Warehouse High Reach Picker Annual Inspection

Annual inspection template for warehouse high reach pickers covering structural integrity, hydraulic systems, controls, safety devices, and harness anchor points.

Inspection Details

• Equipment identification recorded
  Record asset ID, make, model, serial number, and location.
• Inspection date and inspector name recorded
  Confirm the annual inspection date, inspector identity, and whether the inspector is a competent person or qualified technician.
• Inspection type confirmed as annual
  Select the inspection basis.
• Equipment removed from service if critical deficiency found
  Confirm the unit is tagged out and removed from service when a critical item fails.

Structural Integrity

• Frame, mast, and platform free of cracks, bends, or deformation
  Inspect all visible structural members for cracks, distortion, corrosion, weld failure, or impact damage.
• Fasteners, pins, and retaining devices secure and intact
  Verify bolts, pins, clips, and retainers are present, tight, and not damaged or missing.
• Welds and joints show no visible separation or fatigue
  Check welds, brackets, and load-bearing joints for cracking, separation, or evidence of fatigue.
• Platform floor, guardrails, gates, and toe boards in good condition
  Confirm the operator platform is structurally sound, secure, and free of missing or damaged fall protection components.
• Load rating and capacity placards legible and present
  Verify all required capacity labels and operating warnings are visible, legible, and not obscured.

Hydraulic System

• Hydraulic hoses, fittings, and cylinders free of leaks or damage
  Inspect for fluid leaks, abrasion, bulging, cracked hoses, damaged fittings, and cylinder scoring.
• Lift, lower, and tilt functions operate smoothly
  Verify hydraulic motion is smooth, controlled, and free of abnormal noise, drift, or hesitation.
• Hydraulic fluid level within acceptable range
  Record the fluid level or service reading if available.
• No evidence of hydraulic overheating or contamination
  Check for burnt odor, discoloration, foaming, contamination, or other signs of hydraulic degradation.

Controls and Operating Functions

• Directional, lift, and auxiliary controls respond correctly
  Test all primary operating controls for correct response and return-to-neutral behavior.
• Emergency stop functions properly
  Verify the emergency stop immediately disables motion as intended.
• Horn, alarms, and warning indicators operate
  Confirm audible and visual warning devices activate correctly.
• Steering and braking function within normal operating range
  Verify steering response and braking performance are normal and free of excessive play or delay.

Safety Devices and Fall Protection

• Harness anchor point present, secure, and free of damage
  Inspect the designated harness anchor point for deformation, corrosion, cracks, looseness, or missing hardware.
• Operator restraint or fall protection system available and serviceable
  Confirm the required restraint or fall protection system is present, compatible, and in serviceable condition.
• Interlocks, limit switches, and platform safety devices function correctly
  Test any door interlocks, travel limits, tilt limits, or other safety devices for proper operation.

Power, Electrical, and Final Condition

• Battery, charger connection, and cables in safe condition
  Inspect battery case, terminals, cables, and charging connection for damage, corrosion, or exposed conductors.
• No exposed wiring, damaged connectors, or electrical defects
  Check for frayed wiring, loose connectors, heat damage, or other electrical non-conformances.
• Corrective actions documented and equipment status assigned
  Select the final disposition after inspection.