Monthly Maintenance Checklist for Electric Aerial Work Platforms

Applicable to: Electric scissor lifts, electric telescopic/ articulating boom lifts, electric spider lifts, etc.

I. Electrical System (Core)

Battery Pack Inspection

• Clean the battery surface, terminals and connecting cables to remove dust, oil stains and corrosive substances.
• Check that terminals are tight, free from looseness, oxidation, whitening or overheating marks.
• Measure the voltage and internal resistance of single/ whole battery packs to evaluate capacity consistency.
• Water replenishment (for lead-acid batteries): Keep liquid level between MIN and MAX marks; add distilled water only.
• Test the charger: Ensure normal charging, no overheating and automatic stop when fully charged.
• For long-term idleness: Recharge once a month and maintain power ≥ 50%.

Electric Control & Wiring

• Inspect electric control box, wiring harnesses, plugs, sockets and connectors with power off.
• Check cables/ wires: No breakage, aging, extrusion, skin damage or exposed conductors.
• Ensure connectors are secure, free from water ingress, oxidation or ablation.
• Verify grounding connection is reliable, free from looseness or rust.
• Inspect motors: Check appearance, temperature rise, abnormal noise and carbon brushes (for brushed motors).

Control & Display

• Inspect platform/ ground control panels: Buttons, switches, joysticks and displays.
• Ensure normal functions, sensitive response, no lag or misoperation.
• Check potentiometers/ encoders: Stable signal, no drift or abnormality.

II. Hydraulic System

Hydraulic Oil & Filter Elements

• Check oil level: Between MIN and MAX marks on the dipstick.
• Check oil quality: Clear, no emulsification, blackening, impurities or peculiar smell.
• Clean or replace oil suction filter, pressure filter and return filter.
• Inspect for leaks: Oil cylinders, oil pipes, joints, valve blocks, pumps and seals.

Hydraulic Components

• Test manual emergency pump: Function normally, capable of manually lowering the platform.
• Inspect hydraulic cylinders: No oil seepage, scratches, deformation or abnormal noise.
• Check hydraulic valves, solenoid valves and relief valves: Normal operation, no jamming or leakage.
• Ensure cooling/ heat dissipation components are clean, unblocked and well-ventilated.

III. Structural & Mechanical Components

Structural Parts Inspection

• Inspect scissor arms/ boom arms, frame, platform, outriggers and chassis: No cracks, deformation, welding cracks or rust.
• Check welds and key stress parts: No cracks or damages.

Fasteners & Pins

• Ensure all main bolts, nuts, pins, retaining rings and cotter pins are tight, free from looseness, loss or damage.
• Key areas: Turntable, slewing bearing, boom hinge points, outriggers and platform connections.
• Retighten to standard torque using a torque wrench.

Lubrication (Mandatory Monthly)

• Grease all grease nipples (hinge points, pins, sliders, outriggers, slewing mechanisms, rollers).
• Lubricate scissor arms, boom sliding surfaces, guide wheels, chains and steel wire ropes (if equipped).
• Check oil level of slewing bearing and reducer gears/ bearings; replenish or replace oil as needed.

Travel & Steering

• Check tires/ drive wheels: Normal air pressure, no cracks, cuts or excessive wear.
• Inspect wheel axles, bearings and suspension: No abnormal noise, looseness or oil leakage.
• Verify steering mechanism: Flexible, no jamming, with normal clearance.
• Check brakes (electromagnetic/ hydraulic): Effective braking, no abnormal noise or overheating.

. Safety Devices (Full-Function Test)

Emergency Stop

• Platform emergency stop and ground emergency stop: Sensitive, effective and normal reset.

Limit & Protection Devices

• Check lifting/ luffing/ telescopic limit switches and travel switches: Reliable action and normal signal.
• Verify tilt sensor, overload protection, anti-shear device and anti-collision bar: Normal functions.
• Check safety buzzer, horn, warning lights and working lights: Complete and functional.

Platform & Protection

• Inspect platform floor, guardrails and safety chains/ gates: Firm, free from damage or looseness.
• Check fall arrester and safety ropes (if equipped): Intact and reliable.
• Test emergency lowering, emergency steering and emergency straightening: Normal functions.

V. Function Test (No-Load Full Process)

• Test lifting, lowering, luffing, telescoping, slewing, traveling, steering and outrigger retraction.
• Ensure smooth movement, no shaking, crawling, abnormal noise or impact.
• Verify normal operation of all speed modes, linear proportional control and no out-of-control conditions.

VI. Cleaning & Appearance

• Clean the whole machine: Remove oil dirt, mud, debris and dust.
• Remove dust inside electric control box, battery compartment and motors.
• Touch up paint to prevent rust and corrosion.

VII. Recording & Filing

• Fill in the monthly maintenance record form.
• Record: Inspection items, problems, treatments, replaced parts, working hours and operators.