Free telehandler monthly inspection checklist
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Free telehandler monthly inspection checklist. Boom extension chain stretch, wear pads, boom tip rollers, load chart, ROPS/FOPS. AS 2359 and ISO 10896.
Commercial Director
Updated 25 May 2026
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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 three percent rule per AS 2359), 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 against AS 2359, AS 4024.3611, and ISO 10896 for rough-terrain variable-reach trucks. The same record drives the maintenance plan: an extension chain measured at 2.6 percent stretch this month will breach the three percent limit 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.
Learn more about maintenance and work orders in MapTrack.
Benefits of using this telehandler monthly inspection checklist
- Boom chain integrity: Catches Falcon or Pewag chain stretch before it breaches the AS 2359 three percent 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 matches the configured forks, jib, or attachment per ISO 10896 requirements.
- 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.
- 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).
- Trigger work orders automatically when a fault is logged during an inspection.
- 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 AS 2359 3% 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
- 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.
- Measure boom extension chain stretch against the AS 2359 3% 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 exceeding 2.5% stretch for replacement before the next inspection cycle.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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. Each submission is stored as a timestamped PDF against the asset record.
Get the free templateEnter your email above to download the full telehandler monthly inspection checklist as a PDF.Back to download formHow 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 and the AS 2359 inspection regime. 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 licensed 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.
Frequently asked questions
Applicable regulatory standards
This template aligns with the following regulations and standards:
- AS 2359 Powered Industrial Trucks
- AS 4024.3611 Industrial Trucks Safety
- ISO 10896 Rough-terrain Variable-reach Trucks
- WHS Regulations 2011 Chapter 5 Plant Safety
- Safe Work Australia Code of Practice Managing Risks of Plant in the Workplace
Need to schedule and track maintenance digitally?
Register every telehandler in MapTrack, attach digital forms, and get a complete history of every inspection, service and compliance record.
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