Let’s talk about common EWP failures you’re likely to come across in your use of these machines. Safety should be the priority when your business owns or hires elevated work platforms. Staying on top of your EWP servicing helps reduce the risks of working at heights.
Your machine might look fine from the outside – clean paint, sturdy platform, smooth movements. But over time, things happen beneath the surface. If you know what to look out for, you can pick up on issues early. This stops them from snowballing into bigger problems.
Many of the most expensive faults we see in the EWP servicing department at Altequip could have been avoided if the early warning signs had been caught.
So let’s look at the most common EWP failures and what it is that could be causing them.
Hydraulic system issues
Hydraulics are a core component of an EWP. They do the heavy lifting, getting that basket up into the air time after time. As a result, they’re under constant pressure, which means seals and hoses wear down and the fluid can fill with contaminants.
Common failures include:
- Leaking seals and fittings
- Worn or cracked hoses
- Contaminated fluid causing pump wear
- Cylinders creeping or sticking
Signs to look out for:
- Drips from fittings
- A slight drop in lifting speed
- Unusual whining or hissing noises
- Jerky boom movement
If the symptoms are ignored and the problem progresses, you could end up with blown hoses and seized cylinders. That’s when it starts getting expensive. Your EWP mechanic will check all the hydraulics when it comes in for a service, which is another benefit of sticking closely to the service schedule.
Electrical problems
The electrics on a good-quality EWPs such as those from Socage are built to be tough and hardy. Moisture, dust and heat do take their toll over time, though, causing electrical problems to raise their head.
Common failures:
- Corroded connectors and terminals
- Faulty sensors
- Wiring harness issues
- Battery deterioration
- Control box malfunctions
Hidden wear signs:
- Unexpected error codes
- Slow response from controls
- Alarms that appear and disappear without clear cause
An electrical problem can bring your working at heights job to a sudden halt. Regular professional servicing helps you stay on top of it through diagnostic scans, connection and wiring inspection and battery load testing.
Structural fatigue
A structural failure in an EWP doesn’t happen suddenly. Corrosion can get into the joints or platform, especially if you’re operating on the Gold or Sunshine Coasts or near the Bay. High stress areas, such as pins or joints, can also be subject to cracking.
Common failures:
- Fatigue cracks in booms or welds
- Corrosion weakening pins and joints
- Platform wear from constant loading
Hidden wear signs:
- Hairline cracks in paint or metal
- Minor surface rust near stress points
- Creaking or popping noises when the boom is under load
Structural failures are serious and can have catastrophic effects. Perform regular visual checks on your machines, and bring it in for a service where we can check important bolt torques and non-destructive testing to pinpoint any issues.
Tyres, brakes and steering components
These components tend to get overlooked because they’re not as “technical,” but they still play a huge role in site safety and machine reliability.
Common failures:
- Tyre cracking or delamination
- Brake wear or fluid leaks
- Steering linkage fatigue or wear
Hidden wear signs:
- Slight veering during travel
- Small cracks in tyres that worsen quickly under load
- Uneven wear patterns indicate alignment or suspension issues
Regular servicing checks tyre condition, brake integrity and steering components thoroughly. We’ll pick up on small cracks early. Definitely preferable to a burst tyre on site!
Boom chains, cables and safety systems
Chains, cables and safety switches are critical for controlled boom movement and operator safety. They can stretch, fray and wear down with constant use, so this is an important one to watch if your machines are running day-in and day-out..
Common failures:
- Chain tension loss
- Cable fraying
- Safety switches not working
- Limit switches failing intermittently
Hidden wear signs:
- Slight slack in chains
- Intermittent alarms or warning lights
- Irregular boom extension or retraction speeds
These are the kinds of issues that often go unnoticed during your daily operational checks. Your EWP servicing technicians know how to check chain tension accurately and look for other wear and tear that’s tricky to spot.
Why professional servicing makes the difference
Operators are trained to spot obvious problems during daily pre-start checks, and that’s an essential part of keeping EWPs safe. That can help with spotting common EWP failures early.
However – a lot of hidden wear isn’t obvious without the right tools, experience and inspection techniques. That’s where you need professional EWP service technicians to regularly work on your machine.
At Altequip, our servicing team is trained to find the early signs that something’s starting to go wrong. It might be a hairline crack or a change in hydraulic pressure. When we catch these problems early, you’ll enjoy the following benefits:
- Extended equipment life
- Reduced downtime
- Lower repair costs
- Compliance with Australian safety standards
Book your next service with Altequip
Our team of qualified EWP service technicians is based at 110 Delta Street in Geebung, north Brisbane. Contact us today to book a service in with them. We’ve been operating and serving EWPs for decades now, and will seek out any hidden wear and tear issues in your machinery.
The safety and success of your business is very important to us, so get in touch today and let’s get your EWPs running as they should, for the long term.
FAQs – Common EWP Failures
How often should an EWP be serviced?
Check your manufacturers book. It’s usually every 3 months, or more often depending on usage and environment.
What’s included in a standard EWP service?
A typical service covers hydraulic system checks, structural inspection, electrical diagnostics, tyre and brake checks, lubrication, safety switch testing and a general condition assessment. Altequip tailors each service to the machine’s make, model and usage.
Can operators spot hidden wear during daily checks?
Daily pre-starts are great for picking up obvious issues like leaks or visible damage. But hidden wear usually requires a trained technician and specialised tools.
What happens if I delay servicing?
Minor wear can quickly escalate into major failures. Delaying servicing often means higher repair costs and longer downtime.
Does Altequip offer mobile servicing?
Yes, but it depends on availability. Our mobile servicing team can carry out most checks and repairs on site, minimising downtime and transport costs. Contact the office to find out their mobile availability.
