How do you maintain a telehandler?

What should be checked at the start of a shift?

Before starting up, walk around the telehandler on stable ground. Look for leaks, impact damage, cut or underinflated tyres, damaged wheels, chafed hoses and missing guards. Examine the boom, its visible components, the rams, the pins and the attachment coupling device. Check that the attachment fitted matches the planned task and that its locks are engaged. Admissible capacity depends on the configuration: check the load chart for the machine and the attachment.

In the cab, check visibility, the horn, the seatbelt, warning lights and controls as per the manual. Test the functions in an area clear of personnel. Pay attention to alarms and any devices that limit movement or indicate load, depending on the model. On a slope or soft ground, the condition of the stabilisers and outriggers deserves particular attention. A fault affecting stability or lifting requires stopping, reporting it and a decision on returning to service after it has been corrected.

• Tyres, wheels, stabilisers, outriggers and traces of leaks on the ground.
• Boom, hoses, pins, forks or other attachment and locking.
• Controls, seatbelt, alarms and load chart available.
• Working surface, slope, obstacles, pedestrians and traffic around the machine.

What work should be scheduled in the workshop?

The manufacturer sets out fluids, filters, greasing, inspections and any oil changes in operating hours or dates. Record the meter reading at every workshop visit. The engine and transmission need different monitoring from the hydraulic circuit; greasing points depend on the linkages, the carriage and the attachments. Have any leak examined before simply topping up a level. Used fluids and filters must be collected according to the workshop's rules.

On the telescopic boom, look for unusual play, visible wear, uneven movement or damage to hoses and guides. The method for checking, adjusting and replacing parts belongs to the model's manual. Do not work under an unsecured boom or load. Work on pressurised hydraulics and lifting components must be entrusted to a competent person, with suitable energy isolation. A major repair may call for an inspection before the machine is returned to service: ask the inspection body for its opinion.

Merlo or other brand telehandler maintenance: what schedule?

There is no single maintenance interval valid for every telehandler. Even within a brand such as Merlo, engine, transmission, attachment and working environment can change the deadlines. Use the serial number and the manual for the exact model; do not reuse the oil-change hours of a similar machine. The table below is only one way to organise tasks, to be checked against the manufacturer's instructions.

Intensive, dusty or muddy use can justify more frequent inspections. The driver should report any change in behaviour as soon as it appears; the workshop decides on the technical work. Do not postpone a fault just because routine maintenance is scheduled the following week.

Maintenance, VGP and driving: what's the difference?

Maintenance preserves the machine's condition; the VGP inspection looks for dangerous defects as part of the regulatory inspection regime. Keep the report, act on its findings, and have a competent person determine the frequency applicable to the configuration and the lifting operations. Avoid automatically applying the same frequency to every telehandler and every attachment. An up-to-date VGP inspection does not cancel out a leak that has appeared since the check.

For driving, the safety-competence certificate (CACES) corresponds to an equipment family, not a trade name. The INRS classes all-terrain telescopic handlers in recommendation R.482, category F. Recommendation R.489 covers ride-on powered industrial trucks in other categories. Identify the exact equipment and use before choosing the training; the driving authorisation issued by the employer still needs to be checked.

How do you keep a useful history?

A record per machine should bring together model, serial number, hour meter, attachments used and associated documents. For each job, note the date, hours, initial symptom, diagnosis, work done, parts, technician and test result. Distinguish open faults from those whose closure has been checked. A photo of a damaged hose or a cut tyre makes a report more useful than a simple note saying ‘to check’.

Keep VGP reports and the maintenance logbook with easy access for the fleet manager and the workshop. On every return from site, compare actual hours against planned deadlines; if an attachment is fitted temporarily, also check its own tracking. This habit stops a job being lost between hire, workshop and site. The PDF logbook at /carnet-entretien-engin-pdf can be used as a starting template.