The aerial lifts in RBG Inc.’s product lines are built to operate safely in demanding environments, including tree care, construction, and the rental industry where equipment often sees heavy use. When properly maintained, these machines provide reliable performance that crews can count on every day. Recognizing the early warning signs that signal a need for immediate service is critical to reducing the risk of accidents, injuries, and unexpected downtime.
Below are the most important warning signs operators and fleet owners should never ignore.
Hydraulic Problems That Cannot Wait
Hydraulic systems are the heart of any aerial lift. When hydraulics fail, movement becomes unpredictable and unsafe. One of the most obvious warning signs is visible hydraulic oil leaking from hoses, cylinders, fittings, or around the turret. Even small leaks often point to worn components that can fail under pressure.
Another red flag is uneven or jerky movement when raising, lowering, or rotating the boom. A lift should move smoothly and consistently. If it hesitates, surges, or feels delayed, something is not right. Boom drift is also serious. If the boom slowly lowers or the platform sinks while controls are in neutral, the lift should be taken out of service immediately. These issues can lead to sudden drops without warning.
Unusual noises matter too. Whining, knocking, or grinding sounds from the hydraulic pump or valves often signal internal damage or air in the system.
Structural Damage You Can See and Feel
Structural components are engineered to carry specific loads. Any damage to these parts should be treated as critical. Cracks in the boom, basket mount, turret, or weld areas are never acceptable. Even small cracks can grow quickly when the lift is under load.
Bent boom sections or outriggers are another serious concern. A slight bend may not look dramatic, but it changes how forces move through the structure. Over time, this can lead to failure. Rust is also more than a cosmetic issue. Deep pitting, flaking steel, or rust near welds weakens the metal and reduces its ability to safely support weight.
Loose pins, missing retaining clips, or worn pivot points are signs the lift should not be operated until repaired.
Outrigger and Stability Issues
Outriggers are critical for stability, especially on trailer mounted lifts and truck mounted units working on uneven ground. If outriggers do not fully deploy, do not stay planted, or creep after being set, the lift should not be used.
Safety interlocks tied to outriggers are equally important. If the lift will operate without outriggers properly set, the system is not protecting the operator. Any rocking, twisting, or unstable feeling once the platform is raised is a clear signal to stop work and call for service.
Control and Electrical System Failures
Aerial lift controls should be predictable and consistent. If base controls and platform controls behave differently, or if controls respond intermittently, something is wrong. Emergency stop functions must work every time. If an emergency stop fails or feels unreliable, the lift is unsafe.
Burning smells, sparking, or exposed wiring are all reasons to shut the unit down immediately. On electric lifts, batteries that overheat or fail to hold a charge can create serious safety risks.
Safety Systems That Are Not Doing Their Job
Modern aerial lifts rely on multiple safety systems to protect operators. Tilt alarms, load sensing systems, platform leveling systems, and emergency descent functions all exist for a reason. If any of these features are not working, are disabled, or appear to be bypassed, the lift should be removed from service.
Fall protection anchor points should also be checked regularly. If they are loose, damaged, or corroded, they cannot be trusted to protect a worker in a fall.
Contamination and Overheating Warnings
Hydraulic fluid condition tells an important story. Milky or foamy oil often means contamination, usually from water. This reduces lubrication and can cause rapid internal wear. Excessive heat around the hydraulic tank or motor is another warning sign. Overheating shortens component life and increases the risk of sudden failure.
Vehicle and Chassis Concerns on Bucket Trucks
For truck mounted lifts, the vehicle itself is part of the system. Cracks or rust near the lift mounting points, uneven suspension, or problems with the PTO engaging correctly all affect safety. Excessive vibration at idle or under load should also be investigated immediately.
A Simple Rule to Remember
If the lift moves when it should not, does not move when it should, leaks fluid, or has a safety system that does not work, it needs immediate service. Stopping work may feel inconvenient, but it is always less costly than dealing with an accident.
If you suspect you any of the issues listed above, we highly recommend receiving an OSHA/ANSI inspection. RBG Inc. offers numerous service on Dur-A-Lift, DINOlift, HYRAX, and many other aerial lifts, cranes, diggers and more!