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Tip-Top Shape: Telematics and Proper Maintenance Combine to Keep Telehandlers Productive

Words: Tim Palosaari
Photos: Pettibone


It’s nearly impossible to imagine life on a masonry or construction jobsite without a telehandler. These machines dramatically boost productivity by safely lifting heavy materials to elevated work areas. Even the most powerful pieces of equipment, however, require consistent maintenance to ensure peak performance and long-term reliability.

Staying on top of basic upkeep isn’t just about reducing downtime – it’s about getting the most out of your investment by keeping your telehandler profitable on every project. The evolution of telematics has been a key development for all equipment owners. By constantly monitoring machine use, telematics provides valuable insight into maintenance needs, as well as operational habits.

Users can monitor an array of performance metrics in real time, while keeping the focus on their company’s specific needs. This not only simplifies maintenance planning, but also empowers operators to make smarter decisions, thereby enhancing the effectiveness of telescopic handlers in demanding work environments.

Regular Maintenance
Telehandler operators and technicians should follow OEM recommended service intervals and complete pre-operation checks every day. These simple efforts go a long way in preventing breakdowns and extending equipment life.

A telehandler user’s manual provides detailed guidance on maintenance and troubleshooting. Routine tasks like checking the oil, transmission fluid and air filters are essential. Keep the machine greased. A telehandler boom should be lubricated weekly or every 30 hours to prevent friction that can lead to unnecessary wear. Don’t overlook simple tasks like refilling the diesel exhaust fluid (DEF) tank, if your unit has one. Running out of DEF can cause shutdowns, and a technician may need to reset the system.

Visual inspections are also important. Operators should be trained to look for leaks, rust, damaged parts and loose components before starting work. Tires need to be properly inflated and checked for visible wear or issues that could lead to unsafe operation.

Continue checks between jobs as well. Monitor hydraulic hoses, inspect wear pads, and make sure all components remain within spec to keep your telehandler running smoothly and safely.



Telehandler Telematics
Telehandlers are often pushed to their limits by operators and must be properly maintained to function properly. With telematics in place, machines have a better chance of performing at a high level for the long haul.

Telematics is commonly an optional offering from telehandler manufacturers. However, there are manufacturers that include a standard multi-year subscription with every new machine purchase. The cost of a subscription is inexpensive for the information received, especially considering the potential costs of avoidable equipment repairs.

Catching Issues, Avoiding Failures
Telematics provides users with real-time access to the status of their machine. Minor situations can be detected via error codes and alerts before they have the chance to become serious problems.

Owners and fleet managers can be alerted to potential issues such as low fuel, low DEF, low battery voltage, and other critical items. Alerts can be configured to be sent via email or within the telematics app. Such notifications give users time to schedule fuel trucks, advise crews to bring a bottle of DEF to the jobsite, or make other advance arrangements as necessary.

The telematics dashboard on a smartphone app or computer can even allow for remote troubleshooting in some cases. A problem can potentially be diagnosed and solved with a few taps on a screen, saving the time and money of having service technicians drive out to check on an otherwise unknown issue.

Some equipment problems will still require an on-site service call, but having telematics implemented can provide advanced information about the problem. This is a major improvement from the days of having a worker try to describe noises to a mechanic over the phone.

With telematics, diagnosis is technical and to the point. The system provides an error code that explains precisely what is wrong. Depending on the affected components, telematics can even identify the exact part number that needs replacing. Technicians can then ensure they have the necessary replacement parts and tools before traveling to the jobsite to make the repair.

Operator error is always a concern for the short-term uptime and long-term health of a capital investment like a telehandler, especially since crews don’t always have the luxury of putting the most experienced operator at the controls. Telematics can help minimize this issue by providing proactive alerts related to machine operation.



Using Information
Uptime can also be increased by sticking to a consistent maintenance schedule, and telematics can help keep tabs on utilization and service intervals. With multiple pieces of equipment to take care of, it can be easy to lose track of which machines are logging the most hours and may be requiring service sooner than others.

With telematics in place, most of the guesswork is removed. Owners have observable data points such as fuel rate and usage, engine hours, fluid levels, and much more. The system might even recommend modifying existing service intervals to a greater frequency.

The information generated by telematics might also show that some operational habits need to change. Data such as engine speed, torque and load can be analyzed to tell if the machine is being overworked. Likewise, looking at fuel usage might show that a high percentage of fuel is being burned while the machine is just sitting and idling.



Designed for Maintenance
The easier and faster telehandler maintenance can be completed, the better. A side-mounted engine compartment offers good accessibility for daily service checks. It’s important to grease telehandlers regularly, as well as to check the boom’s wear pads to ensure they’re at the proper tolerance, so having easily greased points is helpful.

A telehandler boom with a bottom-mounted external extended cylinder location allows easier service access to internal boom components. Certain designs can help significantly reduce the load on wear pads, so they don’t have to be changed as often. If the telehandler cab features an all-steel dash, then the operator can simply pressure wash the interior without fear of damaging cab components.

Keep your telehandler in good working order with regular maintenance, and consider the use of telematics. Real-time access to machine data can save money, time and hassle for owners, operators and technicians.



About: MAP Partner
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