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March 2016 Maintenance Manual
Specific Interval: blank box is the interval
to be completed and the
interval as not required.
The description of the procedure or
checklist to be completed.
The procedure number or checklist to be
completed.
Check box to indicate status of inspection.
Specific interval is not required for this
procedure.
General area of the machine to complete
the procedure.
If this box has a designated time interval:
this is the specific time interval to complete
the procedure or checklist.
If this box is empty: the maintenance
checklist will include multiple time
intervals, use this box to write in the
specific interval for the inspection
completed.
Maintenance Procedures
Maintenanc e Sche dule
Maintenance Schedule
The maintenance procedures have been divided
into subsections that include: Commissioning,
Quarterly, Annually and Programmed maintenance
intervals. The maintenance inspection report has
been divided into general areas of the machine
that include: Drive Chassis, Booms and Fork,
Functions and Controls and Powertrain.
Failure to perform these procedures may result in
poor performance, component damage and unsafe
operating conditions. They are essential to safe
operation, machine performance and service life.
Commissioning: A series of required one time
maintenance procedures to be performed at
50 and 150 hour intervals.
Quarterly and Annually: A series of maintenance
procedures to be performed quarterly or annually.
Programmed Example (under 1000 HRS):
Programmed Example:
Instructions Legend
Use the following detailed descriptions to identify
the intended use of the maintenance inspection
reports.
Programmed: A series of maintenance
procedures to be performed during a Pre-Delivery
Preparation or based on machine operating hours.
Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliance
with your employer, jobsite and governmental
regulations and requirements.
Instruction Examples
Commissioning Example:
Quarterly and Annually Example:
∅ marks the
Part No. 1272858 Genie Telehandlers 21
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Maintenance Manual March 2016
Legend
Comments
Pre
Pre
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Pre-Delivery Preparation Report
Pre-Delivery Preparati on Repor t
Fundamentals
Instructions
It is the responsibility of the owner or dealer to
perform the Pre-delivery Preparation.
The Pre-delivery Preparation is performed prior to
each delivery. The inspection is designed to
discover if anything is apparently wrong with a
machine before it is put into service.
A damaged or modified machine must never be
used. If damage or any variation from factory
delivered condition is discovered, the machine
must be tagged and removed from service.
Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer's specifications.
Scheduled maintenance inspections shall be
performed by qualified service technicians,
according to the manufacturer's specifications and
the requirements listed in the responsibilities
manual.
Use the operator’s manual on your machine.
The Pre-delivery Preparation consists of
completing the Pre-operation Inspection, the
Maintenance items and the Function Tests.
Use this form to record the results. Place a check
in the appropriate box after each part is completed.
Follow the instructions in the operator’s manual.
If any inspection receives an N, remove the
machine from service, repair and re-inspect it.
After repair, place a check in the R box.
Y = yes, acceptable
N = no, remove from service
R = repaired
-delivery Preparation
-operation inspection
Y N R
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Scheduled and Programmed
March 2016
Maintenance Inspection Report – Telehandlers
Model
Programmed Maintenance
Scheduled M ai nten ance I nspec tio n R epor t - T eleh andl ers
Hour meter Date
Serial number Inspector company Machine owner
Inspected by (print) Inspector signature
Scheduled Maintenance:
Inspection Type
Q = quarterly or frequent
inspections
A = annual inspections
Legend
Y = yes, acceptable
N = no, remove from
service
R = repaired
∅ = not applicable
If any inspection receives an "N," tag and remove the machine from service, repair and re-inspect it. After repair, place a "R" in the box.
Drive Chassis Intervals Q A
Inspect the Tires, Wheels and Lug Nut Torque Q-6
Mechanicals and Hydraulics Intervals Q A
Inspect the Fuel and Hydraulic Tank Cap Venting
Systems
Visual Inspection of the Hydraulic Oil Q-9
Replace Hydraulic Tank Return Filter Element A-5
Replace the Cab Air Intake Filter (if equipped) A-6
Electrical Intervals Q A
Battery Inspection Q-2
Inspect the Electrical Wiring Q-3
Powertrain Intervals Q A
Check the Exhaust System Q-5
Inspect the Engine Air Filter Q-10
Lubricate the Driveshaft Q-11
Boom(s) and Fork Intervals Q A
Check the Boom Wear Pads Q-4
Inspect the Fork Level and Aux. Hydraulic Hoses Q-7
Inspect and Lubricate the Sequencing Chains GTH-636, 1256, 1544, 844, 1056
Inspect the Forks A-1
Adjust the Boom Chains - GTH-636, GTH-844 A-2
Adjust the Boom Chains - GTH-1056 A-3
Adjust the Boom Chains - GTH-1256, GTH-1544 A-4
Functions and Controls Intervals Q A
Check for Open Bulletins and Owner Registration Q-1
Make copies of this report to use for
each inspection.
Select the appropriate procedures
for the type of inspection(s) to
perform.
Commissioning
Perform 50 Hour Service C-1
Engine Maintenance - 50 HRS C-2
Q-8
∅
∅
150 Hour Service C-3
Programmed Maintenance - Under 1000 HRS
Lubricate the Boom P0-1
Deutz Engine Maintenance – Under 1000 HRS P0-2
Perkins Engine Maintenance – Under 1000 HRS P0-3
John Deere Engine Maintenance – Under 1000
HRS
Axle Maintenance – Under 1000 HRS P0-5
Transmission Maintenance – Under 1000 HRS P0-6
All models Perform every: 1 2 3 4 6 12
Engines - all models, 1000 HRS P1-1
Transmissions - all models, 1000
HRS
Axles - all models, 1000 HRS P1-3
Engines - all models, 2000 HRS P2-1
Test or Replace the Hydraulic Oil P2-2
Engines - all models, 3000 HRS P3-1
Engines - all models, 4000 HRS P4-1
Engines - all models, 6000 HRS P6-1
Engines - all models, 12000 HRS P12-1
Q-12
∅
∅
∅
∅
Programmed Maintenance:
Programmed maintenance will be completed based
on machine hours. This program includes the
onetime or commissioning procedures for new
products. The onetime procedures will be completed
at 50 or 150 hours.
50 150
P0-4
Hours are in thousands
∅ ∅ ∅ ∅ ∅
P1-2
∅ ∅ ∅ ∅ ∅
∅ ∅ ∅ ∅ ∅
∅ ∅ ∅ ∅ ∅
∅ ∅ ∅ ∅ ∅
∅ ∅ ∅ ∅ ∅
∅ ∅ ∅ ∅ ∅
∅ ∅ ∅ ∅
∅ ∅ ∅ ∅ ∅
∅
Status
∅
∅
Enter
Hours
8
∅
Part No. 1272858 Genie Telehandlers Maintenance Manual 23
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