Do you know all the maintenance items for aerial work platforms?
Do you know the time points for maintenance of aerial work platforms?
The design service life of an aerial work platform is usually 10–15 years or 10,000–20,000 engine operating hours; high-quality units can reach 15–20 years. Why do many enterprises fail to reach this service life with their purchased equipment? A major reason is inadequate maintenance and servicing.
First, let us understand the hazards of non-standard maintenance:
① Sharp rise in accident rates: Statistics from emergency management authorities show that non-standard maintenance is one of the primary triggers for safety accidents involving aerial work equipment, accounting for approximately 35% of such incidents.
② Shortened service life: Equipment with untimely or incomplete maintenance sees an average service life reduction of 20–30%.
Today, we will elaborate on the daily maintenance of aerial work platforms through this article.
Aerial work platform maintenance work falls into three tiers: pre-operation inspection, periodic maintenance, and periodic in-depth inspection. Below is a breakdown of core maintenance procedures:
1.Pre-operation Inspection (also known as walkaround inspection),This step is performed by the operator.
①Complete Machine and Structure
Check for damage, cracks, deformation, or abnormal wear; focus on key components including booms, outriggers, and scissor arms; ensure all bolts, nuts, and connecting fasteners are fully tightened; promptly repair any damaged exterior surfaces.
②Hydraulics and Electrical Systems
Verify hydraulic oil level and cleanliness, check oil cylinders for leakage; inspect power cords and cables for abrasion, confirm controllers and alarm devices function properly; monitor dashboard warning lights after startup for any alerts.
③Safety Devices
Test the functionality of emergency stop switches, overload alarms, and emergency lowering mechanisms to confirm they are intact.
2.Periodic Maintenance (Scheduled by Hours / Weekly / Monthly),This work must be carried out by qualified personnel in accordance with manufacturer specifications.
①Cleaning
Conduct a full cleaning at least once weekly, focusing on removing dust and oil grime from booms, scissor arms, wiring harnesses, oil cylinders, and hydraulic radiators.
②Lubrication
Regularly apply lubricant to connection pins of booms, oil cylinders, slewing bearings, and other structural joints; some bearings require lubrication every 5 operating hours or every 10 days.
③Power Source Maintenance
• Internal Combustion Engine Driven Units
Regularly check engine oil and antifreeze levels.
Clean air and diesel filters every 100 operating hours, replace them upon the fourth cleaning interval; replace the engine oil filter for the first time after 50 operating hours, then every 200 operating hours or every 6 months, whichever comes first.
Select engine oil suitable for the prevailing season; regularly clean radiators and inspect coolant and drive belts.
• Battery Powered Units
Exterior and terminals: Keep battery tops and terminals dry, clean, and corrosion-free to prevent electric leakage or short circuits.
Cables and connections: Routinely inspect cables for damage and confirm wiring connections are tight and free of corrosion. Address loose or oxidized connections immediately.
Abnormality checks: Watch for cracks, deformation, or bulging on battery casings.
Timely charging: Fully recharge the unit immediately after each use, avoid long-term storage with depleted batteries. The ideal charging standard is "full charge, shallow discharge".
The core principles of proper battery maintenance are: maintaining cleanliness, scientific charging, timely fluid replenishment (where applicable), and safe operation.
3.Periodic In-depth Inspection (Annual / By Operating Hours),Performed by certified engineers in compliance with OEM specifications and local regional standards.
①Hydraulic Oil and Filter Replacement
Replacement is generally recommended every 2 years or 2,000 operating hours; use hydraulic oil of appropriate viscosity grades during extreme high summer temperatures or severe winter cold.
②10-Year Major Overhaul
IPAF recommends that equipment undergo a major overhaul within the first 10 years of commissioning, followed by subsequent overhauls every 5 years (i.e., at the 10th, 15th, and 20th year marks). This requirement especially applies to equipment operating in harsh environments or for special applications. The 10-year major overhaul includes wall thickness measurement of main booms, replacement of internal boom slide blocks, internal boom steel wire ropes, and internal boom pulleys.
4.Conclusion,Proper maintenance of aerial work platforms delivers the following benefits:
① Significant reduction in fatal and injury accidents: IPAF reports indicate that among fatal and serious injury incidents caused by mechanical or technical faults in 2024, strengthened maintenance inspections reduced reported incidents year-on-year by 33%, with fatalities falling 45% year-on-year. The 2025 IPAF report further records a 26% drop in fatal accidents involving aerial work platforms.
② Extended equipment service life
· Exceed expected service life: With standardized maintenance, equipment can reliably reach its designed 10–15 year service lifespan. Relevant data notes that premium units can achieve even longer service life with diligent upkeep.
·Multiplied service life of core components: For example, proper battery maintenance can at minimum double battery service life.
③Lower equipment failure rates
·Reduced critical breakdown frequency: Standardized preventive maintenance cuts critical equipment failure rates by more than 70%.
④Lower full-lifecycle costs
· Optimized total lifecycle expenditure: Initial equipment procurement costs typically account for only 20–30% of total full-lifecycle expenses. Proper maintenance controls the larger proportion of subsequent operational and servicing costs.
