Warehouse Order Picker Pre-Shift Inspection

Pre-shift inspection for warehouse order pickers covering platform, harness, chains, rails, tilt sensor, and key safety controls before equipment use.

Pre-Use Safety Readiness

• Operator is authorized and trained for this order picker
  Verify the operator has current authorization and training for the specific equipment model.
• Pre-shift inspection area is clear and equipment is parked safely
  Equipment should be in a safe, stable position for inspection with no obstruction to access.
• Manufacturer’s operating manual and safety decals are present and legible
  Confirm required labels, warnings, and operating instructions are visible and readable.
• No active lockout-tagout or out-of-service tag present
  Do not operate equipment that is tagged out or otherwise restricted from service.

Platform, Guardrails, and Fall Protection

• Platform surface is clean, dry, and free of cracks, deformation, or loose material
  Check for damage, contamination, or conditions that could cause slipping or instability.
• Platform gate or entry barrier closes and latches securely
  Gate/barrier must function properly and remain secured during use.
• Guardrails are intact, secure, and free of missing fasteners or damage
  Inspect top rail, mid-rail, and attachment points for looseness, bends, or breaks.
• Harness and lanyard are present, correctly fitted, and free of visible damage
  Inspect webbing, stitching, buckles, D-ring, and connectors for wear, cuts, fraying, or distortion.

Chains, Mast, and Structural Components

• Chains are evenly tensioned and show no broken links, rust buildup, or excessive wear
  Look for elongation, corrosion, kinks, or signs of improper lubrication.
• Mast, uprights, and carriage show no cracks, bends, or visible damage
  Inspect all visible structural members for deformation, weld failure, or impact damage.
• Pins, retainers, and mounting hardware are present and secure
  Verify that critical hardware is in place and not loose, missing, or damaged.

Controls, Brakes, and Safety Devices

• Emergency stop functions properly
  Test the emergency stop according to site procedure and confirm it stops motion as intended.
• Forward/reverse, lift/lower, and travel controls operate smoothly and return to neutral
  Controls should respond predictably without sticking, delay, or unintended movement.
• Brakes, steering, and directional controls respond normally
  Confirm the unit can be controlled safely and stops as expected.
• Horn, alarm, and other warning devices operate correctly
  Audible warnings must be functional for pedestrian awareness and safe operation.
• Battery, charger connection, and power indicators show normal condition
  Check for loose connections, damaged cords, leaks, overheating, or abnormal indicator lights.

Tilt Sensor, Interlocks, and Final Operating Check

• Tilt sensor or tilt alarm activates as designed
  Verify the tilt warning or shutdown function responds according to manufacturer requirements.
• Interlocks prevent unsafe movement when platform or gate is not in the proper position
  Confirm safety interlocks are working and no bypass condition is present.
• No visible leaks, unusual noises, or abnormal vibration during test operation
  Perform a brief functional test and stop immediately if any abnormal condition is observed.

Deficiencies and Release to Service

• Deficiencies documented and reported to supervisor or maintenance
  Record all non-conformances, including the specific component affected and the observed condition.
• Equipment removed from service if any critical item failed
  Unsafe equipment must not be used until repaired and cleared for service.
• Inspector signature
  Inspector confirms the pre-shift inspection was completed accurately.