Telehandler Axle Issues: Causes, Solutions, and Maintenance Tips

[MikePhua]

Telehandlers, also known as telescopic handlers or boom lifts, are versatile pieces of equipment commonly used in construction, agriculture, and other industries requiring material handling at height. They combine the features of a forklift and a crane, with the ability to extend their booms, reach high places, and carry heavy loads. Given their heavy-duty use, telehandlers are built to withstand rigorous demands. However, one critical component that often faces issues is the axle. Understanding common axle problems, potential causes, and how to address them can help extend the lifespan of your telehandler and ensure its optimal performance.
Understanding the Telehandler Axle
Before diving into common axle issues, it’s important to understand the role of the axle in a telehandler. The axle serves as the central support structure for the wheels and helps transfer the power from the engine to the wheels, allowing the telehandler to move across different types of terrain. In telehandlers, axles are designed to handle heavy loads, and they are typically equipped with robust suspension systems to help stabilize the machine when lifting and moving materials.
A typical telehandler may have either a rigid or oscillating axle design:

• Rigid Axles: Common on older models, these axles are fixed and do not move. The wheels are always in the same alignment, which can make the telehandler less agile.
  
• Oscillating Axles: More common in newer models, these axles allow the wheels to move independently, improving stability and providing better control over rough terrain. They help distribute weight more evenly and reduce strain on the machine’s frame.
  

Despite these advancements in axle design, telehandlers are still prone to issues due to heavy use, exposure to harsh environments, and improper maintenance.
Common Telehandler Axle Problems
Several axle-related issues can affect the performance of a telehandler. Below are some of the most common problems and their potential causes.
1. Axle Leaks
One of the most frequent issues with telehandler axles is oil or grease leakage. The axles in telehandlers are lubricated with oil or grease to ensure smooth movement. Over time, seals may wear out, or the axle housing may crack, causing leaks. When this happens, the lubrication inside the axle decreases, which can lead to further wear, overheating, and even total axle failure.
Causes:

• Worn or damaged seals.
  
• Cracks or corrosion on the axle housing.
  
• Improper maintenance practices.
  
• Operating in extreme conditions (high heat, dust, or heavy loads).
  

Solution:

• Regularly inspect the axle seals for any signs of wear or damage.
  
• If you notice leaks, replace the seals promptly to prevent further damage.
  
• If the axle housing is cracked or corroded, it may need to be replaced or repaired by a professional.
  

2. Worn-out Bearings
Axle bearings are responsible for reducing friction and ensuring smooth rotation of the axle. Over time, these bearings can wear down due to heavy use, poor lubrication, or prolonged exposure to dirt and debris. Worn bearings can cause instability and uneven wheel alignment, affecting the handling and safety of the telehandler.
Causes:

• Lack of proper lubrication.
  
• Exposure to contaminants such as dust, mud, and water.
  
• Overloading or excessive stress on the axle.
  

Solution:

• Perform regular inspections to check for wear on bearings.
  
• Apply proper lubrication at recommended intervals.
  
• Replace damaged or worn-out bearings as soon as possible.
  

3. Bent or Damaged Axle Shaft
The axle shaft is a critical part of the axle assembly that transfers power from the engine to the wheels. If the telehandler is used to carry loads that exceed its rated capacity or if it is subjected to sudden impacts, such as hitting a large object or driving over rough terrain, the axle shaft can become bent or damaged. A bent axle shaft can cause vibrations, misalignment, and, in extreme cases, complete axle failure.
Causes:

• Overloading the telehandler.
  
• Impact with obstacles such as rocks, curbs, or other heavy equipment.
  
• Poor maintenance or failure to address minor issues before they worsen.
  

Solution:

• Avoid exceeding the maximum load capacity of the telehandler.
  
• Drive cautiously over rough terrain and avoid obstacles that could damage the axle.
  
• Regularly inspect the axle shaft for signs of wear or damage, and replace it if necessary.
  

4. Imbalanced Axle Load
An imbalanced axle load occurs when the weight distribution across the axles is uneven. This can happen if the telehandler is carrying a load that is too heavy on one side or if the weight is improperly distributed. This imbalance can lead to excessive wear on the axles, as well as instability and poor handling.
Causes:

• Improperly loaded cargo.
  
• Uneven distribution of weight when lifting or transporting materials.
  
• Lack of attention to load management practices.
  

Solution:

• Always ensure that the load is evenly distributed on the forks or bucket.
  
• Use proper load management techniques to avoid overloading one side of the machine.
  
• Regularly check the machine’s alignment and make adjustments as needed.
  

5. Axle Alignment Issues
Misalignment of the axles can cause several problems, including poor handling, uneven tire wear, and unnecessary strain on the suspension system. Misalignment often occurs when the telehandler is used for tasks beyond its design limits or when it has been involved in a collision or impact.
Causes:

• Impact with obstacles that causes the axle to shift.
  
• Operating the telehandler on uneven or rough surfaces.
  
• Worn-out suspension components or axle components.
  

Solution:

• Ensure that the telehandler is not subjected to excessive stress or impact.
  
• Have the axle alignment checked and adjusted by a professional if misalignment is suspected.
  
• Replace any worn or damaged suspension components that may contribute to misalignment.
  

Preventive Maintenance for Telehandler Axles
To prevent axle-related problems and ensure the longevity of your telehandler, proper maintenance is essential. Here are some preventive steps that can help you avoid common axle issues:

1. Regular Inspections: Inspect the axles, seals, and bearings frequently for signs of wear, damage, or leaks. Catching problems early can prevent costly repairs down the road.
   
2. Lubrication: Ensure that the axles are properly lubricated with the correct type of oil or grease. Follow the manufacturer’s recommendations for lubrication intervals and types of lubricant to use.
   
3. Proper Loading: Always follow the recommended load capacity and ensure that the load is evenly distributed across the telehandler. Avoid overloading, which can put unnecessary strain on the axles.
   
4. Tire Maintenance: Proper tire maintenance and inflation are crucial for axle health. Under-inflated or over-inflated tires can affect axle performance, leading to premature wear and tear.
   
5. Drive Carefully: When operating the telehandler, avoid sudden impacts, sharp turns, or driving over rough terrain that could damage the axles. Smooth, controlled driving helps protect the machine’s components.
   

Conclusion
The axle is a vital part of your telehandler’s functionality, and addressing axle issues promptly can prevent more serious problems and costly repairs. Regular maintenance, inspections, and proper operation are key to extending the life of the axle and ensuring the overall performance of the telehandler.
By understanding the common axle problems, their causes, and the preventive measures you can take, you can keep your telehandler running smoothly and avoid disruptions in your work. Whether you are using the machine for construction, agriculture, or other heavy-duty tasks, a well-maintained axle system will ensure better performance, stability, and safety.