Boom lifts are aerial lifts used extensively in various industries, particularly construction. A boom lift is a piece of equipment consisting of a hydraulic arm connected to a platform or bucket, allowing workers to reach elevated areas safely and efficiently. They’re known for their ability to extend vertically and horizontally, providing greater flexibility compared to other aerial lifts like scissor lifts.

A well-maintained boom lift is less likely to malfunction, reducing accident risks that could harm workers or bystanders. Regular maintenance also ensures that equipment is available when needed by preventing unexpected breakdowns, which minimizes downtime and avoids costly repairs.

Common Issues Associated with Boom Lifts

Hydraulic System Problems

Dirt or debris in the hydraulic fluid can lead to system failure and safety hazards. Hydraulic seals can fail from heat, chemical exposure, or wear and should be checked and replaced regularly. Within just a few days of contamination, your boom lift could experience jerky or delayed boom movement and erratic joystick responses. Within a week, hydraulic drift, sticking outrigger controls or basket tilt functions can start to happen. Within 2-3 weeks, boom bounce and uncontrolled lowering can occur. If too much dirt accumulates, the filter bypass activates and allows unfiltered fluid to circulate in your hydraulic system which can cause severe damage. Frequently replacing hydraulic filters is essential to preventing system contamination.

Electrical And Power System Maintenance

In a boom lift’s electrical system, the connectors and cables are most prone to wear from exposure to environmental conditions. The elements in control panels and switches operate frequently, affecting their reliability. Also, sensors and alarms, critical for safety, can fail if not properly maintained. This can cause erratic or complete control failure in joysticks, basket controls, ground controls, and even cause “ghost faults,” where the system throws errors without an obvious cause. Automatic lockout of the operational functions, even the machine refusing to start at all, are also results of worn connectors and cables.

In the power systems, batteries wear out from frequent use and environmental conditions, while alternators and charging wear out over time.

Rust and Corrosion Risks and Consequences

Rust and corrosion significantly impact the performance of boom lifts by compromising their structural integrity, functionality and safety. Rust can interfere with the smooth operation of moving parts, causing friction and reducing efficiency, which in turn reduces power output and affects performance.

Corrosion weakens metal surfaces, making them more prone to fractures and catastrophic failures during operation. It can also lead to leaks in hydraulic lines. Additionally, corroded electrical connections can result in poor conductivity and electrical failures, impacting overall system reliability. These occurrences cause significant safety hazards to operators and nearby personnel.

Boom Lift Maintenance Checklist: Key Areas to Inspect Regularly

Safety is the number one priority when it comes to boom lifts, so there are several areas of maintenance to cover. These categories include:

1. Walkaround Inspections

These inspections are done before each use and include a visual inspection of the boom lift for outside damage, leaks or wear of components like tires, hydraulic hoses and the structure itself.

1. Check for missing parts and ensure all components are fastened securely.
2. Our checklist for parts that are most likely to go missing: platform entry gate pin/latch, protective dust caps on hydraulic couplers or electrical connectors, bolt-on covers or access panels, outrigger or wheel chock storage brackets/pins, control/joystick cover boots, and battery hold-down clamps/covers.
3. Verify that the manuals and safety decals are present and legible.
4. Make sure to keep an eye out for the harness anchor point labels/tags and warning labels, decals, and safety placards.
5. Inspect for signs of rust, corrosion or excessive wear on the boom and platform.

2. Startup Checks

These inspections are done before each use and include a visual inspection of the boom lift for outside damage, leaks or wear of components like tires, hydraulic hoses and the structure itself.

1. Ensure the engine starts properly and check the oil pressure.
2. Test all hydraulic components for leaks and proper function.
3. Verify that all gauges and warning lights are functioning.

3. Operational Tests

After completing the walkaround and startup checks, ensure that all mechanical systems operate as intended.

1. Test boom movement (raise, lower, extend, retract).
2. Verify turret rotation to confirm your boom lift can rotate properly.
3. Check the drive and steering capabilities of your lift.

4. Workplace Inspections

These inspections focus on the environment where workers will use the boom lift.

1. Check ground conditions for stability and hazards like uneven surfaces or holes.
2. Identify overhead obstructions such as power lines or building structures.
3. Ensure the work area is clear of pedestrian or vehicle traffic.

Maintenance of Boom Lift Safety Components

Safety components, in particular, should receive extra attention. Regular maintenance of these components ensures safe operation and compliance with aerial lift safety standards. Here are the safety-related maintenance items to complete:

1. Guardrail Systems: Inspect guardrails for damage or wear and ensure they are securely attached to the platform.
2. Safety Features and Alarms: Test the emergency stops and alarms to ensure they function correctly and verify that all the warning lights and gauges are operational.
3. Harness Connection Points: Confirm that all the lanyard anchorage points are secure and in good condition, and ensure that the harnesses are correctly attached and functioning.
4. Platform Rails and Safety Gates: Inspect them for damage or excessive wear and ensure they are securely fastened and functioning.
5. Warning and Instructional Labels: Verify that all safety decals and labels are legible and securely attached. Replace any that are worn or missing.
6. Slippery Conditions: Check the platform for slick areas and clean them to ensure proper traction to prevent falls.
7. Load Capacity: Make sure the load capacity is marked on the platform so workers do not exceed it.

Regular Inspection Schedule

Daily: Conduct a walk-around inspection before each use to check for visible damage or issues with safety components. Weekly: Perform a more thorough inspection of safety features and ensure each one functions correctly. Monthly: Inspect structural components and safety systems more thoroughly. Annually: Hire a certified technician to inspect all safety components and systems.

Best Performance Tips to Extend The Life of Your Boom Lift

Regular aerial lift maintenance is the key to the boom lift's longevity, as with all types of equipment. Checking fluid levels, providing frequent lubrication to moving parts, and ensuring clean filters are essential for operational efficiency.

Daily visual inspections before using the lift can reveal signs of wear, damage or leaks. Detailed inspections every 3 months or 150 hours of operation can identify and address potential issues early.

Adhere to the manufacturer's maintenance schedule for tasks like oil changes, filter replacements and hydraulic system checks, and remember to keep detailed service records and follow a rigid preventive maintenance plan as the best defense against machinery downtime.

Additionally, consider seasonal maintenance factors since components can overheat engines and hydraulic systems, while batteries can drain faster in the summer heat. Conversely, cold temperatures thicken hydraulic oil, reduce battery capacity and cause seals and o-rings to fail more often.

Final Thoughts

Regular inspections and maintenance can identify issues before they become critical, so following manufacturer guidelines for maintenance and replacement is essential. Training operators to recognize signs of wear and promptly report issues is vital in preventing accidents and breakdowns.

When it’s time to service your boom lift, check out MechLink’s comprehensive range of telescopic boom lift parts and articulating boom lift parts. Don’t see exactly what your machine needs? Reach out to our parts experts and get personalized assistance.