Intermediate service - telehandler / telescopic handler (all makes)
Estimated duration: 3 - 4 hours • Frequency: every 500 engine hours
Equipment Details
| # | Service Action | Type | Done | Notes |
|---|---|---|---|---|
| Engine (additional to 250-hour) | ||||
| 1 | Replace fuel filter | REPLACE | ☐ | |
| 2 | Replace outer air filter element | REPLACE | ☐ | |
| Hydraulic System (additional to 250-hour) | ||||
| 3 | Replace hydraulic return filter | REPLACE | ☐ | |
| 4 | Take hydraulic oil sample for analysis | SAMPLE | ☐ | |
| Transmission / Drivetrain (additional to 250-hour) | ||||
| 5 | Check transmission oil level and condition (replace filter if separate) | CHECK | ☐ | |
| 6 | Inspect axle oil levels (front and rear) | INSPECT | ☐ | |
| Brakes (additional to 250-hour) | ||||
| 7 | Full brake inspection - measure pad/shoe thickness front and rear | MEASURE | ☐ | |
| 8 | Adjust park brake | ADJUST | ☐ | |
| Steering (additional to 250-hour) | ||||
| 9 | Inspect steering linkage (ball joints, tie rods, drag link) | INSPECT | ☐ | |
| Wheels (additional to 250-hour) | ||||
| 10 | Torque wheel nuts to spec | CHECK | ☐ | |
| Boom (additional to 250-hour) | ||||
| 11 | Check boom slide pad wear (measure) | MEASURE | ☐ | |
| 12 | Inspect boom extension chains/cables (if fitted) | INSPECT | ☐ | |
| Load Safety (additional to 250-hour) | ||||
| 13 | Test load moment indicator calibration | TEST | ☐ | |
| Cab (additional to 250-hour) | ||||
| 14 | Service A/C system (check refrigerant, clean condenser) | CHECK | ☐ | |
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 (system) |
| Coolant | 50/50 ethylene glycol | 15 - 25 L |
| Transmission | Powershift fluid | 15 - 25 L (system) |
| Axle oil | 80W-90 GL-5 | 5 - 10 L per axle |
| 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.
Parts / Consumables Required (500-hour additional items)
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | Engine oil (15W-40) | 10-18 L | ☐ | |
| 2 | Engine oil filter | 1 | ☐ | |
| 3 | Fuel filter | 1 | ☐ | |
| 4 | Air filter (outer element) | 1 | ☐ | |
| 5 | Hydraulic return filter | 1 | ☐ | |
| 6 | Transmission filter | 1 | ☐ | |
| 7 | Fuel/water separator element | 1 | ☐ | |
| 8 | EP2 grease cartridges | 2-4 | ☐ | |
| 9 | Oil sample bottle (hydraulic) | 1 | ☐ | |
| 10 | A/C refrigerant (if low) | As req. | ☐ | |
| 11 | Coolant (pre-mixed or concentrate) | As req. | ☐ | |
| 12 | Rags, drip tray, waste oil container | - | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Supervisor / Workshop Manager