Telehandler Maintenance 101: Typical Repairs and Common Troubleshooting Tasks
Telehandler Maintenance 101: Typical Repairs and Common Troubleshooting Tasks
Reading time: 5 min
Introduction to Telehandlers
Telehandlers, also known as telescopic handlers, have become a critical type of equipment in the construction industry. They provide an ideal combination of height, reach and load capacity that are unparalleled. This makes them essential to many construction tasks, especially those involving materials handling. Whether used for moving heavy loads or lifting supplies to heights, telehandlers have become a common sight on job sites big and small.
In this guide, we’ll get into the maintenance requirements of telehandlers. Understanding the unique maintenance needs of these machines will help you improve the efficiency of your fleet and minimize operating costs.
Typical Maintenance and Performance Issues
Telehandlers, like other types of heavy equipment, can suffer from a range of common maintenance-related issues that can significantly impact their performance. Most of these issues revolve around the hydraulic system, engine and electrical system.
Hydraulic System
Common problems in the hydraulic system include leaks and a loss of power. Leaks are typically caused by worn out seals and gaskets, whereas a loss of power is often traced back to issues such as low fluid level, air contamination or a malfunctioning pump.
Troubleshooting these issues involves regular inspection for leaks, consistent monitoring of fluid levels and replacing damaged components right away. If overlooked, hydraulic issues can cause slow operations, premature wear of components and even breakdowns.
Engine
Engine issues in telehandlers usually manifest as difficulty in starting the machine and excessive exhaust smoke. Difficulty starting can be attributed to a poorly maintained fuel system, or a weak battery, whereas excess exhaust smoke is usually a sign of engine oil or coolant burn.
To troubleshoot, regular maintenance practices like battery checks, fuel filter changes and coolant level checks are essential. Ignoring these issues can lead to a decrease in fuel efficiency, engine failure, or costly repairs.
Electrical System
Electrical system problems include battery issues and faulty controls. A typical cause of battery issues is corrosion, resulting in difficulty starting the telehandler. Faulty controls, on the other hand, can be caused by worn-out switches or damaged wiring.
Regular visual inspections, cleaning the battery terminals and routine checks of the wiring systems are the best ways to combat these issues. If left unresolved, electrical issues can lead to unreliable operation or complete failure.
Commonly Replaced Components
Some of the most commonly replaced telehandler components include tires, hydraulic hoses, seals and filters.
Tires
The replacement frequency of tires largely depends on their use, type of terrain and weight of load. If left unaddressed, worn-out tires can affect the stability, safety and efficiency of the telehandler, leading to possible accidents or machine breakdowns.
Hydraulic Hoses
Hydraulic hoses should typically be replaced every few years, depending on use and operating environment. If leaks or cracks in these hoses are ignored, it could result in a loss of power or, in extreme cases, complete failure of the hydraulic system.
Seals
Seals within the hydraulic system are a commonly replaced part. Reasons for wear include age, degradation from continuous use and exposure to harsh environments. The average replacement timeline for seals ranges from two to three years. Neglecting worn out seals can result in hydraulic leaks, reducing the telehandler’s efficiency and leading to costly repairs.
Filters
Finally, filters (fuel, oil and air) are all routine replacement components. Most filters should be replaced every six months to a year, depending on the type of filter and the recommendations laid out in the machine’s service manual. Generally speaking, neglecting filter changes can result in decreased performance, inefficient fuel consumption and possibly engine damage.
Key Areas that Require Attention
When it comes to telehandler maintenance, some areas that require special attention include the boom mechanism, brake system, cooling system and battery or electrical system.
Boom Mechanism
The boom mechanism, which is the extending arm of the telehandler, is essential to tasks performed with a telehandler. Keeping it in good condition is vital because failures in this part of the machine could hamper productivity or even lead to safety issues. Common problems include wear and tear of the extending cylinders, damage to the boom chains or blockages in the hydraulic lines.
Brake System
A telehandler’s brake system is another area that requires maintenance attention. Common issues with telehandler brakes include worn-out brake pads, low brake fluid levels and damaged brake lines. If overlooked, these issues can lead to brake failure, causing potentially catastrophic accidents.
Cooling System
A telehandler’s cooling system maintains the engine's temperature while preventing overheating and resulting damage. Malfunctions in the cooling system could lead to reduced efficiency, shortened engine lifespan and even engine failure. Typical issues may involve leakage in the coolant line or a malfunctioning cooling fan.
Battery and Electrical System
The battery/electrical system is required to power the machine's starter motor and control system. Common issues that plague telehandler electrical systems include a weakened battery or faulty wiring/connections. Unresolved, these could result in electrical system malfunctions or a machine that doesn’t start.
Preventive Care Considerations
Keeping your telehandler in top condition requires a combination of operational techniques, training programs, preventive maintenance practices and proper storage.
Operational Techniques
Understanding the telehandler’s load and reach limits, along with avoiding abrupt movements, will prevent unnecessary stress on the machine's components. Operators must be well versed in handling these machines, which is best accomplished through well-structured training programs.
Preventive Maintenance Strategies
Preventive maintenance is the most important aspect of telehandler care. These tasks involve routinely checking and replacing damaged or worn components such as hydraulic hoses, filters, seals and tires. Regular inspections for leaks, along with checking brakes, lights and ensuring the boom mechanism is functioning well are important parts of a thorough preventive care plan.
Proper Storage
Proper storage strategies can also help extend your telehandler’s lifespan. When not in use, telehandlers should be stored in a place that is dry and free of environmental hazards. That minimizes exposure to elements that could corrode metal parts or harm the electronic system.
Final Thoughts
A telehandler is a substantial investment and a required player in many construction projects. By implementing the strategies outlined in this guide, you can ensure the quality, efficiency and lifespan of the telehandlers in your fleet.
The EquipmentShare Shop offers a wide range of OEM and aftermarket telehandler parts to meet the needs of your machine. Whether you require simple filter replacements, replacement hoses or more complex electrical components, our growing catalog has you covered. Don’t see the specific parts you’re looking for? Reach out to our dedicated parts experts and get personalized assistance.
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