What is included in a telehandler 250-hour service?

A 250-hour telehandler service is a minor service that includes draining and replacing engine oil (typically 15W-40), replacing the engine oil filter, inspecting the air filter outer element, draining the fuel/water separator, checking coolant level and condition, checking hydraulic oil level, inspecting hydraulic hoses and fittings, checking boom extension and retraction, greasing boom slide pads, wear strips and pivot pins, greasing steering kingpins and tie rod ends, checking tyre pressures and condition, inspecting outriggers/stabilisers, checking the attachment quick-coupler, testing the load chart/rated capacity indicator, inspecting forks or current attachment, checking seatbelt and ROPS/FOPS, testing lights, horn and reversing alarm, checking mirrors and reversing camera, and inspecting fan belts. It takes approximately 1.5 to 2.5 hours.

How often should a telehandler be serviced?

Telehandlers follow a tiered service schedule based on engine hours. A 250-hour (minor) service covers oil, filters, grease and basic inspections. A 500-hour (intermediate) service adds hydraulic filter replacement, fuel filter replacement, brake inspection, boom slide pad measurement and A/C service. A 1,000-hour (major) service adds hydraulic oil change, coolant flush, axle oil change, transmission service and full structural inspection. Daily pre-start checks are performed by the operator before each shift. Always refer to the manufacturer service manual for your specific make and model.

What grease points does a telehandler have?

Telehandlers have grease points on the boom slide pads and wear strips, boom pivot pins, steering kingpins and tie rod ends. Some models also have grease points on stabiliser/outrigger pivots and the attachment carriage. Use EP2 lithium complex grease and follow the manufacturer service manual for the exact number and location of grease nipples on your specific model.

Is the template free to use without MapTrack?

Yes. Download and use the telehandler 250-hour 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.

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Free telehandler 250-hour service checklist

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A step-by-step 250-hour (minor) service procedure for telehandlers and telescopic handlers. Covers engine oil and filter change, air filter inspection, hydraulic system checks, boom extension and retraction testing, greasing boom slide pads, pivot pins and steering points, tyre checks, attachment inspection and safety device testing. Includes fluid specifications, parts list and technician sign-off. This page explains what the service involves, how to perform it, and offers a free PDF-ready form you can download straight away.

Last updated: 2026-03-26 · MapTrack

Jarrod Milford

Commercial Director

Updated 26 March 2026

How to use: Fill equipment details and hour reading, then work through each service action. Tick Done as each task is completed. Record fluid quantities and part numbers used. Set the next service due hours and sign off.

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What is a telehandler 250-hour service?

A 250-hour service is the first tier of scheduled preventive maintenance for a telehandler (telescopic handler). It is performed every 250 engine hours (or approximately every 4-6 weeks of full-time operation) and is classified as a minor service. The procedure covers engine oil and filter replacement, air filter inspection, fuel system maintenance, hydraulic system checks, boom extension and retraction testing, greasing all slide pads, pivot pins and steering points, tyre condition checks, stabiliser inspection, attachment quick-coupler verification, load chart testing and safety device checks. Unlike a daily pre-start check (which confirms the machine is safe to operate), the 250-hour service involves actual maintenance actions: draining and replacing fluids, replacing filters, greasing components and measuring wear. It is typically performed by a qualified mechanic or fitter, not the operator.

Benefits of scheduled telehandler servicing

Reduced breakdowns: regular oil, filter and fluid changes prevent engine and hydraulic failures that cause unplanned downtime on site.
Extended component life: clean oil and correct lubrication reduce wear on engine, hydraulic pump, boom slide pads, transmission and axle components.
Lower repair costs: a 250-hour service costs a fraction of an emergency breakdown repair. Catching issues early prevents cascading damage.
Operator safety: inspecting safety devices, ROPS/FOPS structure, tyres and hydraulic hoses at regular intervals reduces the risk of on-site incidents.
Compliance: documented service records demonstrate that equipment is maintained to WHS standards, supporting insurance and regulatory obligations.
Resale value: a complete service history with documented 250, 500 and 1,000-hour services 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 250-hour procedure

This service procedure covers 20 service actions across 7 system areas:

Engine: drain and replace engine oil (15W-40), replace oil filter, inspect air filter outer element, drain fuel/water separator, check coolant level and condition, inspect fan belts.
Hydraulic system: check hydraulic oil level in sight glass, inspect hoses, fittings and cylinders for leaks.
Boom / telescopic system: check boom extension and retraction, grease boom slide pads and wear strips, grease boom pivot pins.
Steering / axles: grease steering kingpins and tie rod ends, check tyre pressures and condition (all 4).
Stabilisers / attachments: inspect outriggers/stabilisers, check attachment quick-coupler locking, inspect forks or current attachment.
Load safety: test load chart / rated capacity indicator.
Safety devices: check seatbelt and ROPS/FOPS, test all lights, horn and reversing alarm, check mirrors and reversing camera.

Fluid specifications

General fluid specifications for telehandlers (all makes). Capacities vary by machine size and manufacturer.

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. 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 250-hour service:

Engine oil (15W-40 CI-4/CK-4) - 10-18 litres
Engine oil filter - 1
Fuel/water separator element - 1
EP2 grease cartridges - 2-4
Coolant (pre-mixed or concentrate) - as required for top-up
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 a telehandler 250-hour service

Park the telehandler on level ground, lower the boom and attachment fully, engage the park brake and shut down the engine. Allow the engine to cool before draining oil.
Record the equipment details and current hour meter reading at the top of the service procedure form.
Start with the engine section: drain the old engine oil, replace the oil filter, fill with new oil to the correct level, then inspect the air filter, drain the fuel/water separator and check coolant.
Check hydraulic oil level in the sight glass, inspect all hydraulic hoses and fittings for leaks.
Test boom extension and retraction for smooth operation. Grease boom slide pads, wear strips, pivot pins, steering kingpins and tie rod ends.
Check tyre pressures and condition on all four tyres. Inspect outriggers/stabilisers if fitted.
Check the attachment quick-coupler locking mechanism. Inspect forks or the current attachment for wear and damage. Test the load chart / rated capacity indicator.
Check seatbelt and ROPS/FOPS structure. Test all lights, horn, reversing alarm. Check mirrors and reversing camera.
Start the engine and check for leaks, abnormal noises or warning lights. Record any defects or recommendations in the notes section.
Set the next service due hours (next 250-hour and next 500-hour intervals). 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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Telehandler service interval hierarchy

Telehandler maintenance follows a tiered schedule where each level includes all tasks from the level below. This is called carry-forward or cumulative servicing.

250 hours - Minor service (you are here)

Engine oil and filter, grease points, fluid levels, basic inspections. Estimated 1.5-2.5 hours.

500 hours - Intermediate service

All 250-hour tasks plus fuel filter, air filter, hydraulic return filter, brake inspection, boom slide pad measurement, A/C service. Estimated 3-4 hours.

1,000 hours - Major service

All 500-hour tasks plus hydraulic oil change, coolant flush, axle oil change, transmission service and full structural inspection. Estimated 6-8 hours.

2,000 hours - Overhaul service

All 1,000-hour tasks plus full boom and chassis structural inspection, hydraulic pump and motor assessment, axle rebuild evaluation. Typically 2-3 days.

In MapTrack, you can configure service schedules by engine hours and receive automatic alerts when each interval is due.

Frequently asked questions

What is included in a telehandler 250-hour service?: A 250-hour telehandler service is a minor service that includes draining and replacing engine oil (typically 15W-40), replacing the engine oil filter, inspecting the air filter outer element, draining the fuel/water separator, checking coolant level and condition, checking hydraulic oil level, inspecting hydraulic hoses and fittings, checking boom extension and retraction, greasing boom slide pads, wear strips and pivot pins, greasing steering kingpins and tie rod ends, checking tyre pressures and condition, inspecting outriggers/stabilisers, checking the attachment quick-coupler, testing the load chart/rated capacity indicator, inspecting forks or current attachment, checking seatbelt and ROPS/FOPS, testing lights, horn and reversing alarm, checking mirrors and reversing camera, and inspecting fan belts. It takes approximately 1.5 to 2.5 hours.
How often should a telehandler be serviced?: Telehandlers follow a tiered service schedule based on engine hours. A 250-hour (minor) service covers oil, filters, grease and basic inspections. A 500-hour (intermediate) service adds hydraulic filter replacement, fuel filter replacement, brake inspection, boom slide pad measurement and A/C service. A 1,000-hour (major) service adds hydraulic oil change, coolant flush, axle oil change, transmission service and full structural inspection. Daily pre-start checks are performed by the operator before each shift. Always refer to the manufacturer service manual for your specific make and model.
What grease points does a telehandler have?: Telehandlers have grease points on the boom slide pads and wear strips, boom pivot pins, steering kingpins and tie rod ends. Some models also have grease points on stabiliser/outrigger pivots and the attachment carriage. Use EP2 lithium complex grease and follow the manufacturer service manual for the exact number and location of grease nipples on your specific model.
Is the template free to use without MapTrack?: Yes. Download and use the telehandler 250-hour 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 scheduled by engine hours?

Register every telehandler in MapTrack. Set up 250, 500 and 1,000-hour service schedules, complete procedures on mobile, track parts and costs, and get automatic alerts when the next service is due.

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