Genie Telehandler Maintenance

Genie Telehandler Maintenance Explained


Checking fluid levels and greasing your telehandler regularly goes a long way to reducing the chance of breakdowns. Meanwhile less frequent manufacturer recommended maintenance tasks (quarterly and annual tasks) should never be ignored because they are equally as important to the productivity of the machine. We’ll break down Genie’s telehandler maintenance recommendations for you.


Keep in mind that while some of these tasks can be performed in-house, others should be completed by a qualified telehandler maintenance technician.


Machine hours will determine when certain maintenance tasks need to be performed, while others will go according to the age of the machine. Genie divides its telehandler schedule into three subsections:

  1. Commissioning: A series of required one-time maintenance procedures that need be performed at the 50- and 150-hour intervals
  2. Quarterly and Annually: Maintenance procedures that need to be done every three months or once a year
  3. Programmed: Procedures that need to be done based on the machine’s operating hours. Simple tasks, like changing the engine oil and fuel filters at the proper intervals, will go a long way in preventing potential problems.

There are similar maintenance schedules that Genie telehandlers all share. These are outlined below:


Commissioning Maintenance Procedures

These one-time tasks, defined in the machine’s maintenance manual, need to be done on all new machines.

At 50 hours:

  • Inspect the tires, wheels and lug nut torque
  • Replace the hydraulic filter
  • Check belt tensions
  • Check engine mounts
  • Check hose clamps
  • Replace the engine oil if required

At 100 hours:

  • Change the axle differential oil and axle planetary drive oil if required

At 150 hours:

  • Visual inspection of hydraulic oil


Quarterly Maintenance Procedures

Check for service bulletins on your Genie telehandler.

  • To do this, enter your machine’s serial number at
  • Have any open bulletins completed by your telehandler dealer. It’s essential for safe machine operation.

Schedule an inspection for your telehandler every three months. Certain machine components need to be checked during this time. The technician will:

  • Look at the battery to make sure connections tight and corrosion free
  • Inspect electrical wiring
  • Check on the boom wear pads
  • Look for any loose nuts and bolts on the exhaust system
  • Inspect the tires, wheels and lug nut torque
  • Check the fork level and auxiliary hydraulic hoses tension
  • Make sure the fuel and hydraulic tank cap venting system is working properly
  • Visually inspect the hydraulic oil
  • Make sure the engine air filter is clean
  • Lubricate the driveshaft
  • Inspect and lubricate the sequencing chains (only on certain models)

This inspection should happen annually as well.


Annual Maintenance Procedures

In addition to the quarterly inspection above, a couple machine components should be replaced annually:

  • Starting with the hydraulic tank return filter element. A dirty or clogged filter will cause the machine to perform poorly and could lead to component damage
  • Second, the cab air intake filter element should be replaced if your machine is equipped with one.


Programmed Maintenance Procedures

As a quick refresher: programmed procedures need to be done based on the machine’s operating hours.

  • Lubricate the boom. This task should be performed every 8 hours or daily
  • Engine maintenance — refer to the telehandlers Engine Operator and Maintenance Manual for details
  • Transmission maintenance
    • Replace transmission oil and filter every 1000 hours
    • If your telehandler has a hydrostatic transmission, change the gearbox oil every 1,000 hours
  • Axle maintenance — see model specific Engine Operator and Maintenance Manual
  • Test or replace hydraulic oil — should be done every 2,000 hours

Following the manufacturer’s recommended maintenance schedule outlined in your telehandler’s maintenance manual is the best way to ensure the best performance and reduce the risk of unplanned downtime

Content provided by Genie, a Terex brand.