Truck-Mounted EWP Inspection & Certification

Why truck-mounted EWPs need integrated engineering inspection

A truck-mounted EWP transfers every load applied at the platform down through the boom, the turntable, the subframe and finally into the truck chassis and stabilisers. A defect anywhere in that chain can compromise the whole machine, so inspecting the boom in isolation is not enough. Our engineers follow the load path from cage to outrigger pad, which is why the same technician who examines boom welds also checks the subframe fixings and the condition of the chassis rails they bear on.

These machines also accumulate fatigue differently from self-propelled EWPs. Highway travel, road shock and the constant cycling of a high, slender boom mean fatigue cracking tends to appear at pin bosses, section overlaps and weld toes long before the component fails outright. Detecting those cracks early, before they propagate, is the core purpose of a competent inspection regime.

Annual and routine inspection

Under AS 2550.10 and the general plant duties of the model WHS Regulations, a truck-mounted EWP must be inspected at intervals recommended by the manufacturer, and at least annually, by a competent person. The annual inspection is a functional and structural check that confirms the machine remains safe for continued service and that the log book reflects its true condition.

We verify every safety-related function on both the ground and platform controls, confirm emergency descent works under load, and check that overload and tilt sensing operate at the correct thresholds. Structural elements are examined visually and, where access or history warrants, with targeted non-destructive testing.

• Full function test of upper and lower controls including emergency lowering
• Visual and dimensional check of boom, pins and slew ring
• Hydraulic leak and cylinder drift assessment
• Stabiliser interlock and level-sensing verification
• Load chart, compliance plate and log book review

The 10-year major inspection

AS 2550.10 requires a major inspection of an EWP after ten years of service, and thereafter as determined by the assessment, or earlier if the duty cycle is severe. The major inspection is a deep structural examination that goes well beyond the annual check: primary components are stripped or opened up as needed so that welds, pins and bearings can be examined directly.

For a truck-mounted unit this means removing covers and, in many cases, dismantling the platform and boom-tip linkages to reach fatigue-critical joints. We combine magnetic particle and ultrasonic testing of high-stress welds with dimensional checks of wear points, then issue an engineering report that either certifies the machine for a further defined service period or specifies the remediation required.

Because the major inspection is decisive for whether a machine stays in service, it is worth booking well ahead of the anniversary date. We coordinate the strip-down, testing and reassembly so the vehicle spends the minimum time off the road.

Boom and structural assessment

The boom is the component most likely to determine a truck-mounted EWP's remaining life. Telescopic sections wear at the slide pads, articulating joints wear at the pins and bushes, and the base of the boom sees the highest bending stresses. Our engineers measure pin and bore clearances, inspect slide pad wear, and apply the appropriate NDT method to each weld class.

Where cracking or excessive wear is found, we do not simply condemn the machine. An engineering assessment quantifies the defect, references the original design where available, and advises whether repair to a documented procedure can restore full capacity. This is the difference between an inspection and an engineering-led certification.

Chassis, subframe and stabilisers

The interface between the EWP and the truck is a common source of hidden defects. Subframe U-bolts and fasteners loosen, corrosion forms between the subframe and chassis rail, and stabiliser mounting welds crack under repeated deployment. Because these points are covered by bodywork, they are easy to miss without a deliberate inspection.

We examine the outrigger legs, jacks, pads and their interlocks, confirm the machine will not elevate unless the stabilisers are correctly set, and check the turntable mounting bolts to the manufacturer's torque specification. The chassis itself is checked for cracking and corrosion at the mounting zone, feeding into any separate roadworthiness process the owner runs.

Certification, reporting and record keeping

Every inspection concludes with a written report signed by the responsible engineer, a clear pass, conditional-pass or fail determination, and an updated entry in the machine's log book. Where the machine passes, we confirm the compliance plate and load chart remain accurate and legible; where remediation is required, the report lists each item with a recommended timeframe.

For fleet operators we consolidate these records so that anniversary dates, major inspection due dates and open defects are visible at a glance, which supports both internal safety governance and any regulator or client audit.