What keeps a big boom earning?
Large boom lifts are impressive machines. Their height, outreach
and platform capacity make work possible in locations that smaller equipment simply cannot reach.
But owning or operating a large boom is not only about how high it
can go.
For hire companies, contractors, infrastructure operators and businesses maintaining their own fleets, the real measure of a boom
lift is how consistently it can remain safe, compliant, reliable and available for work.
A large boom sitting idle while awaiting diagnosis, parts or repairs is
not generating revenue. A machine that has not been maintained or documented correctly may also become harder to hire, sell, insure or return to service.
Keeping a big boom earning requires more than reacting when something breaks. It involves planned maintenance, regular inspections, trained operators, reliable service support, accurate records and a clear understanding of the machine’s total cost over its working life.
Large booms require a whole-of-life approach
As boom lifts become larger, their mechanical, hydraulic and electronic systems generally become more complex.
Depending on the machine, this can include multiple boom sections, articulation points, telescopic extension systems, platform-levelling systems, load-sensing equipment, oscillating axles, four-wheel steering, emergency-lowering systems, secondary guarding, onboard diagnostics and telematics.
These systems work together. A fault in one area can affect the performance or availability of the entire machine.
That is why maintenance should be considered from the beginning of ownership—not after the first major breakdown.
Before purchasing or adding a large boom to a fleet, businesses should consider:
- Who will service and inspect the machine?
- Are technicians familiar with the make, model and control system?
- How readily available are common and critical replacement parts?
- Can the machine be diagnosed locally?
- What transport is required to move it?
- Where will major repairs or inspections be completed?
- What records must be maintained throughout its working life?
- How much downtime can the business realistically absorb?
The purchase price is only one part of the investment. The support structure around the machine often determines whether it becomes a productive long-term asset.
Preventative maintenance protects availability
Preventative maintenance is one of the most effective ways to reduce avoidable downtime.
The correct servicing schedule should be based on the manufacturer’s requirements, operating hours, age, operating environment and applicable inspection guidance. A machine working in dust, salt air, extreme heat or demanding construction conditions may require closer attention than one operating occasionally in a controlled environment.
Maintenance requirements vary between manufacturers and models, but important areas commonly include:
Large boom lifts rely heavily on hydraulic components to raise, extend, articulate, rotate and position the platform.
Hoses, fittings, seals, cylinders, valves and hydraulic oil should be monitored for leakage, deterioration, contamination and damage. A minor leak should not automatically be treated as insignificant. It may indicate a worn seal, damaged hose or developing component problem.
Maintaining correct hydraulic oil condition and addressing leaks early can help prevent contamination and more expensive downstream damage.
The joints allowing a boom to articulate and extend are exposed to repeated movement and load.
Wear can develop gradually in pins, bushes and pivot points. Correct lubrication and scheduled inspection are essential. Excessive movement, unusual noise or changes in machine behaviour should be investigated rather than accepted as normal ageing.
Modern booms increasingly rely on electronic controllers, sensors, switches, wiring looms and diagnostic systems.
Intermittent electrical faults can be difficult to trace if the machine’s service history is incomplete. Damaged wiring, moisture ingress, poor connections, incorrect replacement components and unresolved fault codes can all lead to recurring downtime.
Technicians need appropriate diagnostic information and equipment—not just general mechanical experience.
Emergency lowering, platform levelling, load-sensing systems, alarms, interlocks, limit switches, ground controls and secondary-guarding devices must operate correctly.
These systems should not be bypassed simply to return a machine to work. A temporary shortcut can create a serious safety risk and a much larger liability for the owner or operator.
Large booms are heavy machines. Tyre condition, wheel security, steering components, drive systems, axles and braking performance all influence stability and safe movement.
The machine’s ground conditions also matter. Damage can occur when equipment is repeatedly operated on unsuitable terrain, overloaded surfaces or gradients beyond its design limits.
Inspection requirements must be planned—
not discovered at the last minute
Safe Work Australia guidance states that an EWP should undergo a major inspection after ten years of service and every five years thereafter. The machine’s history and condition can also affect what is required.
A major inspection is significantly more involved than an ordinary service. It may require dismantling, cleaning and examination of critical components, assessment of structural areas, replacement or repair of worn parts, testing and detailed documentation.
Owners should prepare for this well before the machine reaches the relevant age. Leaving the decision until the machine is already due may create extended downtime, unexpected expenditure or pressure to replace the asset quickly.
Maintenance and inspection records are equally important. They help demonstrate what work has been completed, identify recurring faults, assist technicians and give future buyers greater confidence in the machine. This brings us to not only the machine, but who operates the machine.
Re
pair?
pair?
Re
build?
build?
Re
place?
place?
Operators play an important role in reliability...
A good maintenance program can be undermined if operators are not trained to recognise and report developing problems.
Small faults are often less expensive to address before they become failures. If operators continue using a machine while warning signs are present, the eventual repair can involve additional components, longer downtime and greater safety risk.
Pre-start inspections should therefore be treated as useful asset-management information—not merely paperwork that needs to be completed.
Operators are often the first people to notice:
- Changes in function speed or responsiveness
- Unusual noises or vibration
- Hydraulic leaks
- Warning lights or recurring fault codes
- Damage to controls, rails or the platform
- Irregular steering or drive behaviour
- Levelling or stability concerns
- Damage caused during transport or site operation
Parts planning becomes more important as machines age
A large boom may remain mechanically valuable for many years, but parts availability can change as a model ages.
Common filters, seals, hoses and service items may be straightforward to obtain. Model-specific controllers, sensors, displays, valves, wiring assemblies or structural components may require more planning.
Fleet owners should consider identifying:
- Frequently replaced service items
- Components with known lead times
- Parts shared across multiple machines
- Model-specific electronic components
- Critical parts capable of stopping the machine completely
- Approved replacement or repair options
This does not necessarily mean storing every possible component. It means understanding where the parts will come from before the machine is out of service.
Strong supplier relationships and accurate machine identification are particularly important. Serial numbers, model details and part numbers should be verified before components are ordered, as variations can exist within the same model range.
Transport and site planning affect the true operating cost
Large booms cannot always be moved as easily as smaller access equipment.
Transport dimensions, machine weight, route restrictions, permits, site access and loading requirements can all affect mobilisation costs and availability. A machine may be suitable for the work at height but unsuitable for the intended access route or ground conditions.
Before committing the machine to a project, businesses should consider:
- Transport configuration and permit requirements
- Ground-bearing capacity
- Site gradients and terrain
- Overhead obstructions
- Available setup and manoeuvring space
- Rescue and emergency procedures
- Nearby powerlines or energised equipment
- Whether the selected boom provides the necessary outreach as well as height
Planning these factors properly helps prevent damage, delays and inappropriate machine selection.
Telematics can help—but it does not replace inspection
Many newer boom lifts include telematics or can be fitted with fleet-monitoring technology.
Depending on the system, telematics may provide information about machine location, operating hours, battery or fuel status, fault codes, utilisation and scheduled servicing.
This data can help fleet managers identify underused assets, plan maintenance and respond to developing issues. It can also support better decisions about whether a machine should remain in the fleet, be transferred to another location or be prepared for sale.
However, telematics should support—not replace—physical inspections and competent technical assessment. Data may identify that a fault exists, but it does not always reveal the complete cause or condition of the machine.
Eventually, every fleet owner faces the same decision:
Should the machine be repaired, rebuilt, refurbished or replaced?
The answer should be based on more age or appearance?
Important considerations include:
- Structural condition
- Mechanical and hydraulic condition
- Availability and cost of parts
- Service and inspection history
- Expected future utilisation
- Current and upcoming inspection requirements
- Likely downtime
- Transport and operating costs
- Resale value
- Suitability for the work
Painting alone does not make a machine mechanically sound.
Likewise, a mechanically reliable machine with extensive corrosion, damaged panels or poor presentation may be less attractive to customers and future buyers.
For the right machine, rebuilding or refurbishing can extend its useful life and delay the capital cost of replacement. For another machine, ongoing repairs and limited parts availability may mean replacement is the better commercial decision.
Downtime should be treated as a
business cost
The most expensive repair is not always the one with the largest workshop invoice.
Lost hire revenue, replacement equipment, transport, project delays, staff time and dissatisfied customers can make downtime far more costly than the repair itself.
Fleet owners should track:
- How often each machine is unavailable
- The cause of each breakdown
- Repeat failures
- Time spent awaiting approval, parts or transport
- Repair cost relative to utilisation
- Revenue or productive hours lost
- Whether preventative work could have reduced the interruption
This creates a more accurate view of machine performance than repair cost alone.
A machine that requires occasional planned expenditure may still be a strong asset if it maintains high utilisation. A seemingly inexpensive machine may be poor value if it repeatedly fails at critical times.
The machines that earn consistently are the machines supported properly
A large boom is a significant asset, but height and capacity alone do not determine its value.
Consistent earnings come from choosing the right machine, maintaining it correctly, responding to faults early, planning inspections, managing parts and keeping reliable documentation throughout its working life.
The best time to think about servicing, parts and major inspections is before the machine stops—not after.
Keep your equipment working and your fleet earning.
Access Markets supports access-equipment owners with scheduled servicing, safety inspections, workshop repairs, engine and component repairs, major inspection and recertification work, rebuilds and complete refurbishments.
With locations in Brisbane, Sydney, Melbourneand Perth, our team can help assess your equipment and determine the practical way forward.
Contact Access Markets on 1300 631 610 to discuss your servicing, repair or refurbishment requirements.
This article provides general information only. Inspection, maintenance and operating requirements should be confirmed against the machine manufacturer’s instructions, current Australian Standards and the work health and safety requirements applying in your jurisdiction.
