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Free telehandler monthly inspection checklist

Free telehandler monthly inspection checklist. Boom chain stretch against the OEM limit, wear pads, boom tip rollers, load chart, ROPS/FOPS.

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Updated 26 Oct 2026

Telehandler Monthly Inspection

Monthly periodic inspection | Wear against OEM limits

Live form
0 of 39 checks

Structure & welds

1ROPS/FOPS canopy welds, mounting bolts, sticker legibility
2Chassis frame and counterweight mounting integrity
3Boom rest and boom support structural welds
4Load chart placard legibility and attachment match
5Stabiliser leg structural welds (MRT models)

Boom, chains & wear pads

6Boom extension chain stretch (Falcon/Pewag) vs OEM elongation limit
7Telescoping boom wear pads and shim pack at each section joint
8Boom tip rollers, side rollers, and head-section structure
9Lift cylinder rod and gland seal weep at full extension
10Tilt cylinder rod and gland seal weep under load
11Fork carriage hooks, locator pins, and positive lock function

Hydraulic system

12Hydraulic reservoir level, oil condition, and filter status
13Hose chafing walk along boom and chassis routing
14Hose tensioner sheaves and routing through section joints
15Manifold, control valve, and holding valve external leak check
16Stabiliser cylinder seal weep (MRT models)

Tyres, wheels & axles

17Tyre tread depth, sidewall cuts, and chunking on all four wheels
18Wheel nut torque to OEM specification
194WD front and rear axle pivot bushings
20Transmission and differential oil level inspection
21Final drive and wheel hub external leak check

Brakes & steering

22Service brake pedal travel and stopping distance
23Parking brake hold on graded surface under rated load
244WS steering mode function (front, rear, crab) where fitted
25Steering cylinder rod, gland seal, and tie rod ends
26Axle pivot pin play and king pin bearing inspection

Operator station & safety devices

27Seat belt webbing, retractor, and anchor integrity
28ROPS/FOPS canopy impact damage and weld inspection
29Cab glass, mirrors, wipers, and door latch function
30Horn, reverse alarm, beacon, lighting, and overload alarm
31Frame level indicator and sway lockout function

Function tests under load

32Boom full extend and retract under rated load
33Boom full lift and lower at maximum reach
34Sway and frame level lockout function verification
35Stabiliser deployment and full-reach lift test (MRT models)

Documentation & close-out

36Defect log review and closeout of prior month items
37Inspection certificate signed by competent person
38Telehandler tagged serviceable or out-of-service
39Next inspection due date recorded against asset

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Jarrod Milford

Jarrod Milford

Co-Founder & Commercial Director

Updated 26 October 2026
Also see:Forklift inspections →Maintenance and work orders →Best CMMS software →MapTrack vs MaintainX →

Short answer

A telehandler monthly inspection checklist records a competent person's deeper check of the boom chains, wear pads, rollers, cylinders, stabilisers, ROPS/FOPS and load chart, measured against the manufacturer's wear limits. Fleet maintainers run it monthly, which is common practice and manufacturer-led rather than a legal interval. Regulation 213 of the model WHS Regulations requires competent-person maintenance and inspection following the manufacturer's recommendations.

Checked against Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011) on by the MapTrack templates team. How we check templates

Key takeaways

  • The MapTrack telehandler monthly inspection checklist contains 39 checks across 8 sections. Sections covered: Structure & welds, Boom, chains & wear pads, Hydraulic system, Tyres, wheels & axles, Brakes & steering, Operator station & safety devices, Function tests under load, Documentation & close-out.
  • Measure boom extension chain stretch against the manufacturer's elongation limit; a chain past the limit keeps the telehandler out of service until it is replaced.
  • Monthly is common practice. Regulation 213 points first to the manufacturer's schedule, then a competent person's, and only then to an annual inspection.
  • AS 10896.1:2019 covers non-slewing telehandlers and ISO 10896-2:2016 covers slewing models; AS 2359.6 excludes variable-reach trucks.
  • Any boom impact, chain replacement, hydraulic component change or reported drift triggers an out-of-cycle inspection before the machine goes back to work.
  • The competent person records each measurement and signs the sheet, so wear can be trended from one month to the next.

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Used by construction, mining and field service teams

Saunders InternationalMineral ResourcesSupagasHacer GroupMetro TunnelUltrabuilt

What is a telehandler monthly inspection checklist?

A telehandler monthly inspection is a structured form used by a competent person to verify the boom, hydraulic, structural, and operator-protective systems of a telescopic handler at a depth that daily pre-start checks cannot reach. Where the pre-start covers visible fluid levels, tyres, horn, lights, and basic boom function, the monthly takes the machine out of service for two to three hours and measures wear against OEM tolerances on a Manitou MT or MLT, JCB 540 or 550, CAT TH-series, Genie GTH-series, or Merlo P-series unit. The deep checks include boom extension chain stretch measurement (Falcon or Pewag chain against the OEM elongation limit), telescoping boom wear pads and shim packs at each section joint, boom tip rollers, lift and tilt cylinder seal weep through full extension, stabiliser legs on MRT or rotating-frame models, 4WD axle pivot bushings, ROPS/FOPS canopy structural integrity, load chart placard legibility, and a function test at full reach under rated load.

Telehandler safety duties under Australian law are heavier than a standard counterbalance forklift because the boom extends out and up, multiplying the consequences of any wear in the chain, pads, or rollers. The competent person signs the checklist and the record stands as evidence under WHS Regulations 2011 Chapter 5 that the duty holder has inspected and maintained the plant to the OEM tolerances. AS 10896.1:2019, a modified adoption of ISO 10896-1, sets the safety requirements for how non-slewing rough-terrain variable-reach trucks are designed and built; rotating models are covered by ISO 10896-2:2016. The same record drives the maintenance plan: an extension chain measured just under the OEM limit this month will pass it before the next inspection, so the planner schedules the chain pair replacement at the upcoming service and avoids a load drop on a structural steel placement job.

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Benefits of using this telehandler monthly inspection checklist

  • Boom chain integrity: Catches Falcon or Pewag chain stretch before it breaches the OEM elongation limit and risks a load drop at full reach.
  • Wear pad measurement: Captures telescoping boom wear pad and shim pack thickness so play stays inside OEM tolerance and the boom tracks straight under load.
  • Boom tip and roller condition: Verifies boom tip rollers, side rollers, and head-section structure remain free of cracking after a month of cyclic loading.
  • Stabiliser assurance (MRT models): Confirms stabiliser leg pivots, cylinder seals, and pad condition before the next rotating or full-reach lift job.
  • Load chart legibility: Verifies the load chart placard is legible and is the manufacturer chart for the configured forks, jib, or attachment.
  • Defect log closeout: Forces a monthly review of operator-reported boom drift, slow extend, or stabiliser anomalies so recurring issues do not accumulate.
  • Reach productivity protection: Measuring chain stretch, wear pads and rollers monthly keeps the boom tracking straight and placing loads accurately at full reach, so the telehandler stays the go-to machine for structural-steel and high-level placement instead of being de-rated.

Benefits of digitising forms in MapTrack

When you digitise telehandler checklists in MapTrack, you get:

  • Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
  • Email the right people when a form is submitted, with an automation you set up.
  • File every completed form against the asset, location or person it covers.
  • Download any completed form as a PDF, with failed answers listed at the top.
  • Fill in forms offline; they upload when the device is back online.
  • 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.
  • Set who can view, fill in or edit forms with user roles.
  • Upload a paper form (PDF, Word, Excel or a photo) and MapTrack's AI builds a digital version for you to check.
  • Raise a work order from a submitted form with an automation you set up.
  • Track service intervals by hours, kilometres or calendar date in one place.
  • Attach supplier invoices and parts receipts to each maintenance record.

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What to include in a telehandler monthly inspection checklist

This telehandler monthly inspection checklist covers 12 key areas:

  • Boom extension chain stretch measurement (Falcon or Pewag) against the OEM elongation limit
  • Telescoping boom wear pads and shim pack thickness at each section joint
  • Boom tip rollers, side rollers, and head-section structural inspection
  • Lift cylinder and tilt cylinder seal weep through full extension and full reach
  • Stabiliser legs, pivots, cylinder seal, and pad condition (MRT or rotating-frame models)
  • 4WD axle pivot bushings, tie rod ends, and steering cylinder seal condition
  • ROPS/FOPS canopy structural inspection, sticker legibility, and mounting bolt torque
  • Hydraulic hose chafing walk along boom routing and chassis
  • Load chart placard legibility and match to current attachment configuration (forks, jib, bucket)
  • Frame level indicator, sway lockout, and longitudinal stability system function
  • Function test at full reach under rated load: extend, retract, lift, lower, sway
  • Defect log review and closeout of prior month operator-reported faults

How to use this telehandler monthly inspection checklist

  1. Take the machine out of service and review history: Lock out, tag out, and pull the last month of pre-start sheets, defect log entries, and work orders. Note recurring faults such as boom drift, slow extend, sway lockout faults, or stabiliser anomalies so the inspection targets those systems rather than treating every observation as new.
  2. Measure boom extension chain stretch against the OEM limit: With the boom fully retracted on a level surface, locate the extension chains (Falcon or Pewag) at the boom side opening. Measure a fixed gauge length (typically 12 to 20 pitches) and compare to the OEM new dimension. Flag any chain nearing the OEM limit for replacement before the next inspection cycle.
  3. Extend the boom and inspect wear pads at each joint: Fully extend the boom on stabilisers (where fitted) or with the chassis level. Inspect each section joint for visible pad wear, shim pack thickness, and lateral play. Measure remaining pad material against OEM minimum and shim out where tolerance allows. Inspect boom tip rollers and side rollers for cracking and pin retention.
  4. Cycle the lift and tilt cylinders for seal weep: Cycle the boom through full lift, lower, extend, and retract with the carriage at ground level and again at full reach with a rated load. Inspect cylinder rods, gland seals, and hose unions for oil weep. Fresh oil tracks at full extension under load indicate active leakage rather than residue from previous service.
  5. Inspect stabilisers and chassis (MRT and rotating-frame models): On stabiliser-equipped models, lower all stabilisers fully, inspect leg pivot bushings for play, cylinder rod and gland seals for weep, and stabiliser pads for cracking. On rotating-frame MRT models, verify slew bearing torque, swing motor function, and frame level indicator calibration.
  6. Inspect ROPS/FOPS canopy and operator-protective structures: Check canopy mounting bolt torque, inspect welds for cracks, confirm the ROPS/FOPS sticker remains legible (manufacturer, serial, certification number), and document any impact damage to the canopy or boom rest. Verify the load chart placard is legible and matches the current attachment.
  7. Walk hydraulic hoses along the boom and chassis: Trace every hose from cylinder to manifold along the boom routing, paying attention to high-flex points at the boom pivot, hose tensioner sheaves, and section joints. Look for chafing against boom edges, outer-jacket cracking, and pinch points at the slewing tower on MRT models.
  8. Function test at full reach under rated load: With a rated load on the forks, extend the boom to maximum reach and maximum height in sequence. Confirm the longitudinal stability indicator, frame level, and sway lockout function correctly. Listen for cavitation, watch for cylinder drift with the engine at idle, and verify holding valves hold load without creep.
  9. Close out the defect log and sign the certificate: Verify each open defect from the prior month is repaired or carried forward with a target close date. Sign the inspection certificate, file the record against the asset, tag the telehandler as serviceable or out-of-service, and update the next inspection due date.

In MapTrack, you can schedule and track maintenance digitally, by date or meter reading. Each submission is stored as a timestamped PDF against the asset record.

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How often should you complete this checklist?

Monthly is the standard cadence for a competent-person structural and safety inspection on a telehandler in regular site service, and it aligns with OEM service intervals from Manitou, JCB, CAT, Genie, and Merlo, whose manuals set the inspection points and wear limits. The daily pre-start covers fluids, lights, tyres, ROPS, boom function, and load chart visibility and stays with the operator; the monthly is a deeper two to three hour inspection by a qualified plant mechanic or competent maintenance supervisor. Escalate to fortnightly if the telehandler operates more than 180 hours per month, works in abrasive environments (concrete plants, quarries, recycling yards), runs structural steel placement at full reach, or has unresolved defects on chain stretch, wear pads, or sway lockout. Escalate immediately and out-of-cycle after any boom impact, chain replacement, hydraulic component change, ROPS strike, or operator-reported drift or stability anomaly.

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Frequently asked questions

A telehandler monthly inspection covers boom extension chain stretch measurement (Falcon or Pewag) against the OEM elongation limit, telescoping boom wear pads and shim pack thickness at each section joint, boom tip and side roller condition, lift and tilt cylinder seal weep through full extension, stabiliser legs and pads on MRT or rotating-frame models, 4WD axle pivot bushings, ROPS/FOPS canopy structural integrity, hydraulic hose chafing along the boom, load chart placard legibility, sway lockout and frame level function, defect log closeout, and a function test at full reach under rated load. Typical duration is two to three hours.

A daily pre-start is a five to ten minute operator walk-around before each shift covering fluids, lights, tyres, ROPS, boom function, hoses, forks, and load chart visibility. A monthly inspection is a two to three hour competent-person inspection that takes the telehandler out of service to measure boom extension chain stretch against OEM tolerance, inspect wear pad and shim pack thickness at each section joint, exercise the boom at full reach under rated load, and verify ROPS/FOPS canopy integrity. The pre-start catches visible faults daily; the monthly catches chain stretch, pad wear, and roller cracking that operators cannot detect from the cab.

A competent person under WHS Regulations 2011 Chapter 5, meaning someone with the training, qualifications, experience, and knowledge to identify telehandler hazards and check the machine against the OEM tolerances. In practice this is a qualified plant mechanic, an OEM-trained dealer technician (Manitou, JCB, CAT, Genie, Merlo), or an in-house maintenance supervisor with documented training on the specific make and model. The operator who runs the telehandler daily is not the right person to sign off the monthly because chain stretch, pad wear, and roller cracking need an independent assessor.

AS 10896.1:2019, a modified adoption of ISO 10896-1, is the Australian safety standard for non-slewing rough-terrain variable-reach trucks and includes stability and load chart requirements; rotating models are covered by ISO 10896-2:2016. AS 2359.6-2013 (ISO 3691-1:2011, MOD), the safety standard for forklifts and other self-propelled industrial trucks, excludes variable-reach trucks. WHS Regulations 2011 Chapter 5 Plant Safety imposes the duty on persons with management or control of plant to inspect and maintain. The Safe Work Australia Code of Practice for Managing Risks of Plant in the Workplace provides regulator-endorsed interpretation. OEM service manuals from Manitou, JCB, CAT, Genie, and Merlo provide the boom chain elongation limit and the wear pad and shim tolerances.

Yes, the checklist is free to download as a printable PDF and adapt for your telehandler fleet. MapTrack also offers a digital version: schedule monthly inspections per telehandler by serial number, assign them to a licensed plant mechanic, capture boom extension chain stretch measurements and wear pad readings inline, attach photos of cracked rollers or boom welds, and route the signed certificate to compliance. Recurring defects across chains, pads, or stabilisers surface in the dashboard so the planner can order parts ahead of the next service.

Applicable regulatory standards

This template is a starting point. Check the current requirements that apply to your equipment, work and location. The template alone does not establish compliance.

  • Model Work Health and Safety Regulations

    Edition: Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011)

    Competent-person maintenance, inspection and, if necessary, testing to the manufacturer's recommendations, else a competent person's; annual inspection where neither is reasonably practicable to follow.

    • reg 213: Plant must be maintained, inspected and, if necessary, tested by a competent person, following manufacturer or competent person recommendations; annual inspection applies only if neither is practicable.
    • Chapter 5: Plant and structures: general duties for plant, duties for registered plant, and registration of plant designs and items of plant.

    Safe Work Australia (drafted by the Parliamentary Counsel's Committee)

  • Work Health and Safety Regulation 2025 (NSW)

    Edition: Work Health and Safety Regulation 2025 (NSW), commenced 22 August 2025, text as at 21 January 2026

    NSW version of the plant maintenance and inspection duty.

    • s 213: Requires competent-person maintenance, inspection and necessary testing of plant, following the manufacturer's recommendations, else a competent person's, or annual inspection if neither is reasonably practicable.

    NSW Parliamentary Counsel's Office (NSW Legislation)

  • Rough-terrain trucks - Safety requirements and verification, Part 1: Variable-reach trucks (ISO 10896-1:2012, MOD)

    Edition: AS 10896.1:2019

    Design and verification standard for non-slewing variable-reach trucks. It sets how the machine is built, not an in-service inspection interval.

    Standards AustraliaSold by the publisher

  • Rough-terrain trucks - Safety requirements and verification - Part 2: Slewing trucks

    Edition: ISO 10896-2:2016 (Edition 1)

    Design and verification standard for slewing (rotating) telehandlers.

    International Organization for Standardization (ISO)Sold by the publisher

  • Model Code of Practice: Managing risks of plant in the workplace

    Edition: November 2024 version (reviewed May 2018; amended 2021, 2023 and 2024)

    Code guidance on competent-person inspection and maintenance of plant. It has legal effect only where approved.

    • Section 3.5: Inspecting plant: how and when plant should be inspected by a competent person, reflecting reg 213.
    • Section 3.6: Maintenance, repair and cleaning of plant, following manufacturer instructions and by competent people.

    Safe Work Australia

Each source was read at its publisher and the page checked on 26 October 2026. The publisher's current text is the authority.

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  <p style="font-size:12px;font-weight:700;letter-spacing:0.05em;text-transform:uppercase;color:#071D49;margin:0;">Free template</p>
  <p style="font-size:18px;font-weight:700;color:#071D49;margin:6px 0 0;">Telehandler Monthly Inspection Checklist</p>
  <ul style="margin:12px 0 0;padding-left:18px;color:#374151;font-size:14px;line-height:1.6;">
    <li style="margin:4px 0;">Boom extension chain stretch measurement (Falcon or Pewag) against the OEM elongation limit</li>
    <li style="margin:4px 0;">Telescoping boom wear pads and shim pack thickness at each section joint</li>
    <li style="margin:4px 0;">Boom tip rollers, side rollers, and head-section structural inspection</li>
    <li style="margin:4px 0;">Lift cylinder and tilt cylinder seal weep through full extension and full reach</li>
    <li style="margin:4px 0;">Stabiliser legs, pivots, cylinder seal, and pad condition (MRT or rotating-frame models)</li>
    <li style="margin:4px 0;">4WD axle pivot bushings, tie rod ends, and steering cylinder seal condition</li>
  </ul>
  <p style="font-size:13px;color:#6B7280;margin:14px 0 0;padding-top:12px;border-top:1px solid #E5E7EB;">Free <a href="https://www.maptrack.com/templates/telehandler-monthly-inspection-checklist" style="color:#071D49;font-weight:600;text-decoration:none;">Telehandler Monthly Inspection Checklist</a> by MapTrack</p>
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The MapTrack telehandler monthly inspection checklist contains 39 checks across 8 sections.

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