What to do If a Hydraulic Line Fails on an Aerial Device

Jim Olson | Senior Product Engineer
Jim Olson - Senior Product Engineer August 27, 2025
Utility lineworker operating Terex bucket truck

Regardless of the make or model of your bucket truck, a quick response is very critical to stop oil flow caused by a hydraulic line failure. Stopping the flow of hydraulic oil is important to prevent an environmental hazard, further damage, and prevent injury.

An evaluation of where the leak is on the machine is required to determine which action will stop the flow. If the leak is under the vehicle and between the pump and the first valve, shutting off the engine or PTO is the only solution.

Ground personnel must be trained in the methods to follow and how to operate the unit if the platform controls cannot be operated.  See the units Operator’s Manual for more information.

The following sequence can be used to stop the flow on an aerial device after determining the location of the leak on the machine. 

From the Platform

  • Release the function being operated. Shut off tool valve if tool, tool hoses, or tool connections are involved.  
  • Activate the stop control, which will divert the flow back to the tank.  
  • Activate the engine stop/start switch, if so equipped. This will stop the engine driving the pump.  
  • Get ground assistance if all these fail

From The Vehicle Bed  

  • Move the control selector at the lower controls to the lower control position. This will stop all flow to upper controls.  
  • Push the engine stop/start switch, if so equipped. This will stop the engine driving the pump.  

From The Ground  

  • Shut off the pump engine. This will stop the pump.  
  • Disengage the power take-off. This will stop the pump.  
  • Move the control selector at the outrigger control valve to the opposite position it is in. This will stop all flow to the failed function.  
  • Push the engine stop/start, if so equipped. This will stop the engine driving the pump.  

In all cases if ground personnel must aid the operator from the lower controls do not approach the vehicle if energized or suspected of being energized. Use hot sticks to move the control levers at the turntable or outrigger controls to stop the flow.  Then evaluate how to get the platform down. 

Hydraulic oil is flammable and oil spray can be explosive if exposed to a spark or high heat.