]			_________________
Ensure that dust levels are minimized to provide adequate visibility for drivers. [7] Check: Dust control measures are in place and effective. If failed: Implement dust control measures or provide respiratory protection. [1590(b)]			_________________

Operational Safety

Item	Pass	Fail	Comments
Confirm that operators use seat belts when operating or riding in vehicles or heavy equipment. [3] Check: Seat belts are in use during operation. If failed: Enforce seat belt usage. [1597(h)]			_________________
Ensure that operators do not exceed safe or posted speed limits. [3] Check: Vehicle speed is within posted limits and appropriate for conditions. If failed: Enforce speed limits. [1590(c)(2) and 1593(a)]			_________________
Verify that vehicles and equipment are not loaded above their designated safe carrying capacity or weight. [1] Check: Loads do not exceed the safe carrying capacity. If failed: Reduce load to within safe limits. [3660(b)]			_________________
Confirm that loads on vehicles are secured against displacement. [1] [3] Check: Loads are properly secured with appropriate tie-downs or restraints. If failed: Secure the load properly. [1593(f)]			_________________
Ensure that a spotter is used to help operators back up vehicles and heavy equipment wherever feasible. [3] Check: A trained spotter is present and in clear view of the operator when backing. If failed: Provide a spotter or eliminate the need for backing. [1592(a)]			_________________
Verify that vehicles and heavy equipment are parked with the parking brake set. [1] Check: Parking brake is engaged when vehicle is stationary. If failed: Set the parking brake. [1593(h)]			_________________
Ensure that unattended loaders and industrial trucks have the bucket or boxes lowered to the ground. [1] Check: Bucket or boxes are lowered or properly blocked. If failed: Lower the bucket or boxes or block appropriately. [1593(k) and 3664(a)(17)]			_________________
Confirm that fueling of vehicles and heavy equipment is done with the engine off. [4] Check: Engine is off during fueling. If failed: Turn off the engine during fueling. [1594(a)]			_________________
Verify that there are no sources of ignition near the fuel storage or refueling area. [4] Check: Area is free from ignition sources. If failed: Remove any ignition sources. [1594(c)]			_________________
Ensure that a dry chemical or carbon dioxide fire extinguisher is accessible to the fueling area. [4] Check: Fire extinguisher is present and readily accessible. If failed: Provide a fire extinguisher. [1594(h)]			_________________

Electrical Safety

Item	Pass	Fail	Comments
Ensure heavy equipment is not operated in areas where there is danger of contact with energized underground or overhead high voltage lines. [1] [2] Check: Equipment is operated at least 10 feet from high voltage lines of 50,000 volts or less. If failed: Relocate equipment or de-energize lines. [2946]			_________________
Verify that electric lines are clearly marked, and precautions are taken to prevent accidental contact. [1] Check: Warning signs are posted, and safety measures are in place. If failed: Mark lines and implement safety measures. [2946]			_________________
Confirm that there are signs in plain view of the operator on all cranes, derricks, power shovels, pile drivers, and similar machinery. [1] Check: Signs are present and legible. If failed: Install or replace signs. [2947]			_________________

General Equipment Condition

Item	Pass	Fail	Comments
Inspect machinery and equipment for defective parts. [5] Check: No defective parts are present that create a hazard. If failed: Do not use machinery and equipment with defective parts. [3328(c)]			_________________
Ensure machinery and equipment is maintained in a safe operating condition. [5] Check: Equipment is clean, lubricated, and functioning as intended. If failed: Maintain machinery and equipment in safe operating condition. [3328(g)]			_________________
Confirm that only qualified persons maintain or repair machinery and equipment. [5] Check: Maintenance and repair are performed by trained and authorized personnel. If failed: Only qualified persons shall maintain or repair machinery and equipment. [3328(h)]			_________________

General Requirements

Item	Pass	Fail	Comments
All drivers are properly licensed and trained in the safe operation of vehicles and equipment. [6] Check: Drivers possess valid licenses and have completed required training. If failed: Provide necessary training and verify licenses. [3664(a)(1) and 5006(a)]			_________________
The company has a written Injury and Illness Prevention Program (IIPP) that meets all Cal/OSHA requirements. [6] Check: IIPP includes hazard identification, regular inspections, accident investigation, and correction of hazardous conditions. If failed: Implement or update the IIPP to meet requirements. [1509]			_________________
Workers exposed to vehicular traffic wear reflectorized warning garments during hours of darkness. [7] Check: Garments are visible at a minimum of 1000 feet. If failed: Provide and enforce the use of reflectorized garments. [1598(d)]			_________________
Ensure that operators maintain three points-of-contact when accessing or exiting heavy equipment. [9] Check: Operators use steps and handrails, maintaining three points of contact. If failed: Provide training on safe access/egress procedures.			_________________

Failed Item Procedures

1. If any item on this checklist fails to meet the verification criteria:
2. Do not operate the equipment until the issue is resolved.
3. Report the failed item to the supervisor immediately.
4. Implement corrective actions as indicated in the checklist.
5. Document the failed item and the corrective actions taken.
6. Retain documentation for review and future reference.

Documentation Requirements

Completed checklists must be retained for a minimum of [insert duration] and be made available for inspection.

Checklist Completion

Overall Status: ☐ Pass     ☐ Fail     ☐ Corrective Actions Required

Inspector Signature: Date:

Supervisor Review: Date:

Corrective Actions Completed By: Date:

References and Standards

• Cal/OSHA regulations [8]
• California State Department of Transportation regulations [7]
• Manual of Traffic Controls for Construction and Maintenance Work Zones 1996, published by the California State Department of Transportation. [1598(a) and (b)] [7]

This checklist must be retained for [RETENTION PERIOD].

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