Strategies for Preventing Hydraulic System Failures in Cherry Pickers on Construction Sites

by | Oct 11, 2023 | Construction Accident, Firm News

Cherry pickers, critical for tasks requiring vertical or aerial reach on construction sites, rely heavily on hydraulic systems to operate safely and efficiently. However, hydraulic system failures can pose significant risks, potentially leading to operational downtime, costly repairs, or serious safety incidents. This article examines the common causes of hydraulic system failures in cherry pickers, discusses the consequences of these failures, and outlines preventative maintenance strategies and best practices to ensure reliability and safety in cherry picker operations.

Common Causes of Hydraulic System Failures

Hydraulic system failures in cherry pickers can be attributed to several factors:

  • Fluid Contamination: Contamination of the hydraulic fluid by water, dust, or other particles can cause significant damage to the hydraulic system. Contaminants can erode hydraulic components and lead to malfunctions or failures.
  • Hose and Seal Deterioration: Hydraulic hoses and seals can deteriorate over time due to regular wear and tear, exposure to extreme temperatures, or contact with corrosive substances. Leaks or bursts in hoses and seals can lead to a loss of hydraulic fluid pressure, rendering the cherry picker inoperable.
  • Improper Fluid Levels: Insufficient hydraulic fluid levels can prevent the system from functioning correctly, while excessive fluid levels may lead to increased pressure and leaks.
  • Mechanical Wear: Components of hydraulic systems, such as pumps and valves, are subject to mechanical wear from regular use, which can degrade their performance and eventually lead to failure.

Consequences of Hydraulic System Failures

The failure of a hydraulic system in a cherry picker can have serious implications:

  • Operational Downtime: A non-functional cherry picker can cause delays in project timelines, affecting productivity and potentially leading to increased costs.
  • Safety Risks: Hydraulic failures can result in uncontrolled movements or sudden drops of the cherry picker platform, posing severe safety risks to the operator and nearby workers.
  • Costly Repairs and Replacements: Repairing or replacing damaged hydraulic components can be expensive, especially if the damage involves critical parts like hydraulic pumps or cylinders.

Preventative Maintenance Strategies

To minimize the risk of hydraulic system failures, several preventative maintenance strategies can be implemented:

  • Regular Inspections and Servicing: Conduct routine inspections of the hydraulic system to check for leaks, hose damage, and wear on seals and fittings. Regular servicing, including changing the hydraulic fluid and filters, should be performed according to the manufacturer’s recommendations.
  • Monitoring Fluid Levels and Quality: Regularly check hydraulic fluid levels and test the quality of the fluid. Replace the fluid and clean the system if contamination is detected.
  • Use of High-Quality Parts and Fluids: Invest in high-quality hydraulic components and fluids that are compatible with the cherry picker’s specifications. High-quality materials can withstand tougher conditions and last longer, reducing the likelihood of failure.
  • Training for Operators: Ensure that all operators are trained on the proper use of cherry pickers, including understanding the limitations of the hydraulic system. Educating operators on the signs of potential hydraulic issues can help in identifying problems before they lead to system failures.


Reliable operation of cherry pickers is essential for the safety and efficiency of construction projects. By understanding the causes and consequences of hydraulic system failures, implementing rigorous preventative maintenance strategies, and ensuring operators are well-trained, construction managers can significantly reduce the risk of hydraulic issues. These practices not only prolong the life of the equipment but also safeguard the well-being of workers, supporting smoother and safer construction operations.

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