Free EWP / boom lift annual service checklist
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A step-by-step annual (500-hour) service procedure for elevated work platforms and boom lifts, covering both diesel and electric models. Includes all quarterly service tasks plus hydraulic filter replacement, structural inspection of boom sections and turntable, non-destructive testing of critical welds, load moment indicator recalibration, overload protection testing, full electrical testing, pin and bush measurement, cylinder rod inspection, and the annual compliance inspection per AS 1418.10 / AS 2550. Includes fluid specifications, parts list and technician sign-off.
Last updated: 2026-03-26 · MapTrack
Commercial Director
How to use: Complete the quarterly service first. Then fill equipment details and hour reading on this form, and work through each additional annual service action. Tick Done as each task is completed. Record measurements and part numbers used. Set the next service due hours and sign off.
- ✓ PDF-ready. Open and print to PDF
- ✓ Includes compliance inspection per AS 1418.10
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See the first part of the service procedure below. Enter your email above to download the full EWP / boom lift annual service procedure (PDF-ready).
What is an EWP / boom lift annual service?
An annual service is the highest tier of scheduled preventive maintenance for an elevated work platform (EWP) or boom lift. It is performed every 12 months or 500 operating hours and includes all quarterly service tasks plus additional items focused on structural integrity, compliance and component wear. The annual service is typically combined with the annual compliance inspection required under AS 1418.10. It includes replacing hydraulic, fuel and air filters, structural inspection of boom sections, turntable and chassis, recalibrating the load moment indicator, testing overload protection, full electrical testing, measuring pin and bush wear, inspecting cylinder rods, and updating the compliance sticker and logbook. It is performed by a qualified technician or an accredited inspector.
Benefits of scheduled EWP servicing
- Structural safety: annual structural inspection of boom sections, turntable and chassis identifies cracks, deformation or corrosion before they become critical failures.
- Regulatory compliance: the annual compliance inspection per AS 1418.10 / AS 2550 is a legal requirement. Combining it with the annual service ensures nothing is missed.
- Accurate load systems: recalibrating the load moment indicator and testing overload protection ensures operators are protected by accurate safety systems.
- Extended component life: measuring pin and bush wear, inspecting cylinder rods and replacing worn components on schedule prevents costly failures and extends machine life.
- Lower total cost: planned annual maintenance with documented measurements allows you to forecast replacement costs rather than reacting to breakdowns.
- Resale value: a complete service and compliance history increases the machine's value at trade-in or auction.
Benefits of digitising forms in MapTrack
When you move from paper or static PDFs to digital forms in MapTrack, you get:
- Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
- Automatically get alerts when faults are identified.
- Link every form digitally as a PDF to the relevant asset, location or person.
- Receive a digital PDF copy with every submission to your email.
- Ability to share forms digitally.
- Build conditional logic (show or hide questions based on answers).
- Take pictures or attach photos. Not possible with a paper-based form.
- Electronic signatures.
- Edit forms later without reprinting.
- Restrict permissions (who can view, complete or approve).
- Build forms with AI (describe what you need and MapTrack suggests the form).
Book a demo to see digital service procedures and hour-based scheduling in MapTrack.
Service actions included in the annual procedure
This annual service includes all quarterly tasks plus 15 additional actions across 7 system areas:
- Filters: replace hydraulic return filter, replace fuel filter (diesel), replace air filter (diesel).
- Structural inspection: inspect boom sections for cracks, deformation and corrosion, inspect turntable and chassis, non-destructive testing of critical welds (if due).
- Load and safety systems: recalibrate load moment indicator / rated capacity limiter, test overload protection at rated load plus 10%.
- Electrical: full electrical test including insulation resistance, wiring and contactors.
- Wear components: measure and record boom pin and bush wear, inspect cylinder rod condition (scoring, pitting), inspect wire ropes or chains (if fitted).
- Compliance: annual compliance inspection per AS 1418.10 / AS 2550, update compliance sticker and logbook.
- Functional testing: test function speed and smoothness at full reach.
Fluid specifications
General fluid specifications for EWPs and boom lifts (diesel and electric). Capacities vary by machine size and manufacturer.
| System | Type / Grade | Approx. Capacity |
|---|---|---|
| Engine oil (diesel) | 10W-30 or 15W-40 | 6 - 12 L |
| Hydraulic oil | ISO VG 32 or 46 | 40 - 80 L (system) |
| Grease | EP2 lithium complex | As required |
| Battery water (electric) | Distilled water | As required |
Specifications are general guidelines. Always refer to the manufacturer's service manual for your specific make and model.
Parts and consumables
Have the following parts and consumables ready before starting the annual service (in addition to all quarterly service parts):
- All quarterly service parts (see quarterly list)
- Hydraulic return filter - 1
- Fuel filter (diesel models) - 1
- Air filter (diesel models) - 1
- Boom pins and bushes (if replacing after measurement)
- Rags, drip tray and waste oil container
Look up part numbers in the manufacturer's parts manual for your specific make and model before ordering.
How to perform an EWP / boom lift annual service
- Complete the quarterly service procedure first. All quarterly tasks are carried forward into the annual service.
- Replace the hydraulic return filter. For diesel models, also replace the fuel filter and air filter.
- Perform a structural inspection of all boom sections, checking for cracks, deformation and corrosion. Inspect the turntable and chassis. Perform non-destructive testing of critical welds if due per the manufacturer schedule or 10-year NDT cycle.
- Recalibrate the load moment indicator / rated capacity limiter. Test overload protection at rated load plus 10%.
- Perform a full electrical test including insulation resistance, wiring condition and contactor operation.
- Measure and record boom pin and bush wear. Compare measurements to manufacturer limits and replace if worn beyond tolerance. Inspect cylinder rod condition for scoring and pitting. Inspect wire ropes or chains if fitted.
- Complete the annual compliance inspection per AS 1418.10 / AS 2550. Update the compliance sticker and logbook.
- Test function speed and smoothness at full reach. Record any defects or recommendations in the notes section.
- Set the next service due hours (next quarterly and annual). Sign off and update the machine's maintenance log.
In MapTrack, you can schedule services based on hour meter readings, get automatic reminders, complete service procedures on mobile and link every record to the machine. Book a demo to see how.
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Back to download formEWP / boom lift service interval hierarchy
EWP and boom lift maintenance follows a tiered schedule where each level includes all tasks from the level below. This is called carry-forward or cumulative servicing.
Daily - Pre-start check
Operator inspection before each shift. Visual checks, controls test, safety devices.
150 hours / quarterly - Service
Engine oil and filter (diesel), battery checks (electric), hydraulics, controls testing, greasing, safety systems. Estimated 2-3 hours.
500 hours / annual - Service (you are here)
All quarterly tasks plus hydraulic filter, structural inspection, load moment indicator recalibration, electrical testing, pin and bush measurement, compliance inspection per AS 1418.10. Estimated 4-6 hours.
In MapTrack, you can configure service schedules by operating hours and receive automatic alerts when each interval is due.
Frequently asked questions
- What is included in an EWP annual service?
- An EWP annual (500-hour) service includes all quarterly service tasks plus replacing the hydraulic return filter, fuel filter and air filter (diesel), structural inspection of boom sections, turntable and chassis, non-destructive testing of critical welds (if due), recalibrating the load moment indicator / rated capacity limiter, testing overload protection at rated load plus 10%, full electrical testing (insulation resistance, wiring, contactors), measuring and recording boom pin and bush wear, inspecting cylinder rod condition, inspecting wire ropes or chains (if fitted), the annual compliance inspection per AS 1418.10 / AS 2550, updating the compliance sticker and logbook, and testing function speed and smoothness at full reach. It takes approximately 4 to 6 hours.
- Is the annual service the same as the annual compliance inspection?
- The annual service is typically combined with the annual compliance inspection under AS 1418.10. The compliance inspection is a regulatory requirement that verifies the EWP meets safety standards. The annual service includes maintenance tasks (filter replacement, greasing, fluid changes) that go beyond the compliance inspection scope. Many organisations perform both at the same time to minimise downtime.
- What Australian standards apply to boom lift inspections?
- Boom lifts and EWPs in Australia must comply with AS 1418.10 (Cranes, hoists and winches - Elevating work platforms) and AS 2550 (Cranes, hoists and winches - Safe use). These standards require regular inspection, annual compliance testing and documented maintenance records. The annual service procedure in this template includes the compliance inspection actions required by these standards.
- Is the template free to use without MapTrack?
- Yes. Download and use the EWP / boom lift annual service procedure for free. Open the file and use your browser's Print, then Save as PDF. No MapTrack account required. If you later want digital service procedures linked to each machine with scheduling by hours, cost tracking and alerts, we would be happy to show you MapTrack.
Need digital service procedures with compliance tracking?
Register every EWP and boom lift in MapTrack. Set up quarterly and annual service schedules, track compliance dates and certificates, complete procedures on mobile, and get automatic alerts when the next service or inspection is due.