Major service - telehandler / telescopic handler (all makes)
Estimated duration: 6 - 10 hours • Frequency: every 1,000 engine hours
Equipment Details
| # | Service Action | Type | Done | Notes |
|---|---|---|---|---|
| Engine (additional to 500-hour) | ||||
| 1 | Replace inner air filter element | REPLACE | ☐ | |
| 2 | Check/clean injectors or send for testing | INSPECT | ☐ | |
| 3 | Inspect turbocharger for shaft play and oil leaks | INSPECT | ☐ | |
| 4 | Inspect exhaust manifold and gaskets | INSPECT | ☐ | |
| Hydraulic System (additional to 500-hour) | ||||
| 5 | Drain and replace full hydraulic oil (ISO VG 46) | DRAIN/FILL | ☐ | |
| 6 | Replace hydraulic suction strainer | REPLACE | ☐ | |
| 7 | Inspect hydraulic pump for noise/pressure/wear | INSPECT | ☐ | |
| Transmission / Drivetrain (additional to 500-hour) | ||||
| 8 | Drain and replace transmission oil | DRAIN/FILL | ☐ | |
| 9 | Drain and replace front axle oil (80W-90 GL-5) | DRAIN/FILL | ☐ | |
| 10 | Drain and replace rear axle oil (80W-90 GL-5) | DRAIN/FILL | ☐ | |
| 11 | Inspect torque converter for slip or overheating | INSPECT | ☐ | |
| Cooling System (additional to 500-hour) | ||||
| 12 | Drain, flush and replace coolant (50/50 EG) | FLUSH/FILL | ☐ | |
| 13 | Pressure test cooling system | TEST | ☐ | |
| 14 | Replace thermostat (if due per manufacturer) | REPLACE | ☐ | |
| Boom (additional to 500-hour) | ||||
| 15 | Detailed boom slide pad wear measurement (record dimensions) | MEASURE | ☐ | |
| 16 | Inspect boom extension chains/cables for stretch and wear | INSPECT | ☐ | |
| 17 | Inspect boom pivot pins and bushes | INSPECT | ☐ | |
| 18 | Inspect all boom section welds for cracking | INSPECT | ☐ | |
| Structural (additional to 500-hour) | ||||
| 19 | Inspect chassis welds and mounting points | INSPECT | ☐ | |
| 20 | Inspect stabiliser leg welds, pins and bushes | INSPECT | ☐ | |
| 21 | Check attachment carriage and quick-hitch for wear | INSPECT | ☐ | |
| Safety Devices (additional to 500-hour) | ||||
| 22 | Test load moment indicator (LMI) calibration | TEST | ☐ | |
| 23 | Test boom limit switches | TEST | ☐ | |
| 24 | Verify emergency stop function (all stations) | TEST | ☐ | |
| 25 | Inspect ROPS/FOPS for damage | INSPECT | ☐ | |
Fluid Specifications (General Guide)
| System | Type / Grade | Approx. Capacity |
|---|---|---|
| Engine oil | 15W-40 CI-4 / CK-4 | 10 - 18 L |
| Hydraulic oil | ISO VG 46 (AW 46) | 80 - 150 L (full change) |
| Coolant | 50/50 ethylene glycol | 15 - 25 L (full system) |
| Transmission | Powershift fluid | 15 - 25 L (system) |
| Axle oil (front) | 80W-90 GL-5 | 5 - 10 L |
| Axle oil (rear) | 80W-90 GL-5 | 5 - 10 L |
| Grease | EP2 lithium complex | As required |
Specifications are general guidelines for typical telehandlers (all makes). Always refer to the manufacturer's service manual for your specific make and model. Capacities vary by machine size. At the 1,000-hour interval, hydraulic oil, coolant, transmission oil and axle oil are fully drained and replaced.
Parts / Consumables Required (1000-hour additional items)
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | Engine oil (15W-40) | 10-18 L | ☐ | |
| 2 | Engine oil filter | 1 | ☐ | |
| 3 | Inner air filter element | 1 | ☐ | |
| 4 | Outer air filter element | 1 | ☐ | |
| 5 | Fuel filter | 1 | ☐ | |
| 6 | Fuel/water separator element | 1 | ☐ | |
| 7 | Hydraulic return filter | 1 | ☐ | |
| 8 | Hydraulic suction strainer | 1 | ☐ | |
| 9 | Hydraulic oil (ISO VG 46) | 80-150 L | ☐ | |
| 10 | Transmission oil | 15-25 L | ☐ | |
| 11 | Front axle oil (80W-90) | 5-10 L | ☐ | |
| 12 | Rear axle oil (80W-90) | 5-10 L | ☐ | |
| 13 | Coolant (pre-mixed or concentrate) | 15-25 L | ☐ | |
| 14 | Thermostat (if replacing) | 1 | ☐ | |
| 15 | Transmission filter | 1 | ☐ | |
| 16 | EP2 grease cartridges | 2-4 | ☐ | |
| 17 | Rags, drip trays, waste oil containers | - | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Supervisor / Workshop Manager