Managing High Hour Telehandlers: JCB and Lull Case Study

[MikePhua]

Telehandlers with high operational hours are common on many job sites and in warehouse settings. However, extended use leads to increased wear and tear on the equipment. JCB and Lull are two of the most popular telehandler brands, known for their durability and robust performance. But when these machines accumulate a high number of operating hours, owners face the challenge of maintaining their efficiency and reliability. This article will explore how to address the issues related to high-hour telehandlers, focusing on common failures and maintenance tips for JCB and Lull models.
Impact of High Operating Hours

1. Engine Strain
   Continuous heavy-duty operation puts significant strain on the engine, leading to potential issues such as starting difficulties, decreased power, or reduced fuel efficiency. High hours often accelerate engine wear, causing it to become less reliable.
   
2. Hydraulic System Failures
   The hydraulic systems in telehandlers bear substantial pressure and load during operation. Over time, high hours of use can lead to wear and tear on seals, hoses, and pumps, resulting in hydraulic fluid leaks, inconsistent control, or failure of key hydraulic functions.
   
3. Wear of Mechanical Components
   As the number of operating hours increases, telehandlers' transmission systems, steering systems, and booms undergo significant wear. This can result in poor operational precision, reduced performance, and eventual mechanical breakdowns.
   
4. Electrical System Aging
   As telehandlers age and accumulate high hours, electrical systems may suffer from wiring degradation, poor connections, and battery failure. These issues can lead to electrical system malfunctions, making the equipment difficult to start or operate.
   

Common Issues with JCB and Lull Models

1. JCB Telehandlers
   JCB telehandlers are known for their reliability and robust performance. However, with increased operational hours, common issues include hydraulic system leaks, engine overheating, and difficulty starting. Hydraulic fluid contamination and worn seals are frequent problems in older JCB telehandlers.
   
2. Lull Telehandlers
   Lull telehandlers, another reliable brand, also experience challenges with high hours of use. Common issues include diminished hydraulic pump performance, hydraulic fluid contamination, and the aging of transmission system components. Regular checks of the hydraulic system and timely replacement of filters and oils are essential.
   

Solutions and Maintenance Tips

1. Regular Hydraulic System Inspections
   Regularly inspect the hydraulic system to ensure clean hydraulic fluid. Replace fluid and filters as needed to avoid contamination, which could lead to system failures. Keeping the hydraulic system in top condition is essential for the longevity of the telehandler.
   
2. Engine and Cooling System Maintenance
   Extended operation can lead to engine overheating. Check the cooling system regularly to ensure that coolant levels are sufficient and that it is functioning correctly. Regular oil changes, as well as replacing air filters, help maintain optimal engine performance and prevent overheating.
   
3. Mechanical Component Inspections
   Inspect mechanical components, such as the transmission, steering system, and boom, for signs of wear. Regular lubrication and timely replacement of worn parts ensure the stability and precision of operations. Neglecting these components could lead to operational inefficiency or breakdowns.
   
4. Electrical System Care
   Electrical systems require regular inspection to ensure reliable power. Check batteries, wiring, and electrical connections for signs of wear, corrosion, or loose connections. Timely replacement of old electrical parts can prevent electrical failures and ensure the telehandler starts reliably.
   
5. Proper Load Management
   High-hour equipment can easily become overworked, so it's essential to manage the load and ensure the telehandler isn't continuously used at maximum capacity. Periodic rest and adjusted work cycles can help reduce wear and extend the life of the machine.
   

Conclusion
Telehandlers with high operating hours, particularly those from brands like JCB and Lull, are likely to face issues such as engine malfunctions, hydraulic system failures, wear of mechanical components, and electrical system aging. Regular maintenance is crucial to keeping the equipment running smoothly, with special attention given to hydraulic, engine, cooling, and electrical systems. By adopting a proactive maintenance routine and managing workloads efficiently, owners can extend the life of their telehandlers, reduce downtime, and maintain optimal performance over time.