Pre-Start Commissioning Checklist: The 10 Steps Before Turning the Key on Site

01 April, 2026

The machine arrives. The driver signs the delivery note, drives away and the equipment is left there on site, ready to work. Or so it seems. What happens in the following hours — before anyone presses the ignition — can make the difference between a smooth integration and a technical problem that brings the project to a halt at the worst possible moment.
This checklist is designed for any company receiving used industrial machinery, whether newly purchased or coming from another of their own job sites. This is not bureaucracy. It is the difference between working safely and working on luck. And it starts at the exact moment of delivery — not when someone decides it is time to fire the machine up.

1. Full Visual Inspection Before Unloading

The first step happens before the machine even touches the ground. While it is still on the transport platform, carry out a visual check of the equipment's general condition: new dents, structural cracks, loose or displaced components during transit. Any damage caused during transport must be photographed on the spot and reported to the driver before signing the delivery note. Once the machine is unloaded and the note signed without observations, responsibility passes to the recipient. This is the only moment at which transit damage can be claimed with any guarantee, which means the pre-unloading inspection is non-negotiable at any machinery delivery

2. Cross-Check Against the Technical Documentation Received

Before going any further, verify that the equipment in front of you matches exactly what appears in the documentation: serial number, model, recorded hours and accessory configuration. With second-hand machinery it is especially important to confirm that the hour meter reading matches the declared history. If there are any discrepancies, they must be resolved before putting the machine into production.

3. Check Fluid Levels: Engine Oil, Coolant, Hydraulic Oil and Fuel

This is one of the most basic steps and one of the most frequently skipped when there is pressure to get started. Transport can cause minor leaks or consumption, and a machine that arrives with levels running low can cause serious damage within the first few minutes of operation. Check engine oil, coolant, hydraulic oil and fuel level. If anything is not where it should be, correct it before starting the engine.

4. Hydraulic System Inspection

The hydraulic system is the heart of most heavy machinery and, at the same time, one of the most sensitive points after a transfer. Check hoses and fittings for chafing, micro-cracks or signs of moisture around the connections. Confirm there are no leaks from the cylinders and that the implement connectors are in good condition. A small hydraulic leak ignored at start-up can turn into a complete failure within just a few hours of work.

5. Undercarriage or Tyre Condition

Depending on the type of equipment, this point varies — but it is never optional. On tracked machines, check the tension and condition of the track links, rollers and pads. On wheeled equipment, check tyre pressure, tread condition and any sidewall damage that may have occurred during loading or unloading. A worn or damaged undercarriage does not only compromise manoeuvrability — it can be a direct safety risk for the operator and for others working in the vicinity.

6. Electrical System and Battery Check

This is particularly important if the equipment has been in storage or has spent several days in transit. Check the battery condition and charge level, inspect for any bare cables or loose connections and verify that all lighting and signalling systems are working correctly. On construction machinery operating in environments shared with other vehicles and people, signalling systems are not an aesthetic detail — they are a safety requirement.

7. Static Controls and Systems Test

Before moving the machine under load, carry out a full test of all controls with the engine at idle and without performing any productive movement. Joysticks, pedals, slew selector, parking brakes, locking systems — everything must respond normally. Any unusual resistance, jerky movement or lack of response must be investigated before the machine is operated. This static test takes fifteen minutes and can prevent a serious accident or breakdown.

8. Safety Systems Verification

This step is non-negotiable. Check that the ROPS and FOPS systems are functioning correctly if fitted, along with reverse alarms, rear-view mirrors and cameras, cab seat belts and any interlocking or emergency stop systems. In many countries these systems are legally required to be in working order. And beyond regulations, they are what protect the operator when something goes wrong.

9. First No-Load Movement Test

With all the above points verified, it is time to move the machine for the first time on site — unloaded and in a clear area. Observe how the engine behaves on a cold start, listen for any abnormal noises, test implement movements through full cycles and confirm that the brakes respond normally. This first operational test under real conditions is the final validation that the equipment is ready to work. If something does not add up, now is the time to catch it — not when production pressure is already bearing down.

10. Record-Keeping and Equipment History Update

The final step is not about the machine itself, but about asset management. Record the delivery date, the current hour meter reading, the condition on arrival and any relevant observations from the inspection. If the equipment has a maintenance logbook or digital history, update it. This record is the foundation for planning preventive maintenance from day one, and when the time comes to rotate or sell the equipment, it is one of the elements that adds the most value to the transaction.

These ten steps do not all require a specialist technician — most of them can be carried out by the operator or site manager with basic training. What they do require is time and discipline. At CYCLICA we emphasise this process because we know that an equipment's reliability on site does not begin when the manufacturer builds it or when we carry out our inspection: it is fully established when the person who receives it treats it, from the very first moment of delivery, with the care it deserves.

A machine that is properly received is a machine that works properly. And a machine that works properly is margin that does not get lost.