The VR-642C is a Variable Reach Telescopic Material Handler designed for lifting and moving heavy materials. This machine features a 4-cylinder diesel engine with 110 hp, a 3-speed powershift transmission, hydraulic brakes on all four wheels, and a closed-circuit load-sensing hydraulic system. This manual provides instructions and maintenance information for this device.
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OPERATION AND MAINTENANCE
MANUAL for VR-642C
Variable Reach Material Handler
CPN 13858295 February 17, 2006
Read and understand this manual before operating or servicing equipment
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
TABLE OF CONTENTS
VR-642C
TITLE PAGE
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
SAFE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
SECTION 1 - SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
BE AWARE OF SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
UNDERSTAND SIGNAL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
PRE-START INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
OPERATOR PROTECTION EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
STARTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
OPERATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
LOAD HANDLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
TRANSPORTING AND HAULING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
LOAD CAPACITY CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
ANGLE INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
HAZARDOUS SUBSTANCE PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
SAFETY RELATED DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
SYMBOL IDENTIFICATION/METRIC CONVERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
INTERNATIONAL MACHINE SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
INTERNATIONAL HIGHWAY SYMBOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
METRIC CONVERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
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TITLE PAGE
OPERATING CONTROLS AND INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
BATTERY GAUGE (VOLTMETER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
ENGINE OIL PRESSURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
TRANSMISSION OIL TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
HOURMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
WATER TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
AUXILIARY FUNCTION SWITCH (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
LEFT AND RIGHT STABILIZER SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
ETHER SWITCH (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
SPARES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
DIRECTION CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
TRANSMISSION RANGE SELECTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
HORN BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
WORK LIGHT SWITCH (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
BOOM LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
SPARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
TURN SIGNAL CONTROL LEVER (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
BEACON SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
PARK BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
SERVICE ENGINE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
CHECK ENGINE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
STOP ENGINE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
STEERING MODE SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
WINDSHIELD WASHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
PARK BRAKE TEST SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
FUSE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
BOOM CONTROL JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
LEVEL AND FORK CONTROL JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
LEVEL INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
SINGLE JOYSTICK CONTROL - OPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
ENGINE DIAGNOSTIC PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
12 VOLT POWER PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
HEATER AND AIR CONDITIONER CONTROLS - OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
2 VR-642C
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VR-642C
TITLE PAGE
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
STABILITY AND CENTER OF GRAVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
INSPECTION BEFORE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
STARTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
PRE-OPERATION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
PARK BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
BASIC OPERATING PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
STEERING AND TURNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
HANDLING AND MOVING LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24
LIFTING, LOWERING, AND TILTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
TRAVELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
PARKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
STABILIZERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
VANDAL PROTECTION COVER - OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
QUICK ATTACHMENT APRON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
SCRAP GRAPPLE BUCKET -- OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
BUCKET LOADER INSTALLATION — OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
TRUSS BOOM INSTALLATION — OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
PINTLE HOOK INSTALLATION — OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
DRY WALL HANDLER INSTALLATION — OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
SIDE TILT CARRIAGE — OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
SWING CARRIAGE -- OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
GENERAL MAINTENANCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
INITIAL MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Powershift Transmission Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Wheel Nut Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Tighten Loose Bolted Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
10 HOUR OR DAILY ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Check Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Check Coolant Level, Radiator, and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Check Transmission Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Check Air Cleaner Connections and Ducts for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Check Air Cleaner Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Cleaning and Replacing the Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Air Cleaner Vacuator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Fuel/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Fill Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Check Park Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Check Tire Pressure and Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Check Seat Belt and Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
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50 HOUR OR WEEKLY ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Grease Chain Sheave Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Check Lug Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Check Oil Level in Axle Differential Planetary Wheel Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Check Oil Level In Axle Differentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Grease Axle Pivot Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Grease Axle King Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Grease Fork Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Grease Frame Level Pivot Bushings and Stabilizer Pivot Bushings . . . . . . . . . . . . . . . . . . . . . . . 5-25
Grease Boom Pivot and Boom Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Clean Heater / A-C Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
250 HOUR OR QUARTERLY ROUTINE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Change Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Change Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Change In Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Clean Hydraulic Tank Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Torque Axle Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Inspect Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Check Boom Wear Pad Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Adjust Boom Chains and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
1000 HOUR OR ANNUAL ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Change Hydraulic Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Change Hydraulic Oil and Clean Suction Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Change Axle Differential Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Change Axle Planetary Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Change Transmission Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Change Transmission Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
LONG TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
ENGINE WILL NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
DIFFICULT STARTING & POOR/IRREGULAR PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
ENGINE MAKING EXCESSIVE FUMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
ENGINE OVERHEATS - STOP ENGINE IMMEDIATELY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
LOW ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
VOLTMETER INDICATES LOW OR NEGATIVE VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
ELECTRICAL CIRCUIT MALFUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
BALLAST / IGNITION KILL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Ignition Kill Switch (Ballast Removal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
GENERAL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
MACHINE DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
MACHINE WEIGHTS AND FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
4 VR-642C
TABLE OF CONTENTS
VR-642C
TITLE PAGE
FUEL AND LUBRICANT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
LUBRICATION CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
HYDRAULIC OIL REQUIREMENTS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
LUBRICATING OIL/GREASE SPECIFICATIONS (EXCEPT ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . 8-7
ENGINE LUBE OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
CUMMINS FUEL OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
HAZARDOUS SUBSTANCE PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1
ISO METRIC TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
SAE TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
USE OF LOCTITE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
SECTION 11 - RECOMMENDED SPARE PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1
VR-642C RECOMMENDED SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
RECOMMENDED LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
VR-642C 5
INTRODUCTION
Congratulations! You have just acquired an Ingersoll Rand Variable Reach Telescopic Material
Handler, an application-designed product built with your needs in mind.
The VR-642C is powered by a direct injected 4 cylinder diesel engine. The turbocharged 110 hp (82 kW) at 2500 rpm engine is standard on the VR-642C machine. A three-speed, powershift transmission with torque converter is directly mounted to the engine flywheel. Hydraulic brakes on all four wheels are used to stop the handler. The service brakes are a hydraulically operated power brake to oil immersed discs in both axles. The parking brake is a spring applied, hydraulically released, multi-disc brake that is mounted inside the rear axle. The parking brake is controlled by a toggle switch on the operator’s control panel and will apply when the engine is shut down. The hydraulic pump is a closed circuit system with load sensing to the hydraulic functions.
This Telescopic Material Handler has three modes of steering:
Front Wheel Only (2 wheel) Steering is normally used only when traveling on roads.
Crab Steering (all wheels turn in same direction) is used to move away from buildings or to escape from wheel ruts.
Coordinated Steering (rear wheels turn opposite of front wheels) provides the greatest maneuverability and is used most of the time.
The VR-642C can be ordered or equipped with options that permit auxiliary functions.
Examples of these options are various buckets, back rests and fork configurations. The information for the operation of these options must be available, read, and understood by the operator. The control levers for these auxiliary functions are normally found on the left side of the control console or on the joystick handle.
Safe operation depends on reliable equipment and the use of proper operating procedures.
Performing the checks and service described in this manual will help keep your Telescopic
Material Handler in good condition. These recommended operation procedures will help you avoid unsafe practices.
Safety notes have been included throughout this manual to help you avoid injury and prevent damage to the equipment. These notes are not intended to cover all eventualities since it is impossible to anticipate and evaluate all possible methods of operation. Therefore, you are the only person who can guarantee safe operation and maintenance.
VR-642C 1
2
INTRODUCTION
It is important that any procedure not specifically recommended in this manual be thoroughly evaluated from the standpoint of safety before it is implemented.
!
WARNING
Severe Personal Injury
Some illustrations in this manual may show guards or cover panels removed for purposes of clarity.
Always replace guards and cover panels before operating the machine.
NOTE
Some illustrations in this manual may show units with optional equipment installed.
This optional equipment may be purchased from your local Ingersoll Rand Road
Distributor.
Some illustrations in this manual may be of prototype models. Production models may vary in some detail.
Continuing improvement and advancement of product design may cause changes to your
Telescopic Material Handler that may not be included in this publication. Each publication is reviewed and revised as required to update and include these changes in later editions.
Ingersoll Rand reserves the right to modify or make changes within a specific model group without notice and without incurring any liability to retrofit units previously shipped from the factory. Contact your Ingersoll Rand Equipment Distributor for non-routine maintenance that is not covered in this publication.
Record the Machine Serial Number, which is found on the Machine Serial Number Plate on the left side of the machine. Refer to 1, Figure 1.
Figure 1
VR-642C
INTRODUCTION
Check to ensure that both the Parts Manual and the Operation and Maintenance Manual are with the machine. The manual case (1, Figure 2) is located under the left side of the control console. ALWAYS RETURN THE OPERATION AND MAINTENANCE MANUAL TO THE
MANUAL POUCH WHEN YOU ARE FINISHED USING IT.
Figure 2
VR-642C 3
INTRODUCTION
4 VR-642C
SAFETY SECTION 1
This is the Safety Alert Symbol. When you see this symbol in this manual, be alert to the potential for personal injury.
Follow recommended precautions and safe operating practices.
A signal word - DANGER, WARNING, or CAUTION - is used with the safety-alert symbol.
DANGER identifies the most serious hazard.
DANGER, WARNING, or CAUTION safety labels are located near specific hazards.
NOTICE labels are for general information.
!
DANGER
RED BACKGROUND
DANGER indicates an imminently hazardous situation which if not avoided, will result in death or serious injury.
!
WARNING
ORANGE BACKGROUND
WARNING indicates a potentially hazardous situation which if not avoided, could result in death or serious injury.
!
CAUTION
YELLOW BACKGROUND
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
VR-642C 1-1
SECTION 1 SAFETY
YELLOW BACKGROUND
CAUTION used without the Safety Alert Symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.
1-2
NOTICE
BLUE BACKGROUND
NOTICE is used to notify people of installation, operation, or maintenance information which is important but not hazard related.
Before you operate, maintain, or in any other way use this telescopic material handler:
READ and STUDY both this Manual and the Variable Reach Material Handler Safety
Manual for Operators and Mechanics. Know how to safely use the telescopic material handler’s controls and what you must do for safe maintenance.
ALWAYS wear or use the proper safety items required for your personal protection.
READ and UNDERSTAND the information about NAMEPLATE and RATED CAPACITY
CHART in this section of the manual.
MAKE SURE that a trained and qualified person will be operating the telescopic material handler. A qualified person experienced in the operation of this machine MUST guide a new operator through several driving and load-handling operations before the new operator attempts to operate the machine alone.
If you have any questions about the safe use or maintenance of this telescopic material handler, ask your supervisor or contact any Ingersoll-Rand distributor. NEVER GUESS
ALWAYS CHECK!
INSPECT your telescopic material handler daily. Ensure that the routine maintenance and lubrication are being dutifully performed. Have any malfunctioning, broken, or missing parts corrected or replaced before use. DO NOT operate a damaged or poorly maintained handler.
You risk lives when operating faulty equipment, INCLUDING YOUR OWN.
VERIFY that all instruction and safety labels are in place and readable. These are as important as any other equipment on the machine.
VR-642C
SAFETY SECTION 1
CLEAN any foreign material from the steps and operators platform to reduce the danger of slipping.
NEVER fill the fuel tank with the engine running, while near an open flame, or when smoking.
ALWAYS wipe up any spilled fuel.
CHECK for WARNING tags placed on the telescopic material handler. DO NOT operate the machine until repairs have been made and the WARNING tags are removed by authorized personnel.
ALWAYS know the capability and limitations of your equipment, speed, gradeability, steering, and braking.
BE AWARE of the dimensions of your telescopic material handler height and width as well as your transporter dimensions and weight.
WATCH for overhanging obstructions such as wires or tree limbs.
CHECK for any conditions that could be dangerous--holes, banks, underground culverts, manhole covers, water meter pits, curb and/or street boxes.
The cab incorporates a ROPS (rollover protective structure) with overhead guard. When used in conjunction with seat belts, the cab is intended to lessen the possibility of death or serious injury in the event of a machine rollover or from falling objects. The ROPS with overhead guard must not be considered a substitute for good judgment and care when operating the telescopic material handler.
CHECK the seat belt regularly for wear or damage. Inspect belt hardware and fabric. Replace if hardware is damaged or if strap is nicked, frayed or loose stiching is found. Seat belt assemblies should be replaced every three (3) years regardless of appearance. Seat belt strength degrades over time due to exposure to weather, UV (ultraviolet radiation), and exposure to dirt. Check that mounting hardware is tight.
ALWAYS fasten the seat belt. The seat belt provides a means to help the operator keep the head and torso substantially within the confines of the Telescopic Material Handler frame if a tip over occurs. This restraint system is intended to reduce the risk of the head and torso being trapped between the machine and the ground, but cannot protect the operator against all possible injury in a tip over.
READ and FOLLOW ALL instruction decals.
Seat belts and other OSHA-required safety equipment MUST be worn when operating the telescopic material handler.
BEFORE you start the telescopic material handler, ENSURE that the direction control lever is in Neutral (N).
BEFORE you start the telescopic material handler, ENSURE that no one is standing between the wheels and the frame.
START the engine from the operators position only.
VR-642C 1-3
1-4
SECTION 1 SAFETY
Jump-starting the engine is NOT RECOMMENDED. If you do jump-start, use EXTREME
CAUTION. Prior to jump-starting, ENSURE:
• Direction control lever is in Neutral (N).
• A TRAINED OPERATOR is at the controls when the engine starts
• The parking brake is ON.
DO NOT use ether or other starting fluids for cold-weather starting. Use of unmetered starting fluids can cause severe engine damage. If the telescopic material handler will not start in cold weather, the machine must be moved to a warmer area for starting. An ether start option is also available.
CHECK the operation of all the telescopic material handlers systems, including transmission, brakes, and boom operation, before beginning work.
ALWAYS make sure that no person or obstruction is in your line of travel BEFORE starting the telescopic material handler in motion.
NEVER climb onto or off the telescopic material handler while it is in motion.
REMAIN seated, with seat belt securely fastened, when operating the machine.
USE extreme caution and be observant when working in close quarters or congested areas.
OPERATE ONLY from the seated position. NEVER carry passengers.
BOOM SAFETY STOP
The Variable Reach Telescopic Material Handler is equipped with a boom stop (1, Figure 1-1) to be used whenever work is to be performed under a raised boom. It is to be placed over one of the boom cylinders and the boom lowered onto the stop. The stop is stowed behind the hood on the deckplate. The stop is equipped with a lock pin (2).
Figure 1-1
VR-642C
SAFETY
!
WARNING
Severe Personal Injury
Never perform maintenance or service operations under the boom while in the raised position without blocking the boom from falling using the boom stop.
Failure to adhere to this warning could result in serious personal injury including death.
NOTICE
Use care not to damage lift cylinder rod. Rod damage may cause seal damage.
Figure 1-2
SECTION 1
Install the boom stop (2, Figure 1-2) as follows:
1. Remove the boom stop from the frame.
2. Raise the boom high enough to allow the boom stop (2, Figure 1-2) to be placed over the boom cylinder (1) rod.
3. Shut down engine.
4. Install boom stop and safety pin.
5. Start engine.
6. Slowly lower the boom until it contacts the boom stop.
VR-642C 1-5
1-6
SECTION 1 SAFETY
!
DANGER
Hazardous voltage.
Will cause severe injury or death.
Keep boom away from power lines.
Coming in contact with electric power lines can cause severe injuries or death by electrocution.
Before operating the material handler in an area with power lines, you should:
•
Notify the utility company to have the power disconnected, or
•
Keep all parts of the machine 3.05 m (10 ft.) from the source of power.
•
Be aware of any federal, state or local safety codes/regulations affecting the job location.
If the machine comes in contact with electric power lines:
•
Stay in the cab.
•
Warn other workers to stay away and to not touch the machine.
•
If contact can be broken, drive the machine away from the danger zone.
•
If contact can not be broken, stay in the cab until told that power is off.
KNOW the area in which you are working. Familiarize yourself with work site obstructions and any other potential hazards in the area.
KNOW and USE the hand signals required for particular jobs and know who has the responsibility for signaling.
DO NOT work in the vicinity of overhanging banks, or on grades that could cause the telescopic material handler to slide or roll over.
AVOID excessively steep slopes or unstable surfaces. If you must drive on a slope, keep the load low and proceed with extreme caution. DO NOT drive across excessively steep slopes under any circumstances.
AVOID turning on an incline, if at all possible. If it is necessary, use extreme caution and make the turn wide and SLOW.
VR-642C
SAFETY SECTION 1
KEEP your seat belt fastened at all times when operating the telescopic material handler. If the machine should tip over:
• DO NOT JUMP; stay on the machine.
• HOLD firmly to the steering wheel.
• BRACE your feet.
• LEAN FORWARD and away from the impact.
ALWAYS look in all directions BEFORE changing your direction of travel.
DO NOT use your telescopic material handler to lift people; it is not designed for such use.
TRAVEL SLOWLY WHEN TURNING. Variable Reach Telescopic Material Handlers can tip over even at very slow speeds. The combination of speed and the sharpness of a turn can cause a tip-over. A machine is less stable when the forks are elevated, with or without a load.
A tip-over can occur with an empty machine; in fact, it will actually tip over more easily when empty than when loaded with the load lowered. Rearward tilt of the carriage and load, offcenter loads, and uneven or soft ground will aggravate these conditions.
KEEP a safe distance from the edge of docks, ramps, platforms, and other similar working surfaces.
KEEP a safe distance from the edges of excavations so that ground does not suddenly collapse and tip over the telescopic material handler. Be careful when operating on slopes when the ground is soft or muddy so that the handler does not suddenly slide and tip over.
Coordinated steering provides the greatest maneuverability and is the mode of steering most often used. It is recommended that the machine be stopped before steering mode is changed.
All steering modes can be selected while stopped, but the wheels should be straightened before moving to make sure they are properly aligned.
KEEP yourself and others away from the lift mechanism. NEVER permit anyone under or on the forks.
NEVER put head, arms, hands, or legs through the boom mechanism nor near the forks or carriage. This rule applies not only to the operator, but also a helper. A helper must not be near the load or lift mechanism when the operator is attempting to handle a load. The lift mechanism has moving parts with close clearances that can cause serious injury.
DO NOT move the direction control lever to the opposite position (FWD to REV or REV to
FWD) when the Variable Reach Telescopic Material Handler is moving.
WATCH for pedestrians at all times. Do not drive up to anyone standing in front of an object.
Use extra care at crossroads, doorways, and other locations where pedestrians can step into the path of travel of the machine. Slow down when approaching blind intersections or turns and sound the horn. The horn can alert pedestrians that there is a vehicle in the area and to be alert to possible danger.
AVOID bumps, holes, soft ground, slick spots, and loose materials that can cause the telescopic material handler to swerve or tip. If such areas cannot be avoided, go slowly.
Always make sure you pick the smoothest route for your machine.
VR-642C 1-7
1-8
SECTION 1 SAFETY
NEVER indulge in stunt driving or horseplay
ALWAYS operate the telescopic material handler at a speed that will permit it to be brought to a stop in a safe manner.
DO NOT tow or push the telescopic material handler, except as explained under “TOWING” in
Section 4 - OPERATING INSTRUCTIONS of this manual.
DO NOT run the engine in a closed building for an extended length of time. EXHAUST FUMES
CAN KILL.
!
WARNING
Serious Personal Injury.
Only attachments which have been fully tested for stablity and have had
Rated Capacity Charts established per ASME B56.6 by Ingersoll Rand company are approved for use on Telescopic Material Handlers. The use of non-approved attachments may cause machine instability and tipover, which may result in severe injury or death to operators or bystanders.
Approved attachments are only those supplied by Ingersoll Rand which are accompanied by applicable Rated Capacity Charts for the specific attachment and machine model.
MAKE SURE you understand the Rated Capacity Chart(s) and the operation of the boom before a load is lifted.
ENSURE that you are using the proper Rated Capacity Chart for the boom attachment fitted to the telescopic material handler at the moment.
HANDLE only loads within the rated capacity as shown on the Rated Capacity Chart(s). This rated capacity represents the maximum load that can be lifted for the boom extensions when the telescopic material handler is on a hard, level surface. However, such factors as weak floors, uneven terrain, soft ground, special load-handling attachments, or loads having a high center of gravity can mean that the safe working load is less than the rated capacity. When such conditions exist, the operator must reduce the load so that the telescopic material handler will remain stable.
USE the frame leveling function to compensate for uneven terrain when operating on a side slope. Use the level indicator to make sure the Variable Reach Telescopic Material Handler is level before raising the boom. DO NOT use the frame leveling function when the load is raised.
DO NOT attempt to use the Variable Reach Telescopic Material Handler as an end loader. The machine is designed for lifting loads, NOT for digging or excavating.
VR-642C
SAFETY SECTION 1
INSPECT the load to be lifted. Lift the load and lower the load only on stable level ground. If a load must be handled several times, put stacking blocks under the load. Handle only stable loads. A load can have unstable items that can easily shift and fall on someone. DO NOT handle a load if any part of it is likely to fall. If a suspended load must be lifted, DO NOT permit it to swing freely; use a tether to control its movement.
DO NOT leave the machine unattended with a suspended load.
MAKE SURE that the floor or surface can hold the weight of the telescopic material handler and the load.
MAKE SURE that the surface or structure onto which you are placing the load is capable of supporting the load safely.
REMEMBER that although the telescopic material handler provides a degree of operator protection from falling objects and a rollover, other personnel in the area have no such protection. Keep all persons out of the area where they could be injured by a falling load or a tilting telescopic material handler.
ALWAYS park the machine on solid, level ground. If this is not possible, always park the machine at a right angle to the slope, set the parking brake, and chock the wheels.
AVOID leaving the operator’s platform with the engine running. ALWAYS move the direction control lever to “Neutral” (N), apply the parking brake, turn the ignition switch to OFF, and lock all lockable compartments.
USE proper flags, barriers, and warning devices, especially when parking in areas of traffic.
AVOID, whenever possible, servicing, cleaning, or examining the telescopic material handler with the engine running.
AVOID, whenever possible, servicing or providing maintenance to the telescopic material handler unless the wheels are adequately chocked.
NEVER fill the fuel tank with the engine running, while near an open flame, or when smoking.
ALWAYS wipe up any spilled fuel.
AVOID removing the pressurized radiator cap until the engines cooling system has cooled.
USE care when removing hydraulic tank breather cap. Hydraulic tank is pressurized. Hot oil can cause severe burns.
DO NOT alter the engine governor settings from those indicated in the engine manual and the engine option plate.
ALWAYS replace damaged or lost decals. Refer to the Parts Manual for the proper location and part number of all decals.
ALWAYS disconnect the battery cables and ground wire to frame before working on the electrical system or when welding on the telescopic material handler. Serious damage to the electronic engine control module (ECM) will occur if battery cables are connected.
VR-642C 1-9
1-10
SECTION 1 SAFETY
BE SURE the battery area is well-ventilated (clear of fumes) should it become necessary to connect a jump battery or battery charger. Fumes from the battery can ignite by a spark and explode.
IF battery charging is required, be sure the battery charger is Off when making the connections.
BE SURE the correct battery polarity is observed (negative to negative and positive [+] to positive [+]) when connecting to a battery charger or jumper cable.
DO NOT attempt to load the Variable Reach Telescopic Material Handler onto the transporter without knowledge and experience with the operation of the telescopic material handler.
ALWAYS use a ramp when loading the Variable Reach Telescopic Material Handler onto the transporter. Be sure ramps are of adequate strength, low angle, and proper height.
USE proper chock blocks in front and rear of the wheels of the transporter when loading the
Variable Reach Telescopic Material Handler.
BE SURE to approach the transporter loading ramps squarely to make sure the telescopic material handler does not drop off the side of the ramp.
KEEP the transporter deck clean of clay, oil, ice, frost, or any other material that can become slippery.
USE proper chock blocks in front and rear of the Variable Reach Telescopic Material Handler wheels.
SHUT the engine OFF, apply the parking brake, and lock all lockable compartments.
ALWAYS know the overall height of the telescopic material handler and hauling vehicle.
Observe height and weight regulations and overhead objects to be sure you can safely pass beneath them.
When roading your Variable Reach Telescopic Material Handler on a public access, obey all traffic regulations and be sure that the proper clearance flags, lights, and warning signs, including the Slow Moving Vehicle emblem, are properly displayed. Know your approximate stopping distance at any given speed. Never turn corners at excessive speeds. Look in all directions before reversing your direction of travel.
A loose telescopic material handler can shift or fall while being transported.
Tie down the machine securely before moving the hauling vehicle or transporter.
1. Position the telescopic material handler on the transporter or hauling vehicle centered from side to side and apply the parking brake.
2. With adequate chains or cables and blocks, secure the machine to the deck of the hauling vehicle or transporter to meet ICC or local regulations.
VR-642C
SAFETY
SECTION 1
!
WARNING
DO NOT add to or modify the Variable Reach Telescopic Material Handler.
Any change to the machine or its equipment can change the lifting capacity. The machine must be rated as equipped and the nameplate must show the new capacity rating.
Failure to adhere to the warning could result in serious personal injury including death.
!
WARNING
Only attachments which have been fully tested for stability and have had
Rated Capacity Charts established per ASME B56.6 by Ingersoll-Rand
Company are approved for use on the Variable Reach Telescopic Material
Handler. The use of non-approved attachments may cause machine instability and tipover, which may result in severe injury or death of operators or bystanders.
Approved attachments are only those supplied by Ingersoll-Rand which are accompanied by applicable Rated Capacity Charts for the specific attachment and machine model.
Use of non approved attachments may cause machine instability and tip over, which may result in serious injury or death to operator or bystanders.
The capacity of the Variable Reach Telescopic Material Handler changes as the boom is raised or extended and with the type of boom attachment being used. The Rated Capacity Charts can be found on the right side of the control panel. The charts show the capacity of the machine at different load positions and with different attachments. When loads are being moved, the operator must refer to the Load Capacity Charts. The rated capacity of the machine is also determined by the location of the center of gravity of the load. The Load Capacity Chart defines the load capacity only when the machine is on a level and stable surface. The following graphic shows a sample Load Capacity Chart.
VR-642C 1-11
SECTION 1 SAFETY
Do not use this chart to determine the lifting capacity of your machine. Refer to the actual charts located on the control panel of your machine.
Figure 1-3
1-12
The weight of the load must be known by the operator before the load is lifted to make sure that the load is within the capacity of the telescopic material handler as shown on the Load
Capacity Charts. When the load is lifted, the load is always raised with the boom retracted.
Raise the boom to the required angle so that it can be extended to the point where the load will be stacked. See the boom angle on the boom angle indicator and find that angle on the
Rated Capacity Chart. Find the letter on the Rated Capacity Chart that shows the extension of the boom permitted for the weight of the load being lifted. The point where the lines cross for the required boom extension and the boom angle is the maximum lifting capacity for those conditions.
VR-642C
SAFETY SECTION 1
!
WARNING
Always raise the boom with the boom retracted. Raise the boom to the angle where the boom can be extended to the point where the load will be stacked or lifted. Then extend the boom to stack or lift the load. When the load is raised, the load center can move away from the Variable Reach
Telescopic Material Handler.
!
WARNING
If the load is larger than the “standard” 1219 mm (48 inch) cube or if the weight of the load isn not evenly distributed, the weight of the load must be less than the capacity shown on the Load Capacity Charts.
Failure to adhere to this warning could result in serious personal injury including death.
!
WARNING
Raise the boom only when the Telescopic Material Handler is on a stable surface. If the surface breaks or the tires sink into the surface, the
Variable Reach Telescopic Material handler can tip over.
!
WARNING
Your Telescopic Material Handler may be equipped with several different
Rated Capacity Charts to accommodate different boom attachments.
Make sure that the Rated Capacity Chart you are using corresponds to the boom attachment fitted to the machine at the moment.
Failure to adhere to this Warning could result in serious personal injury including death.
VR-642C 1-13
SECTION 1 SAFETY
The vertical red angle indicator pointer located on the left front of the outer boom (1, Figure 1-
4) is designed to align with white angle values located on the boom as the boom is raised when the machine is located on level ground. This is the boom angle shown on the Rated Capacity
Charts by lines marked in degrees extending away from the machine. Curved lines on the
Rated Capacity Charts show the position of the load center at various angles as the boom is extended. These lines are lettered A thru G, corresponding A to G letters (2) installed along the operators side of the mid section boom, become visible as the boom is extended. Do not extend beyond the rated load center letter.
Figure 1-4
1-14 VR-642C
SAFETY SECTION 1
The following substances are contained in this machine and may be hazardous to your health if exposed to or used incorrectly.
Table 1:
SUBSTANCE PRECAUTION
Antifreeze Avoid injestion, skin contact, and breathing fumes.
Hydraulic Oil Avoid injestion, skin contact, and breathing fumes.
Engine Lubricating Oil Avoid injestion, skin contact, and breathing fumes.
Preventative Grease
Rust Preventative
Engine Fuel
Battery Fluid
SAE Gear Oil
Avoid injestion, skin contact, and breathing fumes.
Avoid injestion, skin contact, and breathing fumes.
Avoid injestion, skin contact, and breathing fumes.
Avoid injestion, skin contact, and breathing fumes.
Avoid injestion, skin contact, and breathing fumes.
The following substances may be produced during the operation of this machine and may be hazardous to your health.
SUBSTANCE PRECAUTION
Engine Exhaust Fumes Avoid breathing.
Engine Exhaust Fumes Avoid buildup of fumes in confined spaces.
Avoid breathing during maintenance.
Electric Motor Dust
(Brushes/Insulation)
Break Lining Dust * Avoid breathing during maintenance.
* Only on machines with dry axle brakes.
VR-642C 1-15
SECTION 1
SAFETY
1-16
Table 2: Decal Reference Numbers
REF
NO.
DESCRIPTION
8
9
4
7
1
2
3
WARNING: Moving Machine
WARNING: Crush Area
WARNING: Pressure Hazard
WARNING: Carriage
WARNING: Rollover Tire Inflation
WARNING: Improper Operation
WARNING: Rotating Fan
10 WARNING: Falling Load
19 NOTICE: Unmetered Ether
20 WARNING: Runover
QTY.
2
2
2
1
2
1
1
2
1
1
LOCATION
Top of Frame
Counter Weight Box
Rear Engine Cover
Upright Carriage
Front Engine Cover
Front Engine Cover
Rear Engine Cover
Counter Weight Box
Top of Frame
Fuel Tank
VR-642C
SAFETY
SECTION 1
VR-642C 1-17
1-18
SECTION 1
Table 3: Decal Reference Numbers
REF
NO.
DESCRIPTION
6
8
4
5
WARNING: Carriage
WARNING: Block Axle Frame
WARNING: Crush Area
WARNING: Improper Operation
10 WARNING: Falling Load
11 WARNING: Fall from Forks
12 WARNING: Rollover
13 DANGER: Electrical Hazard
14 WARNING: No Riders
15 NOTICE: OSHA
16 WARNING: Frame Level
17 NOTICE: Parking Brake Test
18 WARNING: Unpinned Attachment
QTY.
1
1
1
1
1
2
1
2
1
5
2
2
2
LOCATION
Upright Carriage
Frame Level Cylinder
Behind Each Wheel
Front Engine Cover
Counter Weight Box
Upright Carriage
Operator’s Console
Operator’s Console
Operator’s Cab
Operator’s Cab
Operator’s Cab
Operator’s Console
Operator’s Console
1. WARNING: Moving Machine
SAFETY
VR-642C
SAFETY
2. WARNING: Crush Area
3. WARNING: Pressure Hazard
4. WARNING: Carriage
SECTION 1
VR-642C 1-19
1-20
SECTION 1
5. WARNING: Block Axle Frame
6. WARNING: Crush Area
7. WARNING: Rollover Tire Inflation
SAFETY
VR-642C
SAFETY
8. WARNING: Improper Operation
9. WARNING: Rotating Fan
10. WARNING: Falling Load
SECTION 1
VR-642C 1-21
1-22
SECTION 1
11. WARNING: Fall from Forks
12. WARNING: Rollover
13. DANGER: Electrical Hazard
SAFETY
VR-642C
SAFETY
14. WARNING: No Riders
15. NOTICE: OSHA
16. WARNING: Frame Level
SECTION 1
VR-642C 1-23
1-24
SECTION 1
17. NOTICE: Parking Brake Test
18. WARNING: Unpinned Attachment
19. NOTICE: Unmetered Ether
SAFETY
VR-642C
SAFETY
20. WARNING: Runover
SECTION 1
VR-642C 1-25
SECTION 1 SAFETY
1-26 VR-642C
SYMBOL IDENTIFICATION/METRIC CONVERSION SECTION 2
This section contains symbols that may be used on the VR-642C Variable Reach Material
Handler. The following explains the meaning of international symbols that may appear on your machine.
1.
On/Start
2.
Off/Stop
3.
Horn
4.
Battery Condition
5.
Hourmeter
6.
Grease
7.
8.
9.
Transmission Oil
Temperature
Engine Oil
Coolant Temperature
13.
Fuel (Diesel)
14.
Fuel Level
15.
Work Lights
10.
Ether Inject (Cold Start) 16.
Flashing Beacon
11.
Parking Brake 17.
Remote Cylinder Extent and Retract
12.
Hydraulic Oil 18.
Control Lever -
Multidirectional
VR-642C 2-1
SECTION 2 SYMBOL IDENTIFICATION/METRIC CONVERSION
The following symbols may also appear in a yellow square instead of in a red triangle.
2-2 VR-642C
SYMBOL IDENTIFICATION/METRIC CONVERSION
TO CONVERT bars bars
Celsius centimeters centimeters circumference cubic centimeters degrees (angle) degrees per second
Fahrenheit feet feet per minute gallons
Hertz horsepower inches inches kilograms kilograms-meter kilopascals kilopascals kilowatts liters liters liters
INTO pounds per sq. in.
kilopascals
Fahrenheit inches millimeters radians cubic inches radians revolutions per minute
Celsius meters meters per minute liters vibrations per minute kilowatts centimeters millimeters pounds pounds-foot pounds per sq. in.
bars horsepower gallons (U.S. liquid) pints (U.S. liquid) quarts (U.S. liquid)
MULTIPLY BY
14.5
100
(°C X 9/5) + 32
0.3937
10
6.283
0.06102
0.1745
0.1667
(°F - 32) x 5/9
0.3048
0.3048
3.785
60
0.7457
2.54
25.4
2.205
7.233
0.145
0.01
1.341
0.2642
2.113
1.057
SECTION 2
VR-642C 2-3
2-4
SECTION 2
TO CONVERT meters meters meters per minute miles per hour millimeters
Newtons
Newtons-meter pints (liquid) pounds pounds pounds-foot pounds-foot pounds per square inch pounds per square inch quarts (liquid) radians radians per second revolutions per minute revolutions per minute tons (short) vibrations per minute
SYMBOL IDENTIFICATION/METRIC CONVERSION
INTO feet inches feet per second kilometers per hour inches pounds pounds-foot liters kilograms
Newtons kilograms-meter
Newtons-meter bars kilopascals liters degrees revolutions per minute degrees per second radians per second tons (metric)
Hertz
MULTIPLY BY
3.281
39.37
0.05468
1.609
0.03937
4.448
0.737
0.4732
0.4536
0.225
0.138
1.356
0.06895
6.895
0.9463
57.30
9.549
6.0
0.1047
0.9078
0.0167
VR-642C
OPERATING CONTROLS AND INSTRUMENTS SECTION 3
The following individual controls and instruments are used on the VR-642C Telescopic
Material Handler.
NOTE
Gauge readings are given as a guide only. Engine and machine conditions may cause gauge readings to vary.
Figure 3-1
The Fuel Gauge (1, Figure 3-1) indicates the amount of fuel in the fuel tank. The tank should be filled with #2 filtered diesel fuel when the indicator needle moves below a 1/4 tank.
With the ignition key in the ON position, the Battery Gauge (2, Figure 3-1) indicates the condition of the battery. The gauge should register between 13.5 and 14.5 volts. If the gauge is not within this range, shut down the machine and have maintenance personnel correct the problem.
The Oil Pressure Gauge (3, Figure 3-1) indicates engine oil pressure from 0 to 690 kPa (0 to
100 psi). At normal operating speed, the oil pressure should be between 276-414 kPa (40-60 psi). At idle speed, the pressure should be between 172-207 kPa (25-30 psi). If gauge reads outside these ranges, shut down the engine correct the problem.
VR-642C 3-1
3-2
SECTION 3 OPERATING CONTROLS AND INSTRUMENTS
This Gauge (4, Figure 3-1) displays the Transmission Oil Temperature from 40 to 140° C (100 to 280° F). Normal operating temperature is between 82.2 and 93.3° C (180 and 200° F). If reading is not within this range, shut down the machine and determine the cause.
The Hourmeter (5, Figure 3-1) indicates the operating hours for the engine. Maintenance recommendations are based on the engine operating hours.
The Water Temperature Gauge (6, Figure 3-1) displays the engine coolant temperature. The gauge registers from 38-138° C (100-280° F). Normal operating temperature is between 60 and 100°C (140 and 212°F). If the coolant temperature is not within this range, shut down the machine and correct the problem.
This switch (7, Figure 3-1) is used to control an optional Auxiliary Function. These could include carriage swing, scrap grapple bucket control and side tilt for the 1067 mm (42 in.),
1219 mm (48 in.), 1524 mm (60 in.) and 1829 mm (72 in.) forks. This switch (37, Figure 3-6) is located on the optional single joystick. Information regarding this optional equipment is available from your Ingersoll Rand distributor.
The Stabilizer Switches (8 and 9, Figure 3-1) are nonlatching, rocker type switches that control the right and left stabilizers. Pressing and holding the upper portion of the switches causes the stabilizers to raise while pressing and holding the lower portion of the switches will lower the stabilizers.
The Ether Switch (10, Figure 3-1) controls the optional cold start system. Press and hold this switch while cranking the engine. When smoke appears from the exhaust, release the button so that a measured amount of starting fluid is injected into the manifold. If the weather is very cold, a second injection may be required.
These slots (11, Figure 3-1) are spares and are not used currently.
VR-642C
OPERATING CONTROLS AND INSTRUMENTS
Figure 3-2
SECTION 3
Equipment Damage.
DO NOT move the direction control lever to the opposite position (FWD to REV or REV to FWD) when the Telescopic Material Handler is moving.
The Direction Control Lever (12, Figure 3-2) is used to select the machine travel direction. The lever has three positions: "Forward" (FWD), "Neutral" (N), and "Reverse" (REV). Move the lever to the desired direction position.
NOTE
The lever must be in the "Neutral" (N) position before the engine can be started.
The Transmission Range Selector (13, Figure 3-2) is located on the Direction Control Lever.
The transmission has three speeds in either direction. The selector can be rotated to any setting while the machine is in motion.
NOTE
Downshifting at any speed greater than 3.2 km/h (2 mph) will cause an abrupt change in the speed of the machine.
The Horn Button (14, Figure 3-2) activates the horn. The horn is used to alert personnel to the approach of the telescopic handler or to a change of direction.
VR-642C 3-3
SECTION 3 OPERATING CONTROLS AND INSTRUMENTS
Figure 3-3
3-4
The Work Light Switch (15, Figure 3-3) controls the optional work lights. The switch is a three position, latching type, rocker switch. When the upper portion of the switch is pressed, the forward facing work lights turn on. When the lower portion of the switch is pressed, both the forward and rear facing work lights turn on. With the switch in the center position, the work lights are turned off.
The Boom Light Switch (16, Figure 3-3) controls the optional light at the end of the boom.
Slot (17, Figure 3-3) is a spare and are not used currently.
The Turn Signal Control Lever (18, Figure 3-3) is used to activate the optional turn signals. Pull downward on the lever to activate the right turn flasher and push upward to activate left turn flasher. Rotate the lever knob to the hazard warning light symbol to activate the four-way flashers.
The Beacon Switch (19, Figure 3-3) controls the optional beacon.
VR-642C
OPERATING CONTROLS AND INSTRUMENTS SECTION 3
The Parking Brake Switch (20, Figure 3-3) controls the spring applied, hydraulically released parking brake. Apply the parking brake by pressing the switch at the end marked when the engine is running. When the brake is On, the parking brake red warning light (switch) will be illuminated with the key on. If Park Brake light does not go off when the pushbutton is pressed to release the park brake, call for service.
Service Engine Light (21, Figure 3-3) (yellow) turns on when the key is turned to the ON position prior to starting and when the engine has reached the predetermined number of operating hours where service is required. Refer to Section 5 - Maintenance Instructions.
Check Engine Light (22, Figure 3-3) (yellow) turns on when the key is turned to the ON position prior to starting and when there is a malfunction that is not service related or will not cause damage to the engine. Contact service personnel to have problem corrected.
The Stop Engine Light (23, Figure 3-3) (red) turns on when the key is turned to the ON position prior to starting and when there is a problem with the engine which will cause damage to the engine. Turn off the engine immediately and contact service personnel.
The Steering Selector Switch (24, Figure 3-3) is used to select the steering mode. There are three modes to choose from: coordinated (four wheel), front wheel (2 wheel) and crab.
Coordinated steering is the mode most often used. This mode allows all four wheels to steer the Telescopic Material Handler and permits the operator to make smaller radius turns.
In front wheel mode, only the front wheels steer the machine.
Crab steering mode permits the wheels to turn parallel to each other. This allows the machine to travel along a line that is diagonal to the forward-and-reverse axis of the machine. Crab steering is used to move away from buildings and to escape from wheel ruts.
It is recommended the machine be stopped before steering mode is changed. All steering modes can be selected while stopped, but the wheels should be straightened before moving to make sure they are properly aligned.
The Brake Pedal (25, Figure 3-3) is operated by the operator’s left foot and applies the service brakes to stop the machine. The transmission remains engaged.
VR-642C 3-5
3-6
SECTION 3 OPERATING CONTROLS AND INSTRUMENTS
The Windshield Washer Switch (26, Figure 3-3) activates the pump for the windshield washer.
Press and hold the switch to activate.
The Park Bake Test Switch (27, Figure 3-3) is used to test the operation of the Park Brake.
Refer to "Park Brake Test Procedure" in Section 4.
The Key Switch (28, Figure 3-3) activates the electrical system when it is turned in the clockwise direction to the ON position. Turning the switch past the ON position, against a spring, to the START position engages the starter motor. Release the key as soon as the engine starts. The spring will return the key to the ON position. A mechanical lockout prevents the key from being turned to the START position without first being turned to the OFF position.
The Accelerator Pedal (29, Figure 3-3) is operated by the operator’s right foot and controls the engine speed.
The fuse block is located inside the control panel housing behind panel (30, Figure 3-3).
VR-642C
OPERATING CONTROLS AND INSTRUMENTS
Figure 3-4
SECTION 3
The Boom Control Joystick (31, Figure 3-4) controls the boom operation. Move the joystick forward to lower the boom. Move the joystick backward to raise the boom. Move the joystick to the right to extend the boom. Move the joystick to the left to retract the boom.
!
WARNING
Serious Personal Injury.
Do not use the frame leveling function when the load is raised. Move the frame leveling controls slowly and smoothly. Rapid starting and stopping of frame motion can cause the telescopic handler to tip. The risk of tipping increases as the boom is raised and extended.
Failure to adhere to this warning could result in serious personal injury including death.
The Level and Fork Control Joystick (32, Figure 3-4) is a dual function controller that permits the operator to level the chassis when the machine is on sloping surfaces up to 18 percent and also controls the tilt of the forks at the end of the boom. To operate the frame level feature, press and hold the button (33, Figure 3-4) in the end of the joy stick while moving the joystick control (32, Figure 3-4) to the left to tilt (lower) the left side of the frame or to the right to tilt
(lower) the right side of the frame. Frame level allows the chassis and boom to remain level if the machine is on sloping surface.
VR-642C 3-7
SECTION 3 OPERATING CONTROLS AND INSTRUMENTS
Figure 3-5
The Level Indicator (34, Figure 3-5) is located directly ahead of the operator on the upper crossmember of the overhead guard. The frame of the Telescopic Material Handler is level when the ball is centered in the indicator.
Figure 3-6
3-8
The Single Joystick Control (35, Figure 3-6) is a multi-functional control which allows the operator to control boom operation (extend or retract and up or down), frame and boom leveling, fork tilt, and auxiliary functions such as fork side tilt or swing fork. The decal shown
(Figure 3-7) is located in front of the control and illustrates all single control joystick functions.
VR-642C
OPERATING CONTROLS AND INSTRUMENTS
Figure 3-7
SECTION 3
Move the single joystick control (35, Figure 3-6) forward to lower the boom, and backward to raise the boom. Move the single joystick control to the right to extend the boom and to the left to retract the boom.
Fork tilt is controlled by switch (36, Figure 3-6). Press and hold the upper portion of the switch to tilt the forks down. Press and hold the lower portion the switch tilt the forks up. You do not need to move the joystick control.
Auxiliary functions, if available, are controlled by pressing and holding switch (37, Figure 3-6).
Press and hold the upper portion of the switch to operate an out or left direction function. Press and hold the lower portion of the switch to operate an in or right direction function You do not need to move the joystick control. If auxiliary functions are not available, switch (37) is not connected.
The frame level feature is activated by pressing and holding pushbutton (on the bottom of the control) while moving the single joystick control to the left to tilt (lower) the left side of the frame or to the right to tilt (lower) the right side of the frame. Frame level allows the chassis and boom to remain level if the machine is on sloping surface. The single joystick control must be moved back to the neutral (center) position to start the frame level function.
VR-642C 3-9
3-10
SECTION 3 OPERATING CONTROLS AND INSTRUMENTS
The engine diagnostic port (1, Figure 3-8) is located under the left side of the control panel.
The diagnostic port is used to connect a computer with the engine diagnostic software to the machine.
Figure 3-8
A convenient 12 volt power port (1, Figure 3-9) is located in front of the joystick control console.
Figure 3-9
VR-642C
OPERATING CONTROLS AND INSTRUMENTS SECTION 3
The optional heater and air conditioner controls are located on the right side control panel. Fan switch (1, Figure 3-10) is a rotary switch that controls the fan for both heating and cooling. Air conditioner switch (2) is a rocker type switch that turns the air conditioning unit on and off.
When the air conditioner is operating, a green indicator light on the switch is illuminated.
Rotary switch (3) controls the air temperature. Turn the switch clockwise for warmer air and counterclockwise for cooler air.
Figure 3-10
VR-642C 3-11
SECTION 3 OPERATING CONTROLS AND INSTRUMENTS
3-12 VR-642C
OPERATING INSTRUCTIONS
SECTION 4
!
WARNING
Serious Personal Injury
Improper operation of the Telescopic Material Handler can be hazardous.
Before you start, use or in any other way operate the Telescopic Material
Handler, read and understand SECTION 1 - SAFETY PRECAUTIONS AND
GUIDELINES. Make sure that you also read and understand the
FORKLIFT SAFETY MANUAL FOR OPERATORS AND MECHANICS.
Failure to understand and follow the instructions in these two manuals can cause serious injury or death.
The Telescopic Material Handler is designed to pick up and move materials. The machine has forks or another attachment on the front of the boom to engage the load. The boom lifts the load so that it can be moved and stacked or placed.
In order to understand how the Telescopic Material Handler can pick up a load, you must first know a few basics.
The operation of a Telescopic Material Handler is based on the principle of two weights balanced on opposite sides of a pivot (fulcrum). Refer to Figure 4-1.
Figure 4-1
For this principle to work with a Telescopic Material Handler, the load on the forks must be balanced by the weight of the machine. The location of the center of gravity of both the machine and the load is also a factor.
VR-642C 4-1
4-2
SECTION 4 OPERATING INSTRUCTIONS
This basic principle is used for picking up a load. The ability of the Telescopic Material Handler to handle a load is discussed in terms of center of gravity and both forward and side stability.
The center of gravity (CG) of an object is the single point about which an object is balanced in all directions. Every object has a CG. Refer to Figure 4-2. When the Telescopic Material
Handler picks up a load, the machine and the load have a combined CG. The stability of the machine is determined by the location of its CG; or, if the machine is loaded, by the combined
CG. Refer to Figure 4-3.
Figure 4-2
Figure 4-3
VR-642C
OPERATING INSTRUCTIONS SECTION 4
The Telescopic Material Handler has moving parts and, therefore, the machine CG and the combined CG move. They move forward and backward as the boom is extended and retracted. They also move forward and backward as the forks are tilted forward and backward
and up and down as the boom moves up and down. Refer to Figure 4-4.
Figure 4-4
The combined center of gravity and, therefore, the stability of the loaded Telescopic Material
Handler are affected by a number of factors:
• Size, weight, shape, and position of the load;
• Height to which the load is raised;
• Boom extension;
• Amount of forward and backward tilt;
• Tire pressure;
• Surface conditions where the machine is operating;
• Dynamic forces created when the machine is moving.
These dynamic forces are caused by factors such as acceleration, braking, turning, and operating on uneven surfaces or on an incline. These factors must also be considered when traveling with an unloaded Telescopic Material Handler, because AN UNLOADED MACHINE
WILL TIP OVER TO THE SIDE EASIER than a loaded machine with its load in the lowered position.
VR-642C 4-3
SECTION 4 OPERATING INSTRUCTIONS
In order for the Telescopic Material Handler to be stable (not tip over forward nor to the side), the combined CG must stay within the area represented by a triangle drawn between the front wheels and the pivot of the rear axle. Refer to Figure 4-5.
Figure 4-5
4-4
If the combined CG moves forward of the front axle, the machine will tip forward. If the combined CG moves outside of the line on either side of the stability base, the machine will tip to the side.
Inspect the Telescopic Material Handler for the following items before use and every eight hours or daily. Unless otherwise specified below, detailed procedures for these checks are described in SECTION 5 - MAINTENANCE INSTRUCTIONS.
!
WARNING
Serious Personal Injury
Unexpected machine motion or moving parts can cut or crush.
Do not stand between tire and frame unless the engine is stopped, the key is removed from the key switch, the parking brake is ON, and the tires are blocked.
Failure to adhere to this warning could result in serious personal injury including death.
VR-642C
OPERATING INSTRUCTIONS SECTION 4
!
WARNING
Serious Personal Injury
Fuel is flammable. May cause severe injury or death.
Shut down the engine, extinguish all open flames, and do not smoke while filling the tank.
Always wipe up any spilled fuel. Failure to adhere to this warning could result in serious personal injury including death.
1. Check fuel level gauge (1, Figure 4-6). Fill fuel tank (1, Figure 4-7) if necessary.
Be sure the tank is full at the end of the shift to prevent condensation.
Figure 4-6
Figure 4-7
VR-642C 4-5
4-6
SECTION 4 OPERATING INSTRUCTIONS
2. Drain water from the fuel/water separator by opening drain (1, Figure 4-8) until clear fuel is visible.
Figure 4-8
3. Check engine oil level on dip stick (1, Figure 4-9) and add oil as required at fill point (2, Figure 4-8). Refer to machine lube chart for oil type.
Figure 4-9
VR-642C
OPERATING INSTRUCTIONS SECTION 4
4. Check the air cleaner restriction indicator (1, Figure 4-10). Maintenance of the air cleaner is due when the red band shows on the restriction indicator. After servicing, press the indicator to reset it.
Figure 4-10
5. Check hydraulic tank sight gauge (1, Figure 4-11) and add fresh clean hydraulic oil at (2) as required. Refer to Section 8 for hydraulic oil specifications.
Figure 4-11
VR-642C 4-7
4-8
SECTION 4 OPERATING INSTRUCTIONS
!
WARNING
Serious Personal Injury
Injury can occur when removing the radiator cap. Steam or fluid escaping from the radiator can burn. Inhibitor contains alkali. Avoid contact with skin and eyes.
Always shutdown the engine and allow it to cool down before removing the radiator cap. Remove the cap slowly to relieve pressure. Avoid contact with steam or escaping fluid. Always wipe up any spilled fuel.
Failure to adhere to this warning could result in serious personal injury including death.
6. Check coolant level by removing radiator cap (1, Figure 4-12). The coolant level should be within 38 mm (1.5 in.) of the bottom of the cap when the cap is installed. If coolant level is low, add coolant to the correct level.
Figure 4-12
VR-642C
OPERATING INSTRUCTIONS
7. Check condition of the drive belt (1, Figure 4-13). Replace belt if cracked or worn.
Figure 4-13
SECTION 4
8. Check for leaks from the engine, transmission, hydraulic system, brake system, and fuel system.
9. Check condition of wheels and tires.
10. Check for correct pressure as noted on the tire pressure inflation chart.
11. Check operator restraint system (seat, belt, seat mounts, and floor plates).
Check that mounting hardware is tight.
12. Condition of rollover protective structure (ROPS) cab.
13. Check condition of forks (1, Figure 4-14), carriage (2) and boom (3).
Figure 4-14
VR-642C 4-9
SECTION 4 OPERATING INSTRUCTIONS
!
WARNING
Serious Personal Injury
Improper operation can be hazardous.
Report damage or faulty operation immediately. Do not operate damaged or defective Telescopic Material Handler. A Telescopic Material Handler will only do its job when it is in proper working order. If repairs are required, install a tag in the operator’s area stating "DO NOT OPERATE" and remove the key from the key switch.
Failure to adhere to this warning could result in serious personal injury including death.
4-10 VR-642C
OPERATING INSTRUCTIONS
SECTION 4
!
WARNING
Serious Personal Injury
Unexpected machine motion or moving parts can cut or crush.
Make sure that all personnel are away from the Telescopic Material
Handler before the engine is started. Make sure that no one is standing between the wheels and the frame.
Failure to adhere to this warning could result in serious personal injury including death.
Make sure that the area around the Telescopic Material Handler is clear before starting the engine or making any operational checks. Be careful when making the checks. If the machine is stationary during a check, apply the parking brake and put the directional control lever in
"Neutral". Proceed carefully.
!
WARNING
Serious Personal Injury
Seat belt and other OSHA-required safety equipment MUST be worn while operating the Telescopic Material Handler. Failure to use all safety equipment could result in serious injury or death.
If the Telescopic Material Handler starts to tip overtip over:
• Do not jump -- Stay on the machine.
• Hold the steering wheel firmly.
• Brace feet.
• Lean forward and away from impact.
Failure to adhere to this warning could result in serious personal injury including death.
VR-642C 4-11
4-12
SECTION 4 OPERATING INSTRUCTIONS
Do not start or operate the Telescopic Material Handler, including any of its functions or attachments, from any place other than the operator’s seat.
1. Sit in the operator’s seat (1, Figure 4-15). Fasten seat belt (2), adjust seat position using lever (3) and adjust seat suspension with knob (4).
Figure 4-15
2. Make sure the parking brake is applied. Press Park Brake Switch (20, Figure
Figure 4-16
VR-642C
OPERATING INSTRUCTIONS
3. Put the direction control lever (12, Figure 4-17) in the "Neutral" (N) position.
Figure 4-17
SECTION 4
Equipment Damage
Starter may overheat if operated longer than 30 seconds.
If the engine fails to start, allow the starter to cool two (2) to three (3) minutes before trying again.
Starting fluids can severely damage the engine and void the engine warranty.
Do not use ether or other starting fluids or starting aids that have not been approved.
NOTE
This machine uses an electronic engine. Turn the ignition key to the On position and wait approximately two seconds before attempting to start the engine.
VR-642C 4-13
4-14
SECTION 4 OPERATING INSTRUCTIONS
4. Turn the key (28, Figure 4-18) to ON, wait two seconds, then turn the key to
START to engage the starter. When the engine starts, release the key to the
ON position.
Figure 4-18
NOTE
If the engine does not start after four attempts, contact authorized service personnel.
With the engine running, inspect the Telescopic Material Handler for the following items before use and every eight hours or daily. Unless otherwise specified below, detailed procedures for these checks are described in SECTION 5 - MAINTENANCE INSTRUCTIONS of this manual.
1. Check the operation of the horn, gauges, and indicator lights as described in
SECTION 3 - OPERATING CONTROLS AND INSTRUMENTS.
2. Use Boom Control Lever (31, Figure 4-19) or (35, Figure 4-20) to slowly raise,
lower, extend, and retract the boom several times without a load. Make sure that the boom moves smoothly in accordance with control inputs.
Figure 4-19
VR-642C
OPERATING INSTRUCTIONS
Figure 4-20
SECTION 4
3. Check the operation of the powershift transmission.
4. Check the operation of the steering system.
5. Check the operation of the service brakes.
6. Check operation of the parking brake using the following procedure.
The Park Brake Test Procedure must be performed every 10 hours or daily.
!
WARNING
Serious Personal Injury
Prior to performing this test, make sure the area within 15 m (50 feet) in front of and behind the machine is clear of persons and objects.
Be sure there is no load on the machine.
Failure to adhere to this warning could result in serious personal injury including death.
VR-642C 4-15
4-16
SECTION 4 OPERATING INSTRUCTIONS
1. Be sure Park Brake Switch (20, Figure 4-21) is in the On position. The red indicator light on switch is illuminated.
Figure 4-21
2. Depress service brake pedal (25, Figure 4-22).
Figure 4-22
3. Press Park Brake Test switch (27, Figure 4-21).
VR-642C
OPERATING INSTRUCTIONS SECTION 4
4. Rotate transmission range selector (13, Figure 4-23) to "2" (2nd gear) position.
Figure 4-23
5. Lift and move the direction control lever (12, Figure 4-23) to the FWD (forward) position.
6. Depress the throttle pedal (29, Figure 4-22) completely to the floor.
7. Slowly remove pressure from service brake pedal (25, Figure 4-22).
8. If the machine does not move, the park brake performance is acceptable. If the machine moves forward, remove the machine from service and have the park brake serviced.
!
WARNING
Serious Personal Injury
Improper operation can be hazardous.
There are a number of operations that, if not performed carefully, can cause the Telescopic Material Handler to tip. If you have not read
SECTION 1 - SAFETY PRECAUTIONS AND GUIDELINES of this manual, do so NOW. If you have not read the VARIABLE REACH MATERIAL
HANDLER SAFETY MANUAL FOR OPERATORS AND MECHANICS, do so
NOW. As you study the following information about how to properly operate a Telescopic Material Handler, remember the WARNINGS.
Failure to adhere to this warning could result in serious personal injury including death.
VR-642C 4-17
4-18
SECTION 4 OPERATING INSTRUCTIONS
Many new operators make the mistake of thinking that driving a Telescopic Material Handler is the same as driving an automobile. The procedures are not the same. It is true that some operating procedures are as simple and obvious as driving the family automobile (e.g., Look where you are going, start and stop smoothly, etc.). However, a Telescopic Material Handler is a special machine designed to do a much different job from an automobile. Because of the areas in which a machine operates, and its other operating characteristics (for example: coordinated or crab steering, and frame leveling), every operator must receive special training.
THE VR-642C TELESCOPIC MATERIAL HANDLER IS INTENDED FOR USE BY
AUTHORIZED AND TRAINED OPERATORS ONLY. This statement means that the operator
MUST be trained to drive the machine and must thoroughly understand the procedures for operation.
OSHA regulations require that a trained and qualified person operate the Telescopic Material
Handler. A trained and qualified person experienced in the operation of this machine MUST guide a new operator through driving and load-handling operations until the new operator is trained and qualified to meet OSHA guidelines.
OPERATE THE TELESCOPIC MATERIAL HANDLER ONLY IN AREAS THAT HAVE BEEN
APPROVED FOR ITS OPERATION.
Certain areas contain hazardous flammable gases, liquid, dust, fibers, or other materials.
Machines that are operated in these areas must have special approval. These areas are designated to show the type of approval required for operation in the area. A Telescopic
Material Handler is not normally operated in these restricted areas. If it must be operated in a restricted area, it must have some modifications and special approval. Contact your Ingersoll
Rand distributor if this requirement is necessary.
!
DANGER
Serious Personal Injury or death
Electrocution Hazard. Boom contact with power lines will result in serious injury or death.
Do not operate a Telescopic Material Handler over or near electric power lines.
Failure to adhere to this warning could result in serious personal injury including death.
The Telescopic Material Handler is not insulated. Do not operate any part of the machine within
3.05 m (10 ft.) of an electric power line.
VR-642C
OPERATING INSTRUCTIONS SECTION 4
!
WARNING
Serious Personal Injury
This Telescopic Material Handler is designed and intended for handling materials. A Telescopic Material Handler is not designed to lift people.
Do not use a Telescopic Material Handler to lift people.
Failure to adhere to this warning could result in serious personal injury including death.
DO NOT CARRY RIDERS. A Telescopic Material Handler is built for only one person—the operator. It is dangerous for anyone to ride on the forks or anywhere else on the machine.
If a Telescopic Material Handler must be moved with an elevator or crane, make sure the lifting device has the capacity to lift the machine. The weight of your machine can be found on its nameplate.
Drive carefully, observe traffic rules, and be in full control of the Telescopic Material Handler at all times. Be completely familiar with all the driving and load-handling techniques contained in this manual and the Variable Reach Material Handler Safety Manual for Operators and
Mechanics.
The VR-642C Telescopic Material Handler has a three speed transmission. The transmission range selector switch (13, Figure 4-24) is located in the end of the direction control lever (12).
The three speed ranges are (HIGH [3], INTERMEDIATE [2], and LOW [1]). The direction control lever has three positions: "Forward" (FWD), "Neutral" (N), and "Reverse" (REV).
Figure 4-24
Lift the direction control lever and move the lever to either the "Forward" (FWD) or Reverse"
(REV) position, as desired. Release the lever.
VR-642C 4-19
SECTION 4 OPERATING INSTRUCTIONS
Check the area around the Telescopic Material Handler. Apply the service brakes (25, Figure
4-25) and release the parking brake by placing the park brake switch (20, Figure 4-25) in the release position. The indicator light will turn off. To move the unit, release the brake and push down on the accelerator pedal (29, Figure 4-25). A loaded or unloaded handler can usually begin to move with the transmission range selector in the "2" position. Start in the "1" position when the handler is on a grade or in mud. After the unit is moving, rotate the transmission range selector to increase speed or select a lower range.
Figure 4-25
4-20
Equipment Damage
DO NOT move the direction control lever to the opposite position (FWD to REV or REV to FWD) when the Telescopic Material Handler is moving.
Do not use ether or other starting fluids or starting aids that have not been approved.
To change directions, first stop the machine with the brake pedal (25, Figure 4-25). Select the speed range (13, Figure 4-24), then move the direction control lever (12, Figure 4-24) to the opposite direction. Look in the direction of travel. Release the brake and accelerate by pushing on the accelerator pedal (25, Figure 4-25).
VR-642C
OPERATING INSTRUCTIONS
SECTION 4
!
WARNING
Serious Personal Injury
TRAVEL SLOWLY WHEN TURNING. Telescopic material handlers can tip over even at very slow speeds.
Failure to adhere to this warning could result in serious personal injury including death.
NOTICE
Telescopic material handlers can tip over even at very slow speeds. The combination of speed and the sharpness of a turn can cause the machine to tip over. A machine is less stable when the forks are elevated, with or without a load. Most operators can understand the need to be careful when handling loads, but some operators do not realize that a tip-over can occur with an empty machine because similar dynamic forces are present. In fact, the machine will actually tip over more easily when empty than when loaded with the load lowered. Rearward tilt of the carriage and load, off-center loads, and uneven or soft ground will aggravate these conditions.
Telescopic material handlers are designed to work in a relatively small space. Because of their design, they can turn more sharply than some other vehicles. An operator must be aware of tail swing and always check to make sure the tail swing area is clear before turning. Refer to
Figure 4-26. Failure to observe the tail swing area when making a turn can cause serious injury or death.
Figure 4-26
VR-642C 4-21
4-22
SECTION 4 OPERATING INSTRUCTIONS
!
WARNING
Serious Personal Injury
Keep a safe distance from the edge of docks, ramps, platforms, and other similar working surfaces. Watch the tail swing. Remember that when traveling in the forward direction and the steering wheel is turned to move the Telescopic Material Handler away from the edge of the dock, the rear can swing toward the edge. This action can cause the machine to fall off the dock.
Keep a safe distance from the edges of excavations so that the ground does not suddenly collapse and tip over the Telescopic Material Handler.
Be careful when operating on slopes when the ground is soft or muddy so that the machine does not suddenly slide and tip over.
Failure to adhere to this warning could result in serious personal injury including death.
!
WARNING
Serious Personal Injury
If the Telescopic Material Handler starts to tip over:
• DO NOT JUMP; stay on the machine.
• HOLD firmly to the steering wheel.
• BRACE your feet.
• LEAN FORWARD and away from the impact.
Failure to adhere to this warning could result in serious personal injury including death.
When possible, keep both hands on the steering wheel. During most loading or unloading operations, the operator steers with the left hand. The right hand is used to operate the control levers.
VR-642C
OPERATING INSTRUCTIONS SECTION 4
The VR-642C machine has three modes of steering that are selectable using 3 position steering selector switch (24, Figure 4-27).
Figure 4-27
1. Front Wheel Only (2 wheel) (steering mode selector is in the center position).
This mode is normally used only when traveling on roads. Refer to Figure 4-28.
Figure 4-28
2. Crab (all wheels track in the same direction; upper portion of the steering mode selector switch depressed). Crab steering is used to move away from buildings or escape from wheel ruts. Refer to Figure 4-29.
Figure 4-29
VR-642C 4-23
SECTION 4 OPERATING INSTRUCTIONS
3. Coordinated (4 wheel) (rear wheels turn the opposite of the front wheels; lower portion of steering mode selector switch depressed). Coordinated steering provides the greatest maneuverability and is the mode of steering
most often used. Refer to Figure 4-30.
Figure 4-30
4-24
Equipment Damage
The machine must be completely stopped before the steering mode is changed. Also, the wheels must be aligned for straight travel before another mode is selected.
!
WARNING
Serious Personal Injury
Improper operation can be hazardous.
If you have not read SECTION 1 - SAFETY PRECAUTIONS AND
GUIDELINES, do so NOW. If you have not read the Safety Manual for
Operators and Mechanics, do so NOW. As you study the following information regarding the proper handling and moving of loads, remember the warnings.
Failure to adhere to this warning could result in serious personal injury including death.
VR-642C
OPERATING INSTRUCTIONS SECTION 4
!
WARNING
Serious Personal Injury
Only attachments which have been fully tested for stablity and have had
Rated Capacity Charts established per ASME B56.6 by Ingersoll Rand company are approved for use on Telescopic Material Handlers. The use of non-approved attachments may cause machine instability and tipover, which may result in severe injury or death to operators or bystanders.
Approved attachments are only those supplied by Ingersoll Rand which are accompanied by applicable Rated Capacity Charts for the specific attachment and machine model.
Failure to adhere to this warning could result in serious personal injury including death.
1. Handle only loads within the rated capacity as shown on the Rated Capacity
Chart(s) mounted on the Telescopic Material Handler. MAKE SURE THE
RATED CAPACITY CHART YOU ARE USING CORRESPONDS TO THE
BOOM ATTACHMENT FITTED TO THE MACHINE. This rated capacity represents the maximum load that can be lifted for the boom extensions when the machine is on a hard, level surface. However, such factors as weak floors, uneven terrain, soft ground, special load-handling attachments, or loads having a high center of gravity can mean that the safe working load is less than the rated capacity. When such conditions exist, the operator must reduce the load so that the Telescopic Material Handler will remain stable.
!
WARNING
Serious Personal Injury
Do not use the frame leveling function when the load is raised. Level the frame before the load is lifted. If the Telescopic Material Handler is equipped with a tilt carriage, level the frame before using the tilt carriage adjustment.
Move the frame leveling controls (32 & 33, Figure 4-31 or 35, Figure 4-32) slowly and smoothly. Rapid starting and stopping of frame motion can cause the Telescopic Material Handler to tip. The risk of tipping increases as the boom is raised and extended.
Failure to adhere to this warning could result in serious personal injury including death.
VR-642C 4-25
SECTION 4
Figure 4-31
OPERATING INSTRUCTIONS
Figure 4-32
4-26
2. Inspect the load to be lifted. DO NOT raise the boom unless the frame is level.
Lift the load and lower the load only on stable level ground. If a load must be handled several times, put stacking blocks under the loads.
3. Handle only stable loads. A load can have unstable items that can easily shift and fall on someone. DO NOT handle a load if ANY part of it is likely to fall.
4. If a suspended load must be lifted, DO NOT permit it to swing freely. Use a tether to control its movement. Start and stop the machine slowly and make turns carefully.
5. Position each load the same distance from the center of the carriage. This action will help center the load on the carriage. Set the forks as far apart as possible for maximum support of the load. Center the weight of the load between the forks. Otherwise, the load can fall from the forks when you turn a corner or hit a bump. An off-center load will increase the possibility of the
Telescopic Material Handler tipping over to the side. Make sure that the floor or surface can hold the weight of the Telescopic Material Handler and the load.
The weight of your machine can be found on the machine’s nameplate.
VR-642C
OPERATING INSTRUCTIONS SECTION 4
The boom extension, lift, and tilt functions are controlled by the boom control levers (32 and
33, Figure 4-31) or (35, Figure 4-32) if machine has the single lever control option.
The speed of the hydraulic functions is controlled by the position of the control levers and the speed of the engine. The farther the hand lever is moved from the "Neutral" (N) position, the faster the speed of the hydraulic function.
DO NOT lift or hit anything that can fall on the operator or another person. The Telescopic
Material Handler is equipped with a ROPS and load backrest extension to give reasonable protection to the operator from falling objects, but cannot protect against every possible impact. Do not hit objects such as stacked material so that it can become dislodged and fall.
The operator must be careful when working near stacks or objects that can fall.
!
WARNING
Serious Personal Injury
Keep yourself and others away from the lift mechanism. Never permit anyone under or on the forks. Never put head, arms, hands, or legs through the boom mechanism nor near the forks or carriage. This rule applies not only to the operator, but also a helper. A helper must not be near the load or lift mechanism when the operator is attempting to handle a load. The lift mechanism has moving parts with close clearances that can cause serious injury or death.
Make sure the operation of the boom and the Rated Capacity Chart are understood before a load is lifted.
Failure to adhere to this warning could result in serious personal injury including death.
1. Avoid fast starts. Sudden movement can cause the Telescopic Material Handler to tip or cause the loss of the load from the forks. People can be hurt or killed and material can be damaged. Approach the load carefully. Make sure the machine is perpendicular to the load. Raise the forks to the height to engage the load.
2. Move forward slowly until the forks are in position under the load. When lifting a load, the forks must support at least two-thirds (2/3) of the length of the load.
Refer to Figure 4-33 Make sure that the load is centered between the forks, and that the forks are centered on the carriage. The center of gravity must be as close to the load backrest and the center of the carriage as possible. Make sure the forks do not extend past the load so the loads or equipment that are behind the load being lifted are not damaged. Refer to Figure 4-34.
VR-642C 4-27
SECTION 4
Figure 4-33
OPERATING INSTRUCTIONS
Figure 4-34
4-28
If the forks are longer than the load, move the forks under the load so that the tips of the forks do not extend beyond the load. Lift the load from the surface. Move backward a few inches, then lower the load onto the surface and inch forward to engage the load against the carriage. Tilt the forks backward just far enough to lift the load from the surface. When the boom is raised from the surface level, the tips of the forks move in an arc.
Make sure there is enough clearance so that the forks or the load do not hit loads or equipment that are behind the load being lifted.
!
WARNING
Serious Personal Injury
The forks on this Telescopic Material Handler have a range of tilt. Do not tilt the forks to cause a loss of the load.
Failure to adhere to this warning could result in serious personal injury including death.
VR-642C
OPERATING INSTRUCTIONS SECTION 4
3. Always use a helper if you cannot clearly see the point where the load will be stacked. Move the Telescopic Material Handler into position and make sure the area is clear. Lower the load onto the stack or the surface. Tilt the forks to the horizontal position to disengage the load. Move the machine carefully away from the load to disengage the forks.
!
WARNING
Serious Personal Injury
Be careful when placing a load at a high elevation. When the lift height increases, your depth perception decreases and the area you can see clearly decreases. Placing a load at a high elevation may require a helper to guide you.
Failure to adhere to this warning could result in serious personal injury including death.
4. When stacking a load at a high elevation, make sure that everyone is away from the area where the load can tip or fall. Move the machine as close to the load point as possible with the load lowered. Apply the Park Brake and place the Direction Control in Neutral. Use the frame leveling function as necessary before the load is raised.
Slowly and carefully raise the load. Keep the forks tilted backward a small amount so that load cannot slide from the forks. Never tilt the forks forward unless the load is over the stack point and ready to be disengaged.
If there is any indication, during the lift movement, the load or the machine are not stable, STOP immediately. Retract the boom and lower the load and decrease the size of the load. Move the machine to a more stable and level position. Make sure the machine has the capacity to lift the load.
!
WARNING
Serious Personal Injury
The Telescopic Material Handler becomes less stable as the load is lifted higher.
Failure to adhere to this warning could result in serious personal injury including death.
VR-642C 4-29
4-30
SECTION 4 OPERATING INSTRUCTIONS
5. When the load being lifted approaches the stack height, slow to a minimum lift speed. Lift the load a small amount above the stack height.
!
WARNING
Serious Personal Injury
Do not extend the lift cylinder to the end of its stroke at a high lift speed.
The sudden stop can cause the load to fall or the machine to tip.
Make sure the stack point can safely hold the load. Failure to adhere to this warning could result in serious personal injury including death.
6. When the load is above the stack point, carefully move the load over the stack point. Gently lower the load until the weight is removed from the forks. Do not make a downward force on the stack with the forks or boom when lowering the load. Do not drag the forks on the surface under the load. Tilt the forks so that they are approximately level and parallel to the load surface so that they can be easily disengaged from the load.
Check that floor, support beams, scaffolding, and load surface can support the load before you completely disengage from the load. If there is a problem with the stack point, lift the load, tilt the load backward a small amount, retract the boom, and lower the load to the ground.
After the load is correctly stacked, move the machine slowly backward to disengage the forks.
Retract the boom and lower the forks to a traveling height before moving the machine away from the area.
When lifting round objects, use a block behind the object. Tilt the carriage forward so that the forks can slide along the floor under the object to be lifted. Refer to Figure 4-35.
Figure 4-35
VR-642C
OPERATING INSTRUCTIONS SECTION 4
Tilt the carriage fully backward to help keep the load on the forks. Refer to Figure 4-36. Use
additional caution when carrying drums, reels, cylinders, and other round objects. Use a tether if necessary to control the load. Watch the clearances when the loads are very long, high or wide.
Figure 4-36
NOTE
Not every load can be lifted using only the forks of the Telescopic Material Handler.
Some loads require a special attachment.
When traveling with the load lowered, keep the load against the carriage and the forks tilted backward. This position will help keep the load on the forks and give better forward and side stability.
Travel with the lift mechanism raised only enough to clear the ground or obstacles. When the carriage or load is in an elevated position, the stability of the machine is reduced. A Telescopic
Material Handler without a load can be more likely to tip sideways, especially in a turn, than one with a load carried in the lowered position.
!
WARNING
Serious Personal Injury
When the boom is in the lowered position, the area on the right side of the material handler is difficult to observe. The Telescopic Material
Handler has a mirror (1, Figure 4-37) for viewing the area where the boom can cause interference with the operator’s view. This mirror is an aid to the operator, but is NOT a driving mirror and must not be used as a driving mirror when operating in Reverse. ALWAYS look in the direction of travel to avoid personal injury or property damage.
Failure to adhere to this warning could result in serious personal injury including death.
VR-642C 4-31
SECTION 4 OPERATING INSTRUCTIONS
For better visibility with large loads, travel with the load trailing, but always keep a proper lookout in the direction of travel. If the Telescopic Material Handler must travel in a direction where there is an obstruction to visibility, another person may be required for a lookout.
When traveling up or down a grade with a loaded Telescopic Material Handler, the load should be kept upgrade to maintain control. When operating an unloaded machine on a steep grade, the rear end must be kept upgrade.
Figure 4-37
4-32
Watch for pedestrians at all times. Do not drive up to anyone standing in front of an object.
Use extra care at crossroads, doorways, and other locations where pedestrians can step into the path of travel of the machine. Slow down when approaching blind intersections or turns and sound the horn. The horn can alert pedestrians that there is a vehicle in the area and to be alert to possible danger.
Whenever the machine is moving, keep arms, legs, etc. inside the operator’s compartment.
Arms and legs outside the machine can be injured when passing obstructions.
Do not pass another vehicle traveling in the same direction at intersections, blind spots, or at other dangerous locations.
Avoid bumps, holes, soft ground, slick spots, and loose materials that can cause the
Telescopic Material Handler to swerve or tip. If such areas cannot be avoided, go slowly.
Always make sure you pick the smoothest route for your Telescopic Material Handler.
Do not indulge in stunt driving or horseplay.
Stay away from the edge of the road. Keep the wheels of the Telescopic Material Handler— particularly the steering wheels—on the roadway. If the wheels are allowed to run off the edge of the travel surface onto soft ground, the machine can tip over.
Under all travel conditions, operate the machine at a speed that will permit it to be brought to a stop in a safe manner.
Check the condition of the driving surface of all docks. Make sure the dock floor will hold the weight of the Telescopic Material Handler and the load.
Make sure the dock ramp is secured, in good condition, and of the correct capacity.
VR-642C
OPERATING INSTRUCTIONS
SECTION 4
!
WARNING
Serious Personal Injury
Only attachments which have been fully tested for stability and have had
Rated Capacity Charts established per ASME B56.6 by Ingersoll Rand
Company are approved for use on Telescopic Material Handlers. The use of non-approved attachments may cause machine instability and tip-over, which may result in severe injury or death to operators or bystanders.
Approved attachments are only those supplied by Ingersoll Rand which are accompanied by applicable Rated Capacity Charts for the specific attachment and machine model.
Failure to adhere to this warning could result in serious personal injury including death.
If an attachment or special equipment is installed on the Telescopic Material Handler, make sure that the operating instructions are available and understood before operating the attachment.
Never leave the Telescopic Material Handler in a condition from which it can cause damage or injury. When parking the machine, perform the following procedures:
1. Stop the machine and apply the parking brake.
!
WARNING
Serious Personal Injury
Do not leave the machine unattended with a suspended load.
Failure to adhere to this warning could result in serious personal injury including death.
2. Fully lower the boom and forks. Tilt the carriage forward until the tips of the forks touch the ground.
VR-642C 4-33
4-34
SECTION 4 OPERATING INSTRUCTIONS
3. If the engine has been working hard, let the engine idle for a few minutes before it is stopped. This procedure is very important when operating a turbocharged engine. Turn the key switch to OFF to stop the engine.
4. Remove the ignition key. Lock the cab doors.
If the machine has power:
NOTICE
The Telescopic Material Handler cannot be towed from one job site to another. This procedure is only for use when the machine must be removed from mud or other places where it cannot move under its own power.
1. The engine of the machine must operate. The steering and brakes cannot be operated if the engine is not running. Be sure to release the park brake before attempting to tow the machine.
2. Use extra care if the traction conditions are bad or the machine is on a grade.
Bad traction conditions can cause the machine or the towing vehicle to slide.
Grades can require additional distance to stop the machine.
3. Make sure that the tow chain has the capacity to do the job; the weight of your
Telescopic Material Handler can be found on the machine nameplate.
Carefully fasten the tow chain around the axle of the machine. Make sure that the tow chain is fastened so that the chain will not cause damage to the machine or the towing vehicle.
4. An operator must be on the Telescopic Material Handler to operate the steering and brakes while it is being towed.
VR-642C
OPERATING INSTRUCTIONS
If the machine has no power:
SECTION 4
!
WARNING
Serious Personal Injury
Machine runaway condition could occur.
Always chock the wheels of the disabled machine or hitch to towing vehicle to prevent accidental movement while preparing the machine for towing. This is especially important if the failure occurs on an incline.
Failure to adhere to this warning could result in serious personal injury including death.
To tow the machine a maximum of 300 meters (984 feet):
1. Shut down the engine.
2. Chock the wheels.
Do not attempt to tow the machine with the transmission engaged.
Towing with the transmission will result in damage to the transmission.
3. Disconnect the drive shafts from each axle.
4. Attach each drive shaft to the frame using straps or chains to support the shafts and prevent them from dragging when the machine is moved.
NOTE
The park brake is located on the rear axle.
5. Attach the machine to the tow vehicle using a tow bar.
VR-642C 4-35
SECTION 4 OPERATING INSTRUCTIONS
!
WARNING
Serious Personal Injury
Service brakes will not operate if engine is not running.
Machine can move after park brake is released. Be sure the machine is securely attached to the tow vehicle before removing chocks from wheels. Be sure chain is fastened to the axle in a way that no damage will occur to the axle or machine.
Failure to adhere to this warning could result in serious personal injury including death.
6. Release the park brake as follows: a. Loosen lock nut (1, Figure 4-38).
b. Turn set screw (2, Figure 4-38) until it contacts parking brake arm.
c. Remove cylinder rod nut (3, Figure 4-38). d. Loosen set-screw (2, Figure 4-38) counterclockwise to allowing the brake to release.
Figure 4-38
4-36
7. Remove the chocks from wheels and tow the machine.
VR-642C
OPERATING INSTRUCTIONS SECTION 4
8. Be sure to engage the park brake after the machine has been moved to the desired location. To engage the park brake (refer to Figure 4-38): a. Rotate set screw (2) clockwise applying the brake.
b. Replace and tighten cylinder locknut (3) until lever arm is tight against nut
(4).
c. Rotate setscrew counterclockwise clear of the lever arm and tighten locknut
(1).
9. Reconnect the drive shafts.
Stabilizers (1, Figure 4-39) are available as optional equipment on the VR-642C Material
Handler. The stabilizers should be used whenever you are picking up or placing a load with the boom raised.
Figure 4-39
VR-642C
Stabilizers are used to stabilize the machine when lifting and placing a load only. They are not outriggers and are not designed to lift the machine.
Always raise the stabilizers completely before driving the machine.
Failure to have the stabilizers in the upright position may result in damage to the machine.
4-37
SECTION 4 OPERATING INSTRUCTIONS
To Operate Stabilizers:
1. Move the machine to the area where the load is to be picked or placed.
!
WARNING
Serious Personal Injury
Stabilizers can crush. Be sure no one is near the stabilizers when they are lowered.
Failure to adhere to this warning could result in serious personal injury including death.
2. Check to be sure no personnel are near the stabilizers. Then, press and hold
Left Stabilizer switch (8, Figure 4-40) to lower the left stabilizer. Press and hold
Right Stabilizer switch (9, Figure 4-40) to lower the right stabilizer.
Figure 4-40
4-38
3. Raise the boom and pick up or place the load as required.
4. Lower the boom and raise the stabilizers to the full upright position.
VR-642C
OPERATING INSTRUCTIONS
SECTION 4
!
WARNING
Serious Personal Injury
A loose Telescopic Material Handler can shift or fall while being transported.
Tie down the machine securely before moving the hauling vehicle or transporter.
Failure to adhere to this warning could result in serious personal injury including death.
Telescopic material handlers are not designed for use on public roads and must be transported to job sites on a trailer or flatbed truck. Ensure that the trailer or flatbed truck has enough capacity to carry the machine; the weight of your machine can be found on the nameplate.
Also verify the ramps can hold the machine and the ramps and trailer surfaces are clean so that the machine cannot slide. Use blocks and tiedowns to ensure the machine cannot fall from the trailer. For further details, see "TRANSPORTING AND HAULING" in SECTION 1 -
SAFETY PRECAUTIONS AND GUIDELINES.
The vandal protection cover (Figure 4-41) is used to prevent unauthorized persons from accessing the control console. Install the cover over the console panel and secure using a padlock. When not in use, the cover is stowed on the front fender.
Figure 4-41
1. Remove wing nuts (1, Figure 4-41) and vandal cover plates (2 and 3) from their stowed position on the fender.
2. Install right hand vandal cover plate (3, Figure 4-41) over the locating pins (4) and lock plate (5).
VR-642C 4-39
4-40
SECTION 4 OPERATING INSTRUCTIONS
3. Install left hand vandal cover plate (2, Figure 4-41) over the locating pins (4) and lock plate (5).
4. Secure cover plates with pad locks through lock plates (4, Figure 4-41).
The following options affect the load capacity and CG of the VR-642C. When using an attachment, make sure to review and apply the correct Load Chart for the attachment. See
LOAD CAPACITY CHARTS on Page 1-11 for additional details.
!
WARNING
Serious Personal Injury
Your Telescopic Material Handler may be equipped with several different
Rated Capacity Charts to accommodate different boom attachments.
Make sure that the Rated Capacity Chart you are using corresponds to the boom attachment fitted to the machine at the moment.
Failure to adhere to this warning could result in serious personal injury including death.
The Quick Attachment Apron (1, Figure 4-42) is a one piece adaptor that bolts to the boom to allow quick, toolless mounting and dismounting of the various boom (2) options. The attachment is positioned onto apron pins (3), the boom raised allowing the apron mounted locking pins (4) to be extended into the attachment by handle (5).
Figure 4-42
VR-642C
OPERATING INSTRUCTIONS SECTION 4
To install attachments:
1. Insure the attachment locking pin control handle (3, Figure 4-42) is in the raised position with the locking pins (4) retracted.
2. Position the attachment on level ground.
3. Locate the boom such that the apron mounted lift pins (3, Figure 4-42) can be raised to engage the attachment (2) and lift it clear of the ground.
4. Raise the boom allowing the attachment to swing into position aligning the holes in the attachment with the locking pins (4, Figure 4-42).
5. Shut down the engine.
6. Lower handle (5, Figure 4-42) extending the pins (4) into attachment (2).
To remove attachments:
1. Position the boom so the attachment (2, Figure 4-42) is resting on level ground.
2. Shut down engine.
3. Raise handle (5, Figure 4-42) retracting pins (4) from attachment (2).
4. Start engine.
5. Lower boom to clear attachment and back machine to clear attachment.
VR-642C 4-41
4-42
SECTION 4 OPERATING INSTRUCTIONS
The Scrap Grapple Bucket mounts and connects as shown in Figure 4-43. The figure is keyed to the table below.
Figure 4-43
ITEM
3
4
1
2
5
6
DESCRIPTION
Scrap Grapple Bucket
Adapter
Coupler
Quick Disconnect Nipple
Quick Connect Couple Dust Cap
Quick Connect Nipple Dust Cap
VR-642C
OPERATING INSTRUCTIONS
The Bucket Loader (1, Figure 4-44) mounts as shown in Figure 4-44.
Figure 4-44
SECTION 4
The Truss Boom (1, Figure 4-45) mounts as shown in Figure 4-45.
Figure 4-45
VR-642C 4-43
4-44
SECTION 4 OPERATING INSTRUCTIONS
The Pintle Hook (1, Figure 4-46) mounts and connects to a tapped plate located at the rear of the VR-642C as shown in Figure 4-46.
NOTE
Apply Loctite 271 (Red) for all pintle hook fasteners. Torque the 3/4 in. H.H.C.S. to
610 N-m (450 lb.-ft.) Torque the 1/2 in. H.H.C.S. to 176 N-m (130 lb.-ft.).
Figure 4-46
ITEM
4
5
6
1
2
3
DESCRIPTION
Pintle Hook Plate
Pintle Hook
Washer
H.H.C.S.
Washer
H.H.C.S.
VR-642C
OPERATING INSTRUCTIONS SECTION 4
Refer to Figure 4-47 for the following procedure:
1. Slide forks toward the center of the carriage.
2. With the carriage vertical, lower the carriage so that the forks are on the ground.
There should be no load on the load arm.
3. Unbolt the cover plate over the load arm on the opposite side of the carriage from the end where installing the DH (Drywall Handler) assembly. Slide the load arm out of the carriage allowing enough room to slide the DH assembly over the load arm.
4. Slide the load arm back into the carriage slot and reattach the cover plate.
Repeat Step 3 for the opposite side.
5. To deploy the DH assemblies, rotate the DH assembly forward and slide the DH assembly towards the end plate of the carriage.
6. To engage the load arm float stop, hold the stop so that it goes into the slot in the end plate while hooking the DH assembly slot over the carriage end plate
(RHS — view shown in Figure 4-47)
7. To allow the load arm to float:
• Rotate the float stop towards the front of the carriage while hooking the DH assembly slot over the carriage end plate.
• Turn in the lower wing screw. If aligned properly, the wing screw will engage the catch plate and the float stop (when in use).
8. To place the fork on top of the DH assembly:
• Rotate or tilt the carriage as far forward as the tilt cylinder will allow.
• Lift the tip of the fork if necessary and slide the fork outward until it rests above the DH assembly.
9. To stow the DH assemblies:
• Rotate or tilt the carriage as far forward as the tilt cylinder will allow.
• Lift the tip of the fork if necessary and slide the fork in toward the center of the carriage. Loosen the lower wing screw so that it disengages the catch plate and the float stop (when in use).
• Rotate the DH assembly forward to disengage slot from the carriage end plate.
Slide the DH assembly towards the center of the carriage so that it can be rotated behind the carriage. Slide the DH assembly towards the end plate so that the slot hooks over the carriage end plate.
VR-642C 4-45
SECTION 4 OPERATING INSTRUCTIONS
10. To allow the load arm to float:
• Rotate the float stop towards the front of the carriage end plate. Turn in the upper wing screw. If aligned properly, the wing screw will engage the catch plate and the float stop (when in use).
• If installed properly, the catch plate should prevent the DH assembly from sliding off of the carriage end plate when the carriage is tilted backwards.
Figure 4-47
2
1
5
4
3
2
6
1
4-46
4
5
2
3
6
ITEM
1
DESCRIPTION
Wing Screw M12 x 1.75 x 60mm (Qty 4)
NOTE: Apply Never Seize before installing.
Left Hand Fork Rest (Right Hand Similar)
Left Hand Plate Catch (Right Hand Similar)
Left Hand Float Stop (Right HandSimilar)
Retaining Ring
Wing Nut (Qty 2)
M12 x 1.75 x 60mm
VR-642C
OPERATING INSTRUCTIONS SECTION 4
The Side Tilt Carriage allows carriage to tilt to either side. The carriage mounts and connects as shown in Figure 4-48.
Figure 4-48
VR-642C
4
5
2
3
6
7
ITEM
1
DESCRIPTION
S/T QA Carriage (1219 mm [48 in.], 1524 mm [60 in.], or 1829 mm [72 in.])
Not Used with VR series
Adapter (Qty 2)
Coupler (Quick Disconnect)
Nipple (Quick Disconnect)
Dust Cap (used with item 4)
Dust Cap (used with item 5)
4-47
SECTION 4 OPERATING INSTRUCTIONS
The Swing Carriage allows carriage to swivel to either side. The carriage mounts and connects as shown in Figure 4-49.
Figure 4-49
4-48
ITEM
7
8
5
6
3
4
1
2
9
10
11
12
DESCRIPTION
Swing Carriage Assembly
Load Arm
Adapter
Coupler (Quick Disconnect)
Nipple (Quick Disconnect)
Dust Cap (used with item 4)
Dust Cap (used with item 5)
Hex Head Cap Screw
Lockwasher
Plate
Load Chart / VR Attachment Chart
Metal Tack
VR-642C
MAINTENANCE INSTRUCTIONS
SECTION 5
!
WARNING
Serious Personal Injury
Unexpected machine motion or moving parts can cut or crush. Apply the parking brake and shut down the engine before working on the machine.
Failure to adhere to this warning could result in serious personal injury including death.
!
WARNING
Serious Personal Injury
Improper maintenance can be hazardous. Read and understand Section
1, SAFETY before you perform any maintenance, service or repairs.
Failure to adhere to this warning could result in serious personal injury including death.
To prevent minor irregularities from developing into serious conditions, several other services or checks are recommended for the same intervals as the periodic lubrication. The purpose of these services or checks is to ensure the uninterrupted and safe operation of the unit by revealing the need for adjustment caused by normal wear.
Prior to conducting any maintenance work, ensure that the following instructions are observed:
1. The machine should be parked on firm level ground.
2. Ensure engine is shut down and allowed to cool.
3. Disconnect battery and cover exposed terminals before working on the machine's electrical system.
4. Stop engine and allow hydraulic oil pressures to fall before working on the hydraulic hose installations.
5. The tires are chocked to prevent machine movement.
VR-642C 5-1
SECTION 5 MAINTENANCE INSTRUCTIONS
6. Thoroughly wash all fittings, caps, plugs, etc. with nonflammable, nontoxic cleaning solution before servicing, to prevent dirt from entering while performing the service.
Handling Fluids and Oil, Fuel Filters
1. When draining fluids, ensure that adequate sealable containers are available and that every care is taken to prevent spillage.
2. Always ensure waste fluids are disposed of in an environmentally safe manner.
3. Always ensure that used filters are stored in secure containers and disposed of in an environmentally safe manner.
5-2 VR-642C
MAINTENANCE INSTRUCTIONS SECTION 5
The maintenance chart in this section shows those items that require regular service and the interval at which service should be performed. A regular service program should be geared to the items listed under each interval. These intervals are based on average operating conditions. In the event of extremely severe, dusty or wet operating condition, more frequent maintenance than specified may be necessary.
Table 5-1 : Maintenance Schedule
Function Specification Page
Powershift Transmission Oil Filter
INITIAL MAINTENANCE
Wheel Nut Tightness
Tighten Loose Bolted Connections
599 N-m (442 lb.-ft.)
10 HOUR OR DAILY MAINTENANCE
Check Engine Oil Level
Check Coolant Level, Radiator, and Hoses
Check Transmission Fluid Level
Check Air Cleaner Connections and Ducts for Leaks
Check Air Cleaner Restriction
Cleaning and Replacing the Air Cleaner Element
Air Cleaner Vacuator Valve
Check Hydraulic Oil Level
Fuel/Water Separator
Fill Fuel Tank
Check Park Brake
Check Tire Pressure and Condition
Check Seat Belt and Mounting Hardware
VR-642C 5-3
5-4
SECTION 5 MAINTENANCE INSTRUCTIONS
Function Specification
50 HOUR OR WEEKLY MAINTENANCE
Page
Grease Chain Sheave Bearings
Check Lug Nut Torque
Check Oil Level in Axle Differential Planetary Wheel
Ends
Check Oil Level in Axle Differentials
Grease Axle Pivot Bearings
Grease Axle King Pins
Grease Fork Pins
Grease Frame Level Pivot Bushings and Stabilizer
Pivot Bushings
MPG-EP 2 grease
599 N-m (442 lb.-ft.)
MPG-EP 2 grease
MPG-EP 2 grease
MPG-EP 2 grease
MPG-EP 2 grease
Grease Boom Pivot and Boom Cylinders MPG-EP 2 grease
Clean Heater/A-C Filter
250 HOUR OR QUARTERLY MAINTENANCE
Change Engine Oil and Filter
Change Fuel Filters
Change In Line Filter
Clean Hydraulic Tank Breather
Torque Axle Mounting Bolts
Inspect Chains
Check Boom Wear Pad Clearances
597 N-m (440 lb.-ft.)
Adjust Boom Chains and Hoses
1000 HOUR OR ANNUAL MAINTENANCE
Change Hydraulic Oil Filter
Change Hydraulic Oil and Clean Suction Strainer
Change Axle Differential Oil
Change Axle Planetary Oil
Engine Coolant
Change Transmission Oil
Change Transmission Oil Filter
VR-642C
MAINTENANCE INSTRUCTIONS SECTION 5
Any new equipment requires an initial modification of the maintenance schedule to properly break in the various systems and component units. Perform the onetime initial break-in maintenance tasks below IN ADDITION TO the periodic maintenance tasks described in the following sections. After each initial break-in maintenance task has been performed, the regular service intervals should be followed.
Powershift Transmission Oil Filter
Change the transmission oil filter (1, Figure 5-1) after the first 50 hours of operation and again after the first 100 hours on a new or rebuilt transmission. For the procedure, refer to
1000
HOUR OR ANNUAL MAINTENANCE.
Figure 5-1
VR-642C 5-5
5-6
SECTION 5 MAINTENANCE INSTRUCTIONS
Wheel Nut Tightness
Tighten the wheel nuts (1, Figure 5-2) every ten hours of operation and every ten hours of operation after any wheel has been removed and reinstalled. After the check has been made approximately eight or more times, it will be evident that they have seated and will not require further checks. For the procedures, refer to
50 HOUR OR WEEKLY MAINTENANCE.
Figure 5-2
Tighten Loose Bolted Connections
If any fasteners are found to be loose during daily inspections, ensure that they are properly tightened. Refer to Section 9 - Torque Specifications for required torque against bolt sizes and grades.
Always replace self-locking nuts if they have been loosened.
VR-642C
MAINTENANCE INSTRUCTIONS
Check Engine Oil Level
1. Park the machine on a stable level surface and shut down the engine.
2. Release latch (1, Figure 5-3) and slide the engine cover (2) to the right.
Figure 5-3
SECTION 5
3. Wait approximately 15 minutes after the engine has been shut off. Pull out dip stick (1, Figure 5-4) and wipe it off with a clean, dry, lint-free cloth; then, place the dip stick back in the hole until it stops.
Figure 5-4
VR-642C 5-7
SECTION 5 MAINTENANCE INSTRUCTIONS
4. Pull the dipstick (1, Figure 5-4) out again and check the oil level on the dipstick.
The oil level must be between the Full mark and Low mark. If low, add oil through the fill area (2). Refer to Section 8 - Fuel and Lubricant Specifications.
Check Coolant Level, Radiator, and Hoses
!
WARNING
Serious Personal Injury
Injury can occur when removing the radiator cap. Steam or fluid escaping from the radiator can burn. Inhibitor contains alkali. Avoid contact with skin and eyes.
Always shut down the engine and allow it to cool down before removing the radiator cap. Remove the cap slowly to relieve pressure. Avoid contact with steam or escaping fluid.
Failure to adhere to this warning could result in serious personal injury including death.
1. Check coolant level by removing radiator cap (1, Figure 5-5). The coolant level should be within 38 mm (1.5 in.) of the bottom of the cap when the cap is installed. If coolant level is low, add coolant to the correct level.
Figure 5-5
5-8
2. Check radiator fins and clean as necessary using compressed air or water.
3. Check radiator hoses for leaks or damage.
VR-642C
MAINTENANCE INSTRUCTIONS SECTION 5
Check Transmission Fluid Level
The transmission oil level must be checked daily and be maintained to the FULL mark on the dipstick. To check the transmission oil, the engine must be idling and the transmission must be at operating temperature.
!
WARNING
Serious Personal Injury
Unexpected machine motion or moving parts can cut or crush.
Before checking the transmission oil level:
•
Place the Direction Control Lever in Neutral.
•
Apply the Park Brake.
Failure to adhere to this warning could result in serious personal injury including death.
1. Position the machine on a firm level surface, place directional control lever in
Neutral, and apply the park brake.
2. Start the engine and allow the transmission to reach normal operating temperature, between 82 – 93° C (180 – 240° F).
3. Release latch (1, Figure 5-3) and slide the engine cover (2) all the way to the right.
4. Pull out dipstick (1, Figure 5-6) and wipe with a clean, dry, lint-free cloth. Fully insert the dipstick back into the tube and then pull it out and check the oil level.
Figure 5-6
VR-642C 5-9
SECTION 5 MAINTENANCE INSTRUCTIONS
5. If transmission oil level is low, add recommended transmission oil through the dipstick tube to bring level to “FULL” mark on the dipstick. Refer to Section 8 -
Fuel and Lubricant Specifications.
6. Place the dipstick in the tube; then close and latch the engine cover.
Check Air Cleaner Connections and Ducts for Leaks
Ensure that all connections between the air cleaner and engine are tight and sealed.
Check Air Cleaner Restriction
Maintenance of the air cleaner is due when the red band shows on the restriction indicator (1,
Figure 5-7). After servicing, press the indicator to reset it.
Figure 5-7
5-10
Equipment Damage.
Raw, unfiltered air can cause engine damage.
Never service the air cleaner while the engine is running.
NOTE
Dust that gets past the air cleaner can often be detected by looking for dust streaks on the air transfer tubing or just inside the intake manifold inlet.
VR-642C
MAINTENANCE INSTRUCTIONS SECTION 5
Cleaning and Replacing the Air Cleaner Element
The VR-642C Telescopic Material Handler uses a two-stage air filter system. This system consists of a primary filter element and a secondary safety element.
The primary element may be replaced or it may be cleaned. The safety element cannot be cleaned and must be replaced only.
NOTE
For maximum engine protection, replace the safety element after every third cleaning of the primary element or annually.
1. Pull outward on latch (1, Figure 5-8), then rotate dust cover (2) counterclockwise and pull outward to remove.
Figure 5-8
2. Remove the primary air cleaner element (1, Figure 5-9).
Figure 5-9
VR-642C 5-11
5-12
SECTION 5 MAINTENANCE INSTRUCTIONS
3. Remove safety element (1, Figure 5-10) and clean the inside of the housing (2) and dust cover (2, Figure 5-8) with a damp cloth.
Figure 5-10
4. Clean the element as follows:
• To dry clean the element (Figure 5-11), carefully direct compressed air, not to exceed 500 kPa (73 psi), at an angle to the inside surface of the element.
Figure 5-11
VR-642C
MAINTENANCE INSTRUCTIONS SECTION 5
•
To wet clean the element (Figure 5-12), use lukewarm water mixed with a
commercially available detergent. After cleaning, the element must be thoroughly dried before using.
Figure 5-12
NOTE
The element should be replaced after it has been cleaned six times or annually, whichever comes first.
5. Examine the new or newly cleaned element (1, Figure 5-9), for torn or damaged pleats, bent end covers or liners, or damaged gaskets. Replace as necessary.
6. Replace the safety element if:
• Examination reveals tears or perforations in the safety element.
• The primary element has been replaced three times or element has been in service one year.
7. Install the safety element (1, Figure 5-13) into the housing.
Figure 5-13
VR-642C 5-13
SECTION 5 MAINTENANCE INSTRUCTIONS
8. Carefully install the cleaned or replacement primary element (1, Figure 5-14).
Figure 5-14
9. Apply a light coat of petroleum jelly to the raised ridge (2, Figure 5-14) on the face of the primary element (1).
10. Align the cover (1, Figure 5-15), rotate clockwise to align yellow tab (2) and push tab to lock cover.
Figure 5-15
5-14
Air Cleaner Vacuator Valve
Check the air cleaner vacuator valve (3, Figure 5-15) to see that it is clean and that the rubber is not cracked.
VR-642C
MAINTENANCE INSTRUCTIONS SECTION 5
Hydraulic Oil Level
Check the hydraulic tank sight gauge (1, Figure 5-15) and add fresh clean hydraulic oil at (2) as required. Refer to Section 8 - Fuel and Lubricant Specifications.
Figure 5-16
Fuel/Water Separator
!
WARNING
Serious Personal Injury
Fuel is flammable. May cause serious injury or death.
Shut down engine, extinguish all open flames, and do not smoke while draining fuel/water separator.
Always wipe up spilled fuel.
Failure to adhere to this warning could result in serious personal injury including death.
VR-642C 5-15
5-16
SECTION 5 MAINTENANCE INSTRUCTIONS
Drain water from fuel/water separator (1, Figure 5-17) as follows:
Figure 5-17
1. Open drain cock (2, Figure 5-17) and allow approximately one cup of fuel and any collected water and sediment to drain into a container.
2. Close the drain and dispose of the collected liquid in an environmentally safe manner.
Fill Fuel Tank
NOTICE
Do not allow fuel tank to become completely empty.
If tank is allowed to empty completely, the entire fuel system will require bleeding.
1. Check fuel gauge (1, Figure 5-18). Be sure fuel tank is full at the end of the shift to prevent condensation.
Figure 5-18
VR-642C
MAINTENANCE INSTRUCTIONS SECTION 5
!
WARNING
Serious Personal Injury
Fuel is flammable. May cause serious injury or death.
Shut down engine, extinguish all open flames, and do not smoke while draining fuel/water separator.
Always wipe up spilled fuel.
Failure to adhere to this warning could result in serious personal injury including death.
2. Add fuel at filler (1, Figure 5-19) as required. Refer to Section 8 - Fuel and
Lubricant Specifications. Always fill tank at the end of the shift to prevent condensation from forming.
Figure 5-19
Check Park Brake
Check Park Brake operation every 10 hours or daily. See Park Brake Test Procedure in
Section 4.
VR-642C 5-17
SECTION 5
Check Tire Pressure and Condition
MAINTENANCE INSTRUCTIONS
!
WARNING
Serious Personal Injury
Air pressure in tires can cause tire and wheel parts to explode and cause serious injury or death. Tires must be removed and air pressure added in a safety cage if the air pressure is less than 80 percent of the correct air pressure.
If a tire must be removed for repair, remove the air pressure from the tire before the wheel is removed from the Telescopic Material Handler.
When air pressure is added to tires, use equipment with a gauge or pressure regulator and a clip-on chuck. Make sure the hose is long enough so that the person adding air pressure can stand to the side and not in the path of the wheel parts in case of an explosion.
Failure to adhere to this warning could result in serious personal injury including death.
Tire air pressure that must be maintained is found on the tire inflation decal (1, Figure 5-20).
Check the air pressure with a gauge when the tires are cold. If it is necessary to add air pressure to a tire that is warm, check one of the other tires and add air to the tire that has low air pressure so that the air pressures are equal. The air pressure of a warm tire must always be equal to or greater than the air pressure specified for cold tire.
Figure 5-20
5-18
Check the tires for damage. Check the tread and remove any objects that will cause damage.
Check for bent or damaged rims. Check for loose or missing hardware. Remove any wire, strapping, or other material that may have wrapped around the axle.
VR-642C
MAINTENANCE INSTRUCTIONS SECTION 5
Check Seat Belt and Mounting Hardware
CHECK the seat belt for wear or damage. Inspect belt hardware and fabric. Replace if hardware is damaged or if strap is nicked, frayed or loose stitching is found. Check that mounting hardware is tight.
Seat belt assemblies should be replaced every three years, regardless of appearance. Seat belt strength degrades over time and use due to exposure to weather, UV (ultraviolet radiation) and abrasives (dirt).
Grease Chain Sheave Bearings
There are two chain bearing sheaves that require lubrication at this interval. Refer to Section
8 - Fuel and Lubricant Specifications for type of grease which is to be used.
1. Completely retract the boom and place it in the lowered position.
2. Shut down the engine and apply the parking brake.
Figure 5-21
3. Remove boom cowl (1, Figure 5-21) to access retract chain bearing sheave grease fitting (1, Figure 5-22).
VR-642C 5-19
5-20
SECTION 5 MAINTENANCE INSTRUCTIONS
4. Apply four shots of MPG-EP 2 grease to the retract chain sheave fittings (1,
Figure 5-22).
Figure 5-22
5. Replace boom cowl (1, Figure 5-21).
!
WARNING
Serious Personal Injury
Boom access covers are designed to protect personnel from serious injury and to prevent contamination of internal boom parts. Be sure the variable reach material handler power is shutdown before removing covers and working inside of the boom. Never place fingers or hands in boom access holes while the material handler is operating. Always replace covers after maintenance or service work is completed.
Failure to adhere to this warning could result in serious personal injury including death.
6. Remove access cover on boom (1, Figure 5-23) from the left side of the boom.
Figure 5-23
VR-642C
MAINTENANCE INSTRUCTIONS
7. Apply four shots of MPG-EP2 grease to fitting (1, Figure 5-24) on the extend chain sheave bearing.
Figure 5-24
SECTION 5
8. Install boom access cover.
Check Lug Nut Torque
Make sure the wheel nuts are tight. Tighten the wheel nuts to a torque of 599 N•m (442 lb.-ft.) using a cross pattern as shown in Figure 5-25. When the wheels are removed and installed again, check the nuts after eight hours of operation. When the nuts stay tight after an eighthour check, the interval for checking with a torque wrench can be extended to 250 hours.
Figure 5-25
VR-642C 5-21
SECTION 5 MAINTENANCE INSTRUCTIONS
Check Oil Level in Axle Differential Planetary Wheel Ends
!
WARNING
Serious Personal Injury.
Hot oil or components can burn. Oil must be at normal operating temperature when draining. Avoid contact with hot oil or components
Do not allow oil to drain into ground. Dispose of properly.
Failure to adhere to this warning could result in serious personal injury.
Each axle is equipped with two independent planetary assemblies requiring gear oil lubricant.
To check the level of this oil follow the steps listed below.
1. Park the machine on a firm level surface with planetary wheel end plug (1,
Figure 5-26) positioned at the three or nine o’clock position (2). Shut down the machine, apply parking brake and allow it to sit for a minimum of two minutes.
Figure 5-26
5-22
2. Wipe the fill plug (1) clean and then remove.
3. Check oil level which should be to the bottom of the fill hole. If required add oil as needed. Refer to Section 8 for the correct lubricant.
4. Replace plug and repeat step procedure for the remaining three wheel end planetary units.
VR-642C
MAINTENANCE INSTRUCTIONS SECTION 5
Check Oil Level In Axle Differentials
Each axle assembly requires gear lubricant independent of the planetary assemblies. To check the level of this oil follow the steps listed below.
1. Park the machine on a firm level surface shut down the machine, apply parking brake and allow it to sit for a minimum of two minutes.
Figure 5-27
2. Wipe the fill plug (1, Figure 5-27/Figure 5-28), clean, and then remove.
Figure 5-28
3. Check oil level which should be to the bottom of the fill hole. If required add oil as needed. Refer to Section Five for the correct lubricant.
4. Replace plug and repeat step procedure for the remaining axle.
VR-642C 5-23
SECTION 5 MAINTENANCE INSTRUCTIONS
Grease Axle Pivot Bearings
Each axle is equipped with two integral pivot assemblies which attach the axle to the frame.
Each of the four pivot assemblies requires independent lubrication. Remote grease fittings (1,
Figure 5-29) are provided for pivot bearing lubrication.
To lubricate these assemblies follow the steps below:
Figure 5-29
1. Wipe dirt and grease from each remote grease fitting (1, Figure 5-29).
2. Apply 4 shots of MPG-EP2 grease to each fitting (one on top, one on bottom).
Grease Axle King Pins
Each axle is equipped with two king pins (1, Figure 5-30). Each king pin is equipped with an upper and a lower grease fitting (2). Follow the steps below to lubricate the kin pins.
Figure 5-30
5-24
1. Wipe each fitting clean.
2. Apply four (4) shots of MPG-EP2 grease to each fitting (2, Figure 5-30).
VR-642C
MAINTENANCE INSTRUCTIONS SECTION 5
Grease Fork Pins
Check the condition of the fork pins (1, Figure 5-31). If required, lubricate the fork pins with
MPG-EP2 grease.
Figure 5-31
Grease Frame Level Pivot Bushings and Stabilizer Pivot Bushings
Apply MPG-EP2 grease to the grease fittings (1, Figure 5-32) at each end of the frame level cylinder.
Figure 5-32
VR-642C 5-25
5-26
SECTION 5 MAINTENANCE INSTRUCTIONS
Grease Boom Pivot and Boom Cylinders
Apply MPG-EP2 grease to the lube points shown in Figure 5-33.
Figure 5-33
Clean Heater / A-C Filter
Figure 5-34
Filter element (1, Figure 5-34) should be removed and cleaned in soapy water on a regular basis. Dry and replace behind grid.
VR-642C
MAINTENANCE INSTRUCTIONS
Change Engine Oil and Filter
SECTION 5
!
WARNING
Serious Personal Injury.
Hot oil or components can burn. Oil must be at normal operating temperature when draining. Avoid contact with hot oil or components
Do not allow oil to drain into ground. Dispose of properly.
Failure to adhere to this warning could result in serious personal injury.
1. Park the machine on stable level surface, apply the park brake and shut off the engine.
2. Ensure that the engine oil is at normal operating temperature.
NOTE
At normal operating temperature, the engine water temperature gauge will register between 60 and 100° C (140 and 212° F).
3. Place a container with the capacity of at least 24 liters (25 quarts) under the drain point.
4. Remove drain plug (1, Figure 5-35). Dispose of used oil in an environmentally safe manner.
Figure 5-35
VR-642C 5-27
SECTION 5 MAINTENANCE INSTRUCTIONS
5. Clean the area around the head of the oil filter (1, Figure 5-36). Use a 90-95 mm filter wrench to remove the filter.
Figure 5-36
6. Clean the filter head seal area and be sure that no gasket material remains from the old filter.
7. Apply a light coat of oil to the filter gasket sealing surface before installation.
Refer to Section 8-Fuel and Lubrication Specifications for correct lube oil.
8. Install the filter following the manufacturer’s recommendations. Be careful, mechanical overtightening may distort threads or damage the gasket.
9. Clean the drain plug (1, Figure 5-35) and install. Tighten to a torque of 81 N•m
(60 lb.-ft.).
10. Fill the crankcase through the fill area (1, Figure 5-37) with engine oil to the full mark on the dipstick (2, Figure 5-37). Refer to Section 8 - Fuel and Lubrication
Specifications for correct lube oil.
Figure 5-37
5-28
11. Start the engine. Check the engine oil pressure and for any leaks.
VR-642C
MAINTENANCE INSTRUCTIONS SECTION 5
Change Fuel Filters
1. Clean area around head of fuel filter (3, Figure 5-37) and place a container under the filter to collect any escaping fuel.
2. Remove the filter using a 90-95 mm filter wrench. Discard used filter and fuel in accordance with local guidelines.
3. Be sure that seal area of filter head is completely clean.
4. Lubricate the O-ring seal on new filter with clean oil, and fill the filter with clean fuel.
5. Install the new filter and tighten as specified by the manufacturer.
NOTE
If the fuel filter is changed using these instructions, manual bleeding of the fuel system should be unnecessary. If the fuel system requires bleeding, refer to the engine manufacturer’s manual.
Change In Line Filter
The in-line filter (1, Figure 5-38) must also be changed at this interval.
Figure 5-38
1. Disconnect the fuel line from each side of the in-line filter (1, Figure 5-38).
Discard the used filter in accordance with local guidelines.
2. Install the new in-line filter by reconnecting it in the fuel line. Be sure filter is installed with flow direction arrow pointing toward the fuel pump.
3. Check for leaks.
VR-642C 5-29
SECTION 5 MAINTENANCE INSTRUCTIONS
Clean Hydraulic Tank Breather
1. Clean area around hydraulic breather (1, Figure 5-39). Do not allow dirt to enter the hydraulic tank.
Figure 5-39
2. Remove the breather and clean with solvent. Blow dry with compressed air.
3. Place the cleaned breather on the tank.
Torque Axle Mounting Bolts
The axles are secured to the frame by an axle pivot assembly on each side of the axle. The pivot assemblies are bolted to the machine frame with axle mounting bolts (1, Figure 5-40).
Figure 5-40
5-30
1. Torque front axle mounting bolts to 597 N•m (440 lb.-ft.).
2. Repeat procedure for rear axle.
VR-642C
MAINTENANCE INSTRUCTIONS
Inspect Chains
SECTION 5
!
WARNING
Serious Personal Injury.
Lower the boom completely. Never allow anyone under the raised forks.
Do not place any part of your body in or through the lift or extend mechanism unless all parts of the boom are completely lowered and the engine is shut down.
Before making any repairs, use blocks and chains on the boom sections and forks to ensure that they cannot move. Make sure the moveable parts are attached to non-moveable parts.
Failure to adhere to this warning could result in serious personal injury.
1. Fully retract and lower the boom. Apply the park brake and shut down the engine.
2. Remove boom cowl (1, Figure 5-41) and boom front cover (1, Figure 5-42).
Figure 5-41
Figure 5-42
VR-642C 5-31
5-32
SECTION 5 MAINTENANCE INSTRUCTIONS
3. Inspect the retract chain (1, Figure 5-43) inside the rear of the boom and the extend chain (1, Figure 5-44) inside the front of the boom.
Figure 5-43
Figure 5-44
NOTE
The chains should appear well lubricated, with no signs of wear or rust.
4. If chain appears dry, rusty, or worn, the chains must be removed for a complete inspection and lubrication. Refer to service manual. When the chains are well lubricated, reinstall the cowl (1, Figure 5-41) and the front cover (1, Figure 5-
42).
VR-642C
MAINTENANCE INSTRUCTIONS SECTION 5
Check Boom Wear Pad Clearances
Wear pads (1, Figure 5-45) support the boom components as the boom is extended and retracted. The wear pads must maintain clearance between the contact surface of the pad and the adjacent sliding surface. This clearance ranges between 0.79 – 1.58 mm. (0.031 – 0.062 in.) TOTAL for both sides of the boom. When clearances exceed this amount shims need to be added or the pads replaced.
The wear pads are chamfered on the corner of the wear surface. This is to be used as a wear indicator. When the chamfer is no longer visible the pads must be replaced. Additional wear will allow interference with inserts in the pads.
Lubrication of these pads require application of grease on the boom surfaces which come in contact with the pads.
Figure 5-45
To check the pad to contact surface clearances perform the following steps.
1. Extend the boom and place the forks on a level surface.
2. Shutdown the engine and apply the parking brake.
3. Measure the clearance between the bottom surfaces of the boom and wear pads at each section. Refer to 1, Figure 5-46. Clearance should range between
0.79 – 1.58 mm (0.031 - .062 in.). When clearances exceed this amount shims need to be added or the pads replaced.
Figure 5-46
VR-642C 5-33
SECTION 5 MAINTENANCE INSTRUCTIONS
4. Start the machine and raise the boom so that the forks are not touching the ground and no upward force is being applied to the boom.
5. Shut down the engine and apply the parking brake.
6. Measure the clearance between each side wear pad and the adjacent boom section as follows: a. Measure the clearance between the side of the boom and the lower wear shoe (1, Figure 5-47).
Figure 5-47
b. Without moving the boom measure the clearance between the side of the boom and the lower wear shoe (1, Figure 5-48). Clearance should range between 0.79 – 1.58 mm ( 0.031 – 0.062 in.). When clearances exceed this amount, shims need to be added or the pads replaced.
Figure 5-48
5-34 c. Repeat above steps for pad locations 2, 3, & 4.
VR-642C
MAINTENANCE INSTRUCTIONS SECTION 5
!
WARNING
Severe Personal Injury.
Boom access covers are designed to protect personnel from serious injury and to prevent contamination of internal boom parts. Be sure the telescopic material handler power is shut down before removing covers and working inside of the boom. Never place fingers or hands in boom access holes while the material handler is operating. Always replace covers after work is completed.
Failure to adhere to this warning could result in serious personal injury.
7. Remove boom cowl (1, Figure 5-41) so that rear of the boom sections are visible. Start the engine and retract the boom far enough to see the upper and side wear pads (1 & 2, Figure 5-49) on each boom.
Figure 5-49
8. Lower the boom until the forks are resting on the ground and an upward force is being applied to the boom sections. Shutdown the engine and apply the parking brake.
9. Measure the wear shoe clearance at the top of each boom section (1, Figure
5-49).
Clearance should range between 0.79 – 1.58 mm (0.031 – 0.062 in.). When clearances exceed this amount shims need to be added or the pads replaced.
10. Start the machine and raise the boom high enough to lift the forks off of the ground. Shutdown the engine and apply the parking brake.
11. Measure the side wear shoe clearances at (2, Figure 5-49). The TOTAL clearance should range between 0.79 – 1.58 mm ( 0.031 – 0.062 in.). When the
TOTAL of the clearances exceed this amount shims need to be added or the pads replaced.
VR-642C 5-35
5-36
SECTION 5 MAINTENANCE INSTRUCTIONS
Adjust Boom Chains and Hoses
Extend and retract boom chains are to be checked and adjusted, if necessary, at the 250 hour maintenance interval. Adjustment is required when the chains are making noise as banging on the interior boom parts or the gap identified below is less than the minimum acceptable amount. Proper adjustment of the chains at this interval minimizes the risk of chain failure which could cause extensive damage to other boom components and require extensive labor hours to repair.
The following procedure should be followed to insure correct chain adjustment.
1. Park the machine on level ground, fully retract the boom, lower the boom, set barking brake and shut off engine.
2. Measure the gap (1, Figure 5-50). The minimum acceptable gap is 19 mm (0.75 in.). If the gap is the minimum or more, no adjustment is required.
Figure 5-50
If the measured gap (1, Figure 5-50) is less than 19 mm (0.75 in.), adjust the chains as follows:
1. Start the engine, raise the boom to clear the ground, and extend the boom approximately 300 mm (12 in.).
2. Shut down the engine.
VR-642C
MAINTENANCE INSTRUCTIONS
3. Loosen the boom retract adjustment nut (1, Figure 5-51 & Figure 5-52). The length required to have an acceptable gap is plus 3 mm (0.125 in.).
Figure 5-51
SECTION 5
Figure 5-52
4. Start the engine and fully retract the boom.
5. Stop the engine.
VR-642C 5-37
5-38
SECTION 5 MAINTENANCE INSTRUCTIONS
6. Tighten the extend chain nut (1, Figure 5-53) until the gap (1, Figure 5-50) is a minimum of 19 mm (0.75 in.).
Figure 5-53
7. Loosen the extend chain nut (1, Figure 5-53) slightly to level the extend chain anchor and remove any twist in the chain. Nut must be fully engaged.
8. Torque the boom retract adjustment nut (1, Figure 5-51 & Figure 5-52) to 54
N•m (40 lb-ft.).
9. Loosen the retract chain nut (1, Figure 5-51 & Figure 5-52) slightly to level the extend chain anchor and remove any twist in the chain. Nut must be fully engaged.
10. Start the engine, extend and retract the boom several times.
11. Stop the engine and measure the gap. If it is not within range, repeat procedure.
12. Install the rear boom cover.
VR-642C
MAINTENANCE INSTRUCTIONS
SECTION 5
Change Hydraulic Oil Filter
1. Park the machine on a firm level surface, apply the park brake, and shut down the engine.
2. Remove deck plate (1, Figure 5-54).
Figure 5-54
3. Remove and discard the old hydraulic oil filter (1, Figure 5-55). Be sure all traces of the old filter gasket are removed from the filter head. Discard old filter in accordance with local procedures.
Figure 5-55
4. Apply a light coating of clean oil to the gasket on the new filter.
5. Install the new filter and turn until the gasket contacts the filter head. Tighten an additional 1/2 to 3/4 turn by hand to compress the gasket.
VR-642C 5-39
5-40
SECTION 5
Change Hydraulic Oil and Clean Suction Strainer
MAINTENANCE INSTRUCTIONS
NOTICE
Dirt in the hydraulic system will lead to premature component failure.
A clean, contaminant-free system is extremely important to the machine's proper function.
Take extra care when working around or on the hydraulic system to ensure its complete cleanliness.
1. Completely retract the boom and place it in the lowered the position, so that as much hydraulic oil as possible is returned to the hydraulic tank. Shut down the engine and apply the park brake.
2. Remove hydraulic tank drain plug (1, Figure 5-56) and drain the hydraulic oil into a container capable of holding approximately 190 liters (50 gallons).
Dispose of used oil in accordance with local regulations.
Figure 5-56
3. Disconnect hydraulic hose (1, Figure 5-57) and remove hydraulic suction strainer (2) by unthreading it from the tank.
Figure 5-57
VR-642C
MAINTENANCE INSTRUCTIONS
4. Clean the strainer in a solvent, using a stiff, fiber brush. If impurities cannot be removed, replace with a new strainer.
NOTICE
A partially plugged strainer will lead to cavitation, contamination, and a sluggish operating machine.
Ensure the strainer is cleaned or replaced.
5. Air-dry the suction strainer from the inside out.
6. Install drain plug (1, Figure 5-56) back into tank.
7. Apply pipe sealant to the new or cleaned strainer (2, Figure 5-57) and screw it back into the manifold pipe inside the tank.
8. Remove the breather (2, Figure 5-58) and fill the tank with clean hydraulic oil from unopened containers. When adding oil, be sure to filter it through a 10 micron filter. Refer to Section 8 - Fuel and Lubrication Instructions for oil details.
Figure 5-58
SECTION 5
9. Install the breather.
10. Run engine and work hydraulic functions. Add additional oil as required.
Change Axle Differential Oil
Each axle assembly requires gear lubricant independent of the planetary assemblies. To change this oil follow the steps listed below.
VR-642C 5-41
SECTION 5 MAINTENANCE INSTRUCTIONS
!
WARNING
Hot oil or components can burn.
Oil must be at normal operating temperature when draining.
Avoid contact with hot oil or components.
Do not allow oil to drain into the ground.
1. Ensure that the axle differential oil is at operating temperature.
2. Park the machine on a firm level surface apply parking brake, shut down the machine, and allow it to sit for two minutes.
3. Clean the areas around the three (3) drain plugs (2, Figure 5-59) and level/fill plug (1).
Figure 5-59
5-42
4. Place a drain pan capable of holding ap-proximately 9.5 liters (10 quarts) under the axle drain plugs (2, Figure 5-59).
5. Remove the level/fill plug (1, Figure 5-59).
6. Remove all three (3) drain plugs (2, Figure 5-59) and drain the oil from the differential. Dispose of used oil in accordance with local regulations.
7. Wipe off the magnetic drain plugs (3) with a clean rag and install it in the axle.
8. Slowly fill the axle with 6.6 liters (7 quarts) of gear oil until oil begins to overflow from the level/fill hole (1, Figure 5-58 & Figure 5-59). Refer to Section 8 - Fuel and Lubrication Instructions for oil details.
9. Clean and replace the level fill plug.
10. Repeat procedure for the second axle.
VR-642C
MAINTENANCE INSTRUCTIONS SECTION 5
Change Axle Planetary Oil
Each axle assembly requires planetary gear lubricant independent of the differential assemblies. To change this oil, follow the steps listed below:
1. Ensure that the axle planetary oil is at operating temperature.
2. Park the machine on a firm level surface with the level/fill/drain plug (1, Figure
5-60) at the (2) 6 o’clock position. Shut down the machine, apply parking brake, and allow it to sit for a minimum of two minutes.
Figure 5-60
3. Clean the area around the (1) plug located at (2).
4. Remove the plug and drain the oil from the axle planetary. Dispose of used oil in accordance with local regulations.
5. Wipe off the magnetic drain plug with a clean rag and install it in the planetary.
6. Reposition the plug to the 3 o’clock or 9 o’clock position (3, Figure 5-60).
7. Slowly fill the planetary with 0.95 liters (1 quart) of gear oil until oil begins to overflow from the level/fill hole (1, Figure 5-60). Refer to Section 8 - Fuel and
Lubrication Instructions for oil details.
8. Clean the level/fill plug (1) and install it in the planetary.
9. Repeat procedure for the remaining three planetaries.
VR-642C 5-43
SECTION 5
Engine Coolant
MAINTENANCE INSTRUCTIONS
!
WARNING
Severe Personal Injury.
Injury can occur when removing the radiator cap.
Steam or fluid escaping from the radiator can burn. Inhibitor contains alkali, avoid contact with skin and eyes.
Always shut down the engine and allow to cool down before removing the radiator cap. Remove cap slowly to relieve pressure. Avoid contact with steam or escaping fluid.
Failure to adhere to this warning could result in serious personal injury.
The coolant system should be drained and flushed out at least once a year, preferably twice a year. Any effective, commercial flushing agent may be used. Unless the coolant has a corrosion preventive in it, rust and scale will eventually clog up the system.
NOTE
Remove the radiator cap (1,
Figure 5-61
) when draining the system to ensure proper draining.
Figure 5-61
5-44
1. Open the radiator cap (1, Figure 5-61) to ensure proper draining.
VR-642C
MAINTENANCE INSTRUCTIONS
2. Place a container capable of holding 24 liters (25 quarts) under the radiator petcock (1, Figure 5-62). Open the petcock and allow radiator and coolant bottle to drain.
Figure 5-62
SECTION 5
3. Place a container under the engine block coolant drain plug (2, Figure 5-63) located on the bottom of the engine water inlet hose connection point. Remove the plug and drain coolant from the engine.
Figure 5-63
4. Check for damaged hoses and loose or damaged hose clamps. Replace as required. Check radiator for leaks, damage and buildup of dirt. Clean and repair as required.
5. Following the manufacturer’s instructions, flush the system using a good grade commercial radiator cleaning agent.
6. After cleaning and flushing operations are completed, close the petcock (Figure
5-62 & 1, Figure 5-63) replace and tighten the engine block drain plug (2, Figure
5-63).
VR-642C 5-45
5-46
SECTION 5 MAINTENANCE INSTRUCTIONS
NOTICE
To prevent air locks, the system must be filled properly. Air must be vented from coolant passages during the fill operation.
NOTE
A mixture of ethylene glycol antifreeze and water is recommended to refill the radiator. Refer to the engine manual for the manufacturers's recommendation for proper ratio of antifreeze to water mixture. The addition of a separate lubricant and corrosion inhibitor will guard against internal corrosion and freezing.
7. Replace the radiator cap, start the engine and check for leaks.
Change Transmission Oil
1. Run the machine until the transmission oil temperature reaches operating temperature. Normal operating temperature is between 82 and 93° C (180 and
200° F) as registered on the Transmission Oil Temperature Gauge.
2. Locate the machine on a smooth level surface. Apply the parking brake and shut down the engine.
3. Place a container with a capacity of at least 13 liters (14 quarts) under the transmission drain point (1, Figure 5-64).
Figure 5-64
VR-642C
MAINTENANCE INSTRUCTIONS
!
WARNING
Hot oil or components can burn.
Oil must be at normal operating temperature when draining.
Avoid contact with hot oil or components.
Do not allow oil to drain into the ground. Dispose of properly.
4. Remove the drain plug (1, Figure 5-64) and drain the transmission.
5. Remove deck cover (1, Figure 5-65).
Figure 5-65
SECTION 5
6. Fill the transmission with 13 liters (14 quarts) of fresh clean transmission oil
through the dipstick tube (2, Figure 5-66). Refer to Section 8 - Fuel and
Lubrication Specifications.
Figure 5-66
VR-642C 5-47
SECTION 5 MAINTENANCE INSTRUCTIONS
7. Replace the dipstick (1, Figure 5-66).
8. Run the engine until the transmission oil is at operating temperature. With the engine running and the Direction Control Lever in Neutral, pull out the dipstick
(1, Figure 5-66) and check the transmission oil level. Add as required.
Change Transmission Oil Filter
1. Clean the area around the transmission filter (1, Figure 5-67).
Figure 5-67
5-48
2. Remove the used filter and discard in accordance with local guidelines.
3. Apply a light coating of oil to the filter gasket and install it on the transmission.
Hand tighten the filter until it touches the base then tighten an additional 1/2 to
3/4 turn.
4. Install deck plate (1, Figure 5-65).
Whenever the machine will be stored for an extended period of time (up to six months), the following preparations must be made:
1. Ensure that all protective covers are in place and are secure.
2. Change all fluids which may have deteriorated with use. Be sure coolant is in good condition. If it was not added when coolant was last changed, add a corrosion inhibitor and lubricant.
3. Ensure that fuel tank is full and add a fuel stabilizer to the fuel.
4. Apply MPG-EP 2 grease to all wear pad contact surfaces on the boom to prevent rust.
5. Ensure that storage site is not subject to flooding or other natural hazards.
VR-642C
TROUBLESHOOTING
SECTION 6
!
WARNING
When carrying out trouble shooting procedures, it is important to strictly observe the safety precautions and guidelines in Section 1 of this manual.
Improper operation and maintenance is the most frequent cause of machinery failures and problems. In the event of a failure, it is recommended to read through this manual.
If you are unable to determine the cause of the problem or are unable to find a solution when following the troubleshooting chart below, contact your local Ingersoll Rand service office.
The troubleshooting chart is limited to machine control operational problems which will guide the operator to rectifying the cause of the failure.
Figure 6-1 displays the Fuse Chart decal which is located on the back of cover plate (1, Figure
6-2). All the fuses in the Variable Reach Material Handler are located on this fuse panel. Each fuse controls an electrical section of the machine.
Figure 6-1
VR-642C 6-1
6-2
SECTION 6
Figure 6-2
TROUBLESHOOTING
Additional fuses are listed in Table 6-1. The additional fuses are located on the chassis harness located next to the frame.
Table 6-1
F21 7.5 AMP
F22
F23
F24
F25
7.5 AMP
7.5 AMP
10 AMP
10 AMP
ENGINE ECM
BATTERY +
ENGINE ECM
BATTERY +
ENGINE ECM
BATTERY +
ENGINE ECM
(FUEL PUMP)
ENGINE ECM
(FUEL PUMP)
VR-642C
TROUBLESHOOTING
Relays are also included on this machine. They are identified in Table 6-2.
Table 6-2
RELAY CHART
FUNCTION RELAY
NO.
CR1
CR2
CR3
CR4
CR5
CR6
CR7
POWER RELAY
BRAKE TEST
(ALT DROOP)
BRAKE TEST (NEUTRAL)
BRAKE TEST (LATCHING)
BRAKE TEST
(REVERSE LOCKOUT)
(STARTER)
BRAKE TEST
(PRESS SWITCH)
Starter does not rotate
• Fuse F1 defective
• Battery discharged
• Battery cable connections loose or disconnected
• In-line fuse to starter blown
• Starter relay fault
• Ignition Switch defective
• Starter solenoid or starter defective
• Ballast kill switch defective
• Park Brake not switched on
• Transmission shifter lever NOT in
NEUTRAL
SECTION 6
• Check console fuse and replace
• Check battery, charge if necessary
• Clean and tighten terminal connections
• Call for service to correct fault
• Call for service to correct fault
• Call for service to correct fault
• Call for service to correct fault
• Call for service to correct fault
• Turn on Park Brake
• Place shifter in NEUTRAL
VR-642C 6-3
6-4
SECTION 6 TROUBLESHOOTING
Starter does rotate
• Empty Fuel Tank
• Clogged Fuel Filter
• Fuel solenoid at fuel pump defective
• Defective wiring
• Fill fuel tank
• Call for service to clean/replace
• Call for service to test/replace
• Check fuel solenoid with test lamp
• Call for service to correct fault
• Low battery power
• Batteries discharged
• Battery cable connections loose or corroded
• Using too high a viscosity oil in low ambient temps.
• Fuel line blockage due to wax separation in winter
• Incorrect valve clearances
• Loose or badly adjusted throttle cable
• Defective fuel injectors
• Defective turbocharger
• Blocked air cleaner element
• Check battery
• Charge battery, if necessary
• Clean and tighten terminal connections, cover with acid-free grease
• Use appropriate oil grade for the ambient temperature conditions
• Change fuel filters, and bleed fuel system, check for fuel line leaks and loose connection. Always use winter grade fuel in winter
• Call for service to adjust
• Adjust or replace control cable
• Call for specialist service
• Call for specialist service
• Clean or replace element
VR-642C
TROUBLESHOOTING
SECTION 6
• Engine oil level too high
• Blocked air cleaner element
• Low compression due to poor condition of the valve or incorrect valve clearance
• Drain engine oil to correct level on the dip stick
• Clean or replace element
• Call for specialist service
• Excessive dirt on cooling system
• Engine belt broken
• Defective injector nozzle
• Incorrect fuel pump calibration
• Blocked cooling air flow
• Clean the radiator/cooling fins
• Call for service to correct fault
• Call for service to correct fault
• Call for service to correct fault
• Clear blockage
• Low engine oil level
• Defective oil pressure switch
• Leaks from lubrication system
• Fill oil level to dipstick mark
• Check with test lamp.
• Stop engine and check for leaks, and tighten any loose fittings on the system oil lines
• Speed of alternator too low
• Battery discharged or dead
• Not charging due to defective alternator or regulator
• Check belt tensions, change belt if required
• Check battery, charge if necessary.
• Call for service to correct fault
VR-642C 6-5
6-6
SECTION 6 TROUBLESHOOTING
IGNITION, RELAY, LIGHTS RELAY,
FRAME LEVEL, ETHER (OPT), BEACON
(OPT)
• Fuse F1 defective
• Defective wiring/parts
• Check console fuse and replace
• Call for service to correct fault
TRANS, BACKUP ALARM, PARK BRAKE
• Fuse F2 defective
• Defective wiring/parts
• Check console fuse and replace
• Call for service to correct fault
STEER SELECTION, FUEL SOLENOID
• Fuse F3 defective
• Defective wiring/parts
GAUGES, HORN
• Fuse F4 defective
• Defective wiring/parts
ENGINE INDICATOR LAMPS, ECM
SWITCH POWER
• Fuse F5 defective
• Defective wiring/parts
REAR AXLE STABILIZER (RAS)
• Fuse F6 defective
• Defective wiring/parts
POWER PORT
• Fuse F7 defective
• Defective wiring/parts
• Check console fuse and replace
• Call for service to correct fault
• Check console fuse and replace
• Call for service to correct fault
• Check console fuse and replace
• Call for service to correct fault
• Check console fuse and replace
• Call for service to correct fault
• Check console fuse and replace
• Call for service to correct fault
VR-642C
TROUBLESHOOTING
WIPER (REAR)
• Fuse F8 defective
• Defective wiring/parts
WORK LIGHTS
• Fuse F9 defective
• Defective wiring/parts
STABILIZERS
• Fuse F10 defective
• Defective wiring/parts
AUXILIARY HYDRAULICS
• Fuse F11 defective
• Defective wiring/parts
TURN, HAZARD, BRAKE LIGHTS
• Fuse F12 defective
• Defective wiring/parts
BOOM LIGHTS
• Fuse F13 defective
• Defective wiring/parts
WIPER (FRONT)
• Fuse F14 defective
• Defective wiring/parts
WIPER (TOP)
• Fuse F15 defective
• Defective wiring/parts
VR-642C
SECTION 6
• Check console fuse and replace
• Call for service to correct fault
• Check console fuse and replace
• Call for service to correct fault
• Check console fuse and replace
• Call for service to correct fault
• Check console fuse and replace
• Call for service to correct fault
• Check console fuse and replace
• Call for service to correct fault
• Check console fuse and replace
• Call for service to correct fault
• Check console fuse and replace
• Call for service to correct fault
• Check console fuse and replace
• Call for service to correct fault
6-7
6-8
SECTION 6
WASHER, FAN, INTERIOR LIGHT
• Fuse F16 defective
• Defective wiring/parts
HEATER VALVE, AIR CONDITIONING
• Fuse F17 defective
• Defective wiring/parts
BLOWER
• Fuse F18 defective
• Defective wiring/parts
OPEN
• Fuse F19
OPEN
• Fuse F20
ENGINE ECM (BATTERY +)
• Fuse F21 defective
• Defective wiring/parts
ENGINE ECM (BATTERY +)
• Fuse F22 defective
• Defective wiring/parts
ENGINE ECM (BATTERY +)
• Fuse F23 defective
• Defective wiring/parts
TROUBLESHOOTING
• Check console fuse and replace
• Call for service to correct fault
• Check console fuse and replace
• Call for service to correct fault
• Check console fuse and replace
• Call for service to correct fault
• Check console fuse and replace
• Call for service to correct fault
• Check console fuse and replace
• Call for service to correct fault
• Check console fuse and replace
• Call for service to correct fault
VR-642C
TROUBLESHOOTING SECTION 6
ENGINE ECM (FUEL PUMP)
• Fuse F24 defective
• Defective wiring/parts
• Check console fuse and replace
• Call for service to correct fault
ENGINE ECM (FUEL PUMP)
•
•
Fuse F25 defective
Defective wiring/parts
• Check console fuse and replace
• Call for service to correct fault
NOTE
Fuses F21 to F25 (Engine ECM) are located on the chassis harness next to the engine.
The Variable Reach Material Handler is equipped with a weighted ballast box (1, Figure 6-3) mounted to the front of the main frame.
Figure 6-3
VR-642C 6-9
6-10
SECTION 6
Figure 6-4
TROUBLESHOOTING
Ignition Kill Switch (Ballast Removal)
To ensure the machine is not operated without the weight of the ballast box or the optional stabilizers (Figure 6-4) an engine ignition kill switch (1, Figure 6-5) is mounted behind the ballast box . A switch actuator protrudes through the front vertical frame of the handler and is in contact with the ballast box when attached to the frame. Removal of the ballast box without replacement or the addition of the stabilizer assembly allows this actuator to be fully extended thus eliminating power to the machine’s starting circuit.
Figure 6-5
VR-642C
TECHNICAL SPECIFICATIONS
Name of machine
Type of machine
Serial number and product range
Name and address of manufacturer
VR-642C
Vertical Reach Material Handler
Effective with Serial Number 175803
Ingersoll Rand Construction Technologies
Road Development
312 Ingersoll Drive
Shippensburg, Pennsylvania 17257
SECTION 7
VR-642C 7-1
7-2
SECTION 7 TECHNICAL SPECIFICATIONS
VR-642C DESCRIPTION
Overall Length (less forks)
Overall Width
Overall Height
Wheelbase Reach
Drive Axle to Carriage Front
Ground Clearance
Overall Length (w/forks)
Carriage Width Maximum:
Minimum:
Carriage Length
Carriage Height
Drive Axle to Rear
Tread Width
Frame Leveling mm (in.)
> 70° 10° each side
< 70° 4° each side kg (lbs.) Shipping Weight
Turning Radius:
Inside
Outside
Steering Wheel Turns:
Stop to Stop
Travel Speeds:
Range 1
Range 2
Range 3 m (ft.) m (ft.)
3.25 turns km/h (mph) km/h (mph) km/h (mph)
F
G
D
E
H
H
A
B
C
I
J
K
DESIGNATION
406
7390
1490
290
1220
1210
1303
DIMENSION mm in.
6170 243.0
2590
2413
3048
1480
102.0
95.0
120.0
58.0
16.0
291.0
58.5
9.0
48.0
47.8
51.3
2210 (87.0)
10,723 (23,590)
1.96 (6.42)
3.64 (11.94)
1 - 7 (0 - 4)
8 - 13 (5 - 8)
14 - 32 (9 - 20)
VR-642C
TECHNICAL SPECIFICATIONS
VR-642C MACHINE STANDARD EQUIPMENT
ENGINE:
Standard Cummins 4BT3.9 “Elite” Diesel
Cylinders
Capacity
Power @ 2500 RPM
Torque @ 1500 RPM
4 cm
3
(cu. in.) kW (HP)
N-m (lb.-ft.)
3917 (239)
82 (110)
397 (293)
TRANSMISSION:
Type
Range
Make
DRIVE AXLES:
Front & Back
Type
Powershift with Soft Shift
3 speeds forward and reverse
Ingersoll Rand
All Wheel Drive
Planetary Steering
SECTION 7
BRAKES:
Service
Parking Brake
TIRES:
Front
Rear
Ballast
Internal wet disk
Internal - SAHR
13.00 x 24 14PR/G2
13.00 x 24 14PR/G2
Not Required
VR-642C 7-3
7-4
SECTION 7
ELECTRICAL:
Negative Ground
Alternator
Battery
Backup Alarm
12 volts
62 Amps
900 Amps
107 DBM
TECHNICAL SPECIFICATIONS
STEERING:
3 modes
HYDRAULIC SYSTEM:
2-wheel, 4-wheel, or Crab
Pump, Variable displacement piston
129 Lpm @ 241 bar
34 gpm @ 3500 psi
GAUGES:
Oil Pressure
Fuel Level
Transmission Oil Temperature
Water Temperature
Voltmeter
Hourmeter
INDICATORS/ACCESSORIES:
Air Cleaner Restriction
Boom Angle Indicator
Frame Level Indicator
Backup Alarm
Engine Coolant Heater
Horn & Seat Belt
Lockable Engine Hood
Lockable Fuel Cap
Lockable Hydraulic Cap
Park Brake Light
Rear Axle Stabilization Indicator
Rear Wiper / Washer Stabilizers
Engine Service, Check, and Stop/Indicator Lights
VR-642C
FUEL AND LUBRICANT INSTRUCTIONS SECTION 8
Lubrication is an essential part of preventive maintenance, affecting to a great extent the useful life of the unit. Periodic lubrication of the moving parts reduces to a minimum the possibility of mechanical failures.
Different lubricants are needed and some components in the unit require more frequent lubricant than others. Therefore, it is important that the instructions regarding types of frequency of the application be explicitly followed.
The Lubrication Chart that follows in this section shows those items requiring regular service and the interval at which they should be performed. Details concerning fuel, oil and other lubricants follow the lubrication chart. A regular service program should be geared to the items listed under each interval. These intervals are based on average operating conditions. In the event of extremely severe, dusty or wet operating conditions, more frequent lubrication than specified may be necessary.
Specific recommendations of brand and grade of lubricants are not made here due to regional availability, operating conditions, and the continual development of improved products. Where questions arise, refer to the component manufacturer's manual and a reliable supplier.
All oil levels are to be checked with the machine parked on a level surface and while the oil is cold, unless otherwise specified.
On plug type check points, the oil levels are to be at the bottom edge of the check port.
All grease fittings are SAE STANDARD unless otherwise indicated. Grease non-sealed fittings until grease is seen extruding from the fitting. Twenty-eight grams (one ounce) of EP-MPG equals one pump on a standard 0.45 kg (one pound) grease gun.
Over lubrication on non-sealed fittings will not harm the fittings or components, but under lubrication will definitely lead to a shorter lifetime.
Unless otherwise indicated, items not equipped with grease fittings (linkages, pins, levers, etc.) should be lubricated with oil once a week. Motor oil, applied sparingly, will provide the necessary lubrication and help prevent the formation of rust. An anti-seeze compound may be used if rust has not formed. Otherwise, the component must be cleaned first.
Grease fittings that are worn and will not hold the grease gun, or those that have a stuck check ball, must be replaced.
VR-642C 8-1
8-2
SECTION 8 FUEL AND LUBRICANT INSTRUCTIONS
To prevent minor irregularities from developing into serious conditions several other services or checks are recommended for the same intervals as the periodic lubrication.
1. Thoroughly wash all fittings, caps, plugs, etc. with non-flammable, non-toxic cleaning solution before servicing, to prevent dirt from entering while performing the service.
2. Lubricants must be at operating temperature when draining.
3. During regular lubrication service, visually check the entire unit in regard to capscrews, nuts and pins being properly secured.
4. Spot check several capscrews and nuts for proper torque. If any are found loose, a more thorough investigation must be made.
5. If a defect is detected which requires special maintenance service, stop the machine operation until the defect has been corrected. If necessary, contact the local Ingersoll-Rand distributor for assistance.
6. This symbol represents an area where lubrication is required.
Periodic lubrication requirements are listed in the following Lubrication Chart. These requirements include lubricant checks and greasing designated areas of the machine.
VR-642C
FUEL AND LUBRICANT INSTRUCTIONS
SECTION 8
VR-642C 8-3
8-4
SECTION 8 FUEL AND LUBRICANT INSTRUCTIONS
SERVICE FUNCTIONS:
S - CHECK
C - CHANGE
F - FILL
T - TORQUE
G - GREASE
A - ADD
CL - CLEAN
AR - AS REQUIRED
D - DRAIN
FTLH - FILL TO LEVEL HOLE/MARK
SERVICE
INTERVAL
REF. NO
1
2
10 HRS. OR
DAILY
50 HRS. OR
WEEKLY
250 HRS. OR
QUATERLY
3
4
5
6
7
8
9
12
14
15
16
17
18
20
21
22
31
32
33
34
35
36
37
DESCRIPTION
ENGINE OIL
ENGINE COOLANT
TRANSMISSION OIL
LEVEL
AIR CLEANER INDICATOR
HYDRAULIC OIL LEVEL
FUEL/WATER
SEPARATOR
FUEL TANK
PARKING BRAKE
TIRES
CHAIN SHEAVE
BEARINGS
WHEEL LUGS
AXLE DIFFERENTIAL OIL
LEVEL
AXLE PLANETARY
WHEEL ENDS
AXLE PIVOT BEARINGS
AXLE KING PINS
FORK PINS
FRAME LEVEL PIVOT
BUSHINGS
BOOM PIVOT AND
CYLINDERS
ENGINE OIL TURBO
ENGINE OIL FILTER
FUEL FILTER
HYD. TANK BREATHER
BOOM CHAINS
BOOM WEAR PADS
CHAIN AND BOOM HOSE
SERVICE PART NO. OR LUBRICANT
S, A
S, A
S, A
S
S, A
D
S, A
S
S, A
G
S, T
S, A
S, A
G
G
G
G
G
S
G
T
D, F
C
C
C
*
WATER/ANTI-FREEZE
**
**
COLLECTED WATER
#2 DIESEL FUEL
SEE SECTION 3
PRESSURE / CONDITION
EP-2 GREASE
619 N-M/442 LB.-FT.
***
***
EP-2 GREASE
EP-2 GREASE
EP-2 GREASE
EP-2 GREASE
EP-2 GREASE
*
SEE PARTS MANUAL
SEE PARTS MANUAL
CHAIN LUBRICANT
EP-2 GREASE
SEE SECTION 5
COMMENTS
FULL ON DIPSTICK
AR
FULL ON DIPSTICK
AR 1 PLACE
FILL TO SIGHT GAUGE
AR 1 PLACE
AR
SEE INFLATION DECAL
2 FITTINGS
40 PLACES
2 PLUGS
4 PLUGS
4 FITTINGS
8 FITTINGS
AR
2 FITTINGS
13 FITTINGS
11 L (11.6 QUARTS)
1 REQUIRED
1 REQUIRED
1 REQUIRED
AR
30 PADS
ADJUST
VR-642C
FUEL AND LUBRICANT INSTRUCTIONS SECTION 8
SERVICE
INTERVAL
REF. NO
51
52
53
54
1000 HRS.
OR
ANNUALLY
55
56
57
58
59
DESCRIPTION
HYD. TANK BREATHER
AXLE DIFFERENTIAL OIL
BOOM CHAINS
HYD. OIL SUCTION
STRAINER
HYDRAULIC OIL
ENGINE COOLANT
AXLE PLANETARY
TRANSMISSION OIL (1)
TRANSMISSION OIL
FILTER (1)
SERVICE PART NO. OR LUBRICANT
c
D, F
S
CL, A
C
D, F
D, F
D, F
C
SEE PARTS MANUAL
***
CHAIN LUBRICANT
**
WATER/ANTI-FREEZE
***
**
SEE PARTS MANUAL
COMMENTS
1 REQUIRED
31 L (32.8 QUARTS)
AR
(3)
FILL TO SIGHT GAUGE
18.9 L (20 QUARTS)
0.9 L (1 QUART)
11.3 L (12 QUARTS)
1 REQUIRED
* IR Multi-Purpose Premium Engine Oil
** IR Premium Multi-Purpose ATF
*** IR Premium Limited-Slip Component Lubricant
NOTES:
1. Change transmission oil and filter after first 50 hours.
2. Without Chlorine Additive
3. See Parts Manual for Part Number
The following fluid capacities are provided for servicing personnel who must perform machine maintenance in remote locations where complete shop facilities and resources are not available. These capacities will give the servicing personnel an approximation of the fluid capacities of the components to be serviced. Always ensure that the specified method of checking for accurate fluid levels is used.
Table 8-1
FLUID/OIL USEABLE CAPACITY
Diesel Fuel (#2 ASTMD-975-60T)
Engine Oil (SAE 15W40)
Transmission Oil (Multipurpose ATF)
132 Liter (35 Gallon)
11 Liter (11.6 Quart) - Turbocharged
12.9 Liter (13.6 Quart)
Engine Coolant (50% Water/50% Glycol) 18.9 Liter (20 Quart)
Hydraulic Oil (Mobil DTE 13M, Multipurpose ATF) 151 Liter (40 Gallon)
Drive Axle, Total 8.51 Liter (9.0 Quart)
Drive Axle, Center Section (Mobilube 80W-90 EP) 6.62 Liter (7.0 Quart)
Drive Axle, Wheel End (per side) (SAE 80W-90 EP) 0.95 Liter (1 Quart)
VR-642C 8-5
8-6
SECTION 8 FUEL AND LUBRICANT INSTRUCTIONS
The quality of the hydraulic oil is important to the satisfactory performance of any hydraulic system. The oil serves as the power transmission medium, system coolant, and lubricant.
Selection of the proper oil is essential to ensure proper system performance and life. For the specifications and requirements that hydraulic oil used in this machine should meet, refer to information below.
Viscosity :
Table 8-2
60 SUS minimum at operating temperature
7500 SUS maximum at starting temperature
Viscosity Index :
Aniline Point :
API gravity :
150 TO 225 SUS AT 38° C (100° F) (generally)
44 TO 48 SUS AT 99° C (210° F) (generally)
90 minimum
-175 minimum
28 minimum
Recommended Additives :
Desirable Characteristics :
Paraffinic oils: 28 OR MORE
Mixed base: 24 TO 28
Napthanic or asphaltic base: 24 or less
Rust and oxidation inhibitors
Foam depressant
Stability of physical and chemical characteristics
High demulsibility (low emulsibility) for separation of water, air, and contaminants
Resistance to the formation of gums, sludges, acids, tars, and varnishes
High lubricity and film strength
The following are only a few examples of the commercial brand oils meeting specifications for use at temperatures above -12° C (10° F).
International Harvester Tran
Auto. Trans. Fluid
Mobil Oil Company
Sun Oil Company
Type F
Mobil DTE 15M
Sun Oil 2105
For temperatures below -12° C (10° F), the following examples meet specifications.
Auto Transmission Fluid
Mobil Oil Company
Shell Oil Company
Type F
Mobil DTE 13
Tellus T-27
VR-642C
FUEL AND LUBRICANT INSTRUCTIONS SECTION 8
Extreme Pressure Multipurpose Lubricant
This gear lubricant is compounded to achieve high load carrying capacity and meet the requirements of either API-GL-5 or MIL-L-2105C. Unless otherwise specified, SAE-90 viscosity oil may be used for year-round service. Low temperature usage is restricted as follows:
SAE VISCOSITY NO.
75W
80W
85W
90
140
250
MIN. AMBIENT TEMP °C (°F)
-40°C (-40°F)
-26°C (-15°F)
-12°C (+10°F)
-7°C (+20°F)
+4°C (+40°F)
+10°C (+50°F)
Extreme Pressure Multi-Purpose Grease
This is a lithium soap base grease with a high load carrying capacity. The following properties are recommended:
Timken OK Load
Dropping Point
Oil Viscosity
Water Resistance
18 kg (40 lb.) Minimum
177° C (350° F) Minimum
75 SUS Minimum at 99° C (210° F)
Excellent
Under normal operating conditions, the following consistency grades are recommended:
NLGI No. 0 for temperatures below -18° C (0° F).
NLGI No. 1 or No. 2 for ambient temperatures -18° C to 38° C (0 - 100° F).
NLGI No. 2 or No. 3 for temperatures over 38° C (100° F).
NOTE
For latest applicable engine lubricating oil specifications, contact engine manufacturer, engine distributor or your Ingersoll Rand distributor.
VR-642C 8-7
8-8
SECTION 8 FUEL AND LUBRICANT INSTRUCTIONS
Cummins diesel engines have been developed to take advantage of the high energy content and generally lower cost of No. 2 Diesel Fuels. Experience has shown that a Cummins diesel engine will also operate satisfactorily on No. 1 fuels or other fuels within the specifications shown in Table 8-3.
Table 8-3
Viscosity (ASTM D-445)
Cetane Number (ASTM D-613)
1.3 to 5.8 mm per second at 40° C
(1.3 to 5.8 centistokes per second at 104° F)
40 minimum except in cold weather or in service with prolonged idle, a higher cetane number is desirable.
Sulfur Content (ASTM D-129 or 1552)
Water and Sediment (ASTM D-1796)
Not to exceed 1 percent by weight.
Not to exceed 0.1 percent by volume.
Carbon Residue (Ramsbottom, ASTM-D-524 or Conradson, ASTM D-189)
Not to exceed 0.25 percent by weight on 10 percent volume residue.
Flash Point (ASTM D-93)
Density (ASTM D-287)
Cloud Point (ASTM D-97)
Active Sulfur
Ash (ASTM D-482)
Distillation (ASTM D-86)
At least 52° C (125° F) or legal temperature if higher than 52° C (125° F).
-1 to 6° C (30 to 42° F ) API gravity at 16° C
(60° F) (0.816 to 0.876 Sp. Gr.).
6° C (10° F) below lowest ambient temperature at which the fuel is expected to operate.
Copper strip corrosion not to exceed No. 2 rating after 3 hours at 49° C (122° F).
Not to exceed 0.02 percent by weight.
The distillation curve must be smooth and continuous. At least 90 percent of the fuel must evaporate at less than 360° C (680° F). All of the fuel must evaporate at less than 385° C (725° F).
VR-642C
FUEL AND LUBRICANT INSTRUCTIONS
SECTION 8
The following information is provided to assist the owners and operators of Ingersoll Rand
Road Machinery Equipment. Further information may be obtained by contacting your Ingersoll
Rand Road Machinery Equipment Distributor.
Table 8-4
SUBSTANCE PRECAUTION
Engine Exhaust Fumes Avoid breathing.
Engine Exhaust Fumes Avoid buildup of fumes in confined spaces.
Electric Motor Dust (Brushes/Insulation) Avoid breathing during maintenance.
Brake Lining Dust * Avoid breathing during maintenance.
SUBSTANCE PRECAUTION
Antifreeze (Water-cooled engine)
Hydraulic Oil
Engine Lubricating Oil
Preservative Grease
Rust Preventative
Engine Fuel
Battery
SAE Gear Oil
Avoid ingestion, skin contact and breathing fumes.
Avoid ingestion, skin contact and breathing fumes.
Avoid ingestion, skin contact and breathing fumes.
Avoid ingestion, skin contact and breathing fumes.
Avoid ingestion, skin contact and breathing fumes.
Avoid ingestion, skin contact and breathing fumes.
Avoid ingestion, skin contact and breathing fumes.
Avoid ingestion, skin contact and breathing fumes.
VR-642C 8-9
SECTION 8 FUEL AND LUBRICANT INSTRUCTIONS
8-10 VR-642C
TORQUE SPECIFICATIONS
SECTION 9
Use the following Recommended Torque Chart for bolts and nuts of ISO Metric strength
Class 8.8 or 10.9. If other torques are required, they will be indicated in the text.
NOTE
Torque values are based on dry zinc-plated capscrews. Value will be approximately 30% less if lubricated bolts are used.
BOLT SIZE (MM)
14
16
20
24
10
12
6
8
30
36
TORQUE
GRADE 8.8 N-m
(POUNDS-FOOT)
GRADE 10.9 N-m
(POUNDS-FOOT)
11 (8)
28 (20)
53 (39)
92 (68)
145 (107)
212 (156)
415 (306)
717 (529)
1424 (1050)
2488 (1835)
15 (11)
37 (27)
72 (53)
126 (93)
201 (148)
312 (230)
609 (449)
1054 (777)
2094 (1544)
3656 (2696)
VR-642C 9-1
9-2
SECTION 9 TORQUE SPECIFICATIONS
Use the following Recommended Torque Chart for bolts and nuts of SAE Grade 5 or better quality. If other torques are required, they will be indicated in the text.
NOTE
Torque values are based on plain, unplated hardware, degreased, dried, clamping steel to steel.
BOLT SIZE
7/8 - 9
7/8 - 14
1 - 8
1 - 12
1 1/8 - 7
1 1/8 - 12
1 1/4 - 7
1 1/4 - 12
1 3/8 - 6
1 3/8 - 12
1 1/2 - 6
1 1/2 - 12
1/4 - 20
1/4 - 28
5/16 - 18
5/16 - 24
3/8 - 16
3/8 - 24
7/16 - 14
7/16 - 20
1/2 - 13
1/2 - 20
9/16 - 12
9/16 - 18
5/8 - 11
5/8 - 18
3/4 - 10
3/4 - 16
CLAMP LOAD kg
12247
13517
16102.5
17599
19187
21546
24403
27034
29075
33112
35380
39780
4105
4853
5262
5874
6532
7688
9661.5
10795.5
916
1052
1515
1678
2241
2540
3084
3425
lbs.
27000
29800
35500
38800
42300
47500
53800
59600
64100
73000
78000
87700
9050
10700
11600
12950
14400
16950
21300
23800
2020
2320
3340
3700
4940
5600
6800
7550
TORQUE lb.-ft
400
440
580
640
800
880
1120
1240
1980
2278
2631
2983
75
90
110
120
150
180
260
300
96 lb.-in.
120 lb.-in.
17
19
30
35
50
55
N•m
542
597
786
868
1085
1193
1519
1681
1460
1680
1940
2200
102
122
149
163
203
240
353
407
41
47
68
75
11
14
23
26
VR-642C
TORQUE SPECIFICATIONS SECTION 9
All thread fasteners will be Loctited except the following:
1. Wheel nuts
2. Nylon insert nuts
3. Whizlock bolts and nuts
4. Fasteners less than ¼ inch diameter
5. If instructed not to apply Loctite
Type of Loctite to be used:
1. No. 242 for 5/16 diameter and below
2. No. 271 for greater than 5/16 diameter
3. No. 242 for aluminum
All Loctited fasteners will be degreased and dried. When accelerated Loctite cure times are required, Loctite primer must be used.
VR-642C 9-3
SECTION 9 TORQUE SPECIFICATIONS
9-4 VR-642C
SCHEMATICS
SECTION 10
Hydraulic and electrical schematics are included here for the convenience of the owner/ operator. Additional full-size copies of the schematics are available by contacting the Ingersoll
Rand Road Development Division. See your authorized Ingersoll-Rand dealer for assistance, if required.
For ultimate machine life and maximum performance, we recommend the use of genuine
Ingersoll Rand brand parts.
The electrical and hydraulic schematics included herein that are applicable to the VR-642C
Vertical Reach Material Handlers are outlined below.
Electrical Schematics
• Electrical Schematic for the VR-642C Vertical Reach Material Handler, Drawing No.
13443197, pages 10-3 to 10-5.
Hydraulic Schematics
• Hydraulic Schematic for the VR-642C Vertical Reach Material Handler, Drawing No.
18006643, page 10-6.
VR-642C 10-1
SECTION 10 SCHEMATICS
10-2 VR-642C
SCHEMATICS
Electrical Schematic for VR-642C Vertical Reach Material Handler (13443197 Sheet 1 of 3)
SECTION 10
VR-642C 10-3
10-4
SECTION 10
Electrical Schematic for VR-642C Vertical Reach Material Handler (13443197 Sheet 2 of 3)
SCHEMATICS
VR-642C
SCHEMATICS
Electrical Schematic for VR-642C Vertical Reach Material Handler (13443197 Sheet 3 of 3)
SECTION 10
VR-642C 10-5
10-6
SECTION 10
Hydraulic Schematic VR-642C Vertical Reach Material Handler (18006643)
SCHEMATICS
VR-642C
SPARE PARTS SECTION 11
VR-642C RECOMMENDED SPARE PARTS
This section of the manual identifies the spare parts that the owner/operator is encouraged to keep on hand in support of the service schedule for the VR-642C Vertical Reach Material
Handler. The owner/operator can expect to use these spare parts over the course of normal use to keep his machine performing optimally if service is kept current in accordance with the recommended service intervals in Section 5’s Maintenance Schedule and the Lubrication
Chart of Section 8. More or less of these spare parts may actually be used depending on how your machine is equipped, how frequently your machine is used, and how well it is cared for.
The recommended spare parts are tabulated below, grouped by major assemblies and the service interval (operating hours).
Table 11-1: Spare Parts for VR-642C Vertical Reach Material Handler
Service Interval (Hours)
0 - 1000 1000 - 3000 3000 +
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Component
Description
Air Cleaner
Air Cleaner 54524418
Air Cleaner Primary Filter Element 54484092
Air Cleaner Secondary Filter
Element
Axle and Wheels
Front Drive Shaft Assembly
54493259
54568837
Rear Drive Shaft Assembly
Frame Level Cylinder
Frame Level Cylinder Locknut
Rim (Standard)
Tire (Standard)
Air Valve (Foamless Wheel & Tire
Assemblies)
CPN
54479878
13224969
59644465
59182097
59158345
59254447
59163758
VR-642C 11-1
11-2
SECTION 11
Service Interval (Hours)
0 - 1000 1000 - 3000
Component
Description
3000 +
Boom and Carriage
4
4
Bearing
Bearing
2
4
1
1
1
Cylinder Pivot Pin
Anchor
Tilt Compensation Cylinder
Lift Cylinder
2
2
Fork Tilt Cylinder
Anchor Pin
Anchor Chain
Chain Anchor Rod 1
1
2
1
1
1
Chain Extension
Anchor Chain Pin
Base Ring
Pin
2
1
1
Crowd Cylinder
Wear Pad
Bushing
Bracket Guide Plate
1
2
1
Anchor Guide
Chain Sheave Guard
Chain Sheave
SPARE PARTS
CPN
50268127
13232277
13232244
59455154
59221895
59221721
59221770
59001891
59101170
59101048
59157339
59456962
59462895
59454801
59282715
13156799
59455204
59116459
59116467
59135087
59169953
VR-642C
SPARE PARTS
Service Interval (Hours)
0 - 1000 1000 - 3000 3000 +
2
2
2
2
2
2
6
1
Outer Boom Section
Wear Pad
Wear Pad
Shim Plate
Shim Plate
Shim Plate
Shim Plate
Wear Pad
Component
Description
Boom Cowling
2 Block
Intermediate Boom Section
2
2
2
2
2
4
2
1
Shim Plate
Wear Pad
Wear Pad
Wear Pad
Finger
Shim Plate
Shim Plate
Shim Plate
2
2
2
2
Inner Boom Section
Wear Pad
2 Spacer Plate
Shim Plate
Shim Plate
Shim Plate
SECTION 11
CPN
13156799
13156781
59269134
59100941
59135194
59136804
59182196
13351135
59451641
59100941
13156799
13243639
59182196
13183074
59115873
59135194
59136804
13156799
59116491
59100941
59135194
59136804
VR-642C 11-3
11-4
SECTION 11
Service Interval (Hours)
0 - 1000 1000 - 3000 3000 +
2
1
Component
Description
Quick-Attach Carriage
Inner Bearing
Cylinder Pivot Pin
2
1
2
1
1
1
2
1
1
48 in. Load Arm
60 in. Load Arm
72 in. Load Arm
Plate
Pin
Handle
Rod End
Threaded Rod
1
1
1
1
1
1
1
1
1
1
Apron Handle
Quick-Attach Apron
Rubber Stop Pin
Electrical
Power Relay with Diodes
Relay
Battery
Battery Hold Down
1
1
1
1
1
1
1
Horn
Switch
Backup Alarm
Fuse, 10 A
Fuse, 15 A
Fuse, 20 A
Diode Assembly
SPARE PARTS
CPN
13316831
59436899
59436931
59181875
13111422
59112011
13273354
59325712
59483339
59398016
59149146
59454215
13232251
58793209
58793191
58793183
59451815
59101758
59129593
59101774
13161872
13199393
13187364
13195862
VR-642C
SPARE PARTS SECTION 11
Service Interval (Hours)
0 - 1000 1000 - 3000 3000 +
1
1
1
1 1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
Component
Description
CPN
Engine
Engine Oil Filter
Fuel Filter
Inline Fuel Filter
Fan Belt
Starter
Alternator
13284716
13284708
58827932
13284732
13284724
54726948
Transmission Temperature Sender 59302554
Engine Oil Pressure Sender 58878000
Engine Coolant Temperature
Sender
59816322
Engine Oil Pressure Switch
Muffler
Exhaust Clamp
Tail Pipe
59124578
58933623
59179218
13195912
Radiator Cap
Upper Radiator Hose
Lower Radiator Hose
Frame
Cable
Ferrule
Fuel Level Sender
Fuel Cap
Magnetic Plug
Hydraulic Tank Cap
Sight Gauge
13281571
13267067
13307863
59436741
59436758
59129528
59182428
59144428
59182410
58849829
VR-642C 11-5
11-6
SECTION 11 SPARE PARTS
Service Interval (Hours)
0 - 1000 1000 - 3000 3000 +
1 1
1
2
Component
Description
1
1
1
1
1
Hydraulics
Hydraulic Pump
Hydraulic Filter
Steering Unit
Brake Valve
Steering Selector Valve
Pressure Switch
Pressure Reducer
Stabilizer
1
1
1
Stabilizer Cylinder
Brake Light Switch
Stabilizer Valve
Instrument Panel
1
1
1
1
1 1
Ignition Switch
Ignition Switch Key
Ignition Switch Cover
Fuel Level Gauge
1
1
1
1
1
1
1
Voltmeter
Oil Pressure Gauge
Transmission Temperature Gauge
Water Temperature Gauge
Hourmeter
Brake Test Switch
Parking Brake Switch
CPN
54535646
13173802
13267596
59113480
13163274
13259189
13284633
59221812
59157792
13173331
13316849
58917261
58892902
59046920
59044297
59046904
59113761
59132324
59165001
54666102
54666094
VR-642C
SPARE PARTS
Service Interval (Hours)
0 - 1000 1000 - 3000
Component
Description
3000 +
Operator Compartment
1
1
1
1
1
1
Horn Button
Transmission Shifter
Steering Wheel
Spinner Kit
Level Gauge
Standard Seat
1
1
1
1
Open Cab
Suspension Seat (Optional)
Pointer
Mirror
Heater Valve
1
1
1
Rear Wiper Arm
Wiper Blade
Wiper Motor Kit
1
1
1
1
Enclosed Cab
1 Front Window
1 Sliding Window
Rear Wiper Arm
1
1
1
1
1
1
1
Wiper Blade
Wiper Motor Kit
Level Gauge
Armrest
Defrost Fan
Door Seal
Door Strap
Outside Door Latch
Inside Latch Handle
Door Key
VR-642C
SECTION 11
CPN
59159558
59113696
13158647
59199141
59181545
59156893
59156901
59116558
59450734
13200027
59072694
59194514
59194548
13174081
59154641
59072694
59194514
59194548
59181545
54473004
59154757
59072702
59142851
59142661
59154955
59155598
11-7
11-8
SECTION 11 SPARE PARTS
Service Interval (Hours)
0 - 1000 1000 - 3000 3000 +
1
1
1
Component
Description
CPN
1
1
1
1
1
1
Kits
VR-642C Decal Kit
Frame Level Cylinder Seal Kit
13363247
13248505
Tilt Compensation Cylinder Seal Kit 13421896
Lift Cylinder Seal Kit 13268271
Fork Tilt Cylinder Seal Kit
Crowd Cylinder Seal Kit
Steering Selector Valve Seal Kit
Hydraulic Pump Seal Kit
Brake Valve Seal Kit
1 Stabilizer Cylinder Seal Kit
Optional Equipment
Wheel and Tire Assemblies
13281431
13284104
13263249
59154310
59154617
13284120
54503016 1 Foam Filled Tire
72 in. Swing Carriage
1
1
Load Arm
Plate
1
1
2
2
Hydraulic Cylinder
Counterbalance Valve
Seal Kit
Bearing
1
2
Flow Control Valve
Cover Plate
Truss Boom
1 12 ft. Truss Boom
Load Bucket
1 Load Bucket
58793183
59451815
13170147
58874751
54728886
50275395
13170188
59583450
59199513
59149484
VR-642C
SPARE PARTS SECTION 11
Service Interval (Hours)
0 - 1000 1000 - 3000 3000 +
Component
Description
Tapered Forks
1
1
48 in. Tapered Fork
60 in. Tapered Fork
2
2
Scrap Grapple Bucket
1 Cylinder
1
Block Heater
Seal Kit
1
Worklights
Block Heater
3
Work Lamp
Work Lamp Light Bulb
Cable Seal
CPN
59272583
59272591
59110932
59231282
59118521
58837949
58875543
59854877
RECOMMENDED LUBRICANTS
This section of the manual contains a list of the recommended Ingersoll Rand lubricants for the VR-642C Vertical Reach Material Handler.
Table 11-2: Recommended Lubricants
1 Qt.
1 Gal.
5 Gal.
55 Gal.
IR All-Season Premium Hydraulic Oil
IR Multi-Purpose Premium Engine Oil
N/A N/A 59045179 59045187
59022343 59023507 57022327 59022335
IR Premium Limited-Slip Component Lubricant 13248455 13248463 59022418 59022426
IR Premium Multi-Purpose ATF 13248471 13248489 59023572 59023580
IR Synthetic Component Lubricant
IR Synthetic Plus Component Lubricant
13248430 13248448 58977597 59022459
13248414 13248422 59046177 59046165
VR-642C 11-9
SECTION 11 SPARE PARTS
11-10 VR-642C
WORD INDEX
Numerics
10 Hour or Daily Routine Maintenance . . . . . . . . 5-19
1000 Hour or Annual Routine Maintenance . . . . 5-39
250 Hour or Quarterly Routine Maintenance . . . 5-39
50 Hour or Weekly Routine Maintenance . . . . . . 5-27
A
Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Adjust Boom Chains and Hoses . . . . . . . . . . . . . 5-36
Air Cleaner Element, Cleaning the . . . . . . . . . . . 5-11
Air Cleaner Restriction, Check . . . . . . . . . . . . . . 5-10
Air Cleaner Restriction Indicator, Check . . . . . . 5-22
Air Cleaner Vacuator Valve . . . . . . . . . . . . . . . . . 5-14
Air Conditioner Controls . . . . . . . . . . . . . . . . . . . 3-11
Angle Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Annual Routine Maintenance, 1000 Hour or . . . . 5-39
Apron, Quick Attachment . . . . . . . . . . . . . . . . . . 4-40
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Auxiliary Function Switch . . . . . . . . . . . . . . . . . . . 3-2
Axle Differential Planetary Wheel Ends,
Check Oil Level in . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Axle Differentials, Check Oil Level in . . . . . . . . . 5-23
Axle King Pins, Grease . . . . . . . . . . . . . . . . . . . . 5-24
Axle Mounting Bolts, Torque . . . . . . . . . . . . . . . . 5-30
Axle Pivot Bearings, Grease . . . . . . . . . . . . . . . . 5-24
B
Ballast / Ignition Kill Switch . . . . . . . . . . . . . . . . . . 6-9
Battery Gauge (Voltmeter) . . . . . . . . . . . . . . . . . . . 3-1
Battery Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Beacon Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Boom Chains and Hoses, Adjust . . . . . . . . . . . . 5-36
Boom Control Joystick . . . . . . . . . . . . . . . . . . . . . 3-7
Boom Light Switch . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Boom Pivot and Boom Cylinders, Grease . . . . . 5-26
Boom Safety Stop . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Boom Stop Installation . . . . . . . . . . . . . . . . . . . . . 4-5
Boom Wear Pad Clearances, Check . . . . . . . . . 5-33
Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Bucket Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Button, Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Check Air Cleaner Restriction . . . . . . . . . . . . . . . 5-10
Check Air Cleaner Restriction Indicator . . . . . . . 5-22
Check Boom Wear Pad Clearances . . . . . . . . . . 5-33
Check Coolant Level . . . . . . . . . . . . . . . . . . . . . . . 5-8
Check Engine Belts . . . . . . . . . . . . . . . . . . . . . . . 5-44
Check Engine Light . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Check Engine Oil Level . . . . . . . . . . . . . . . . . . . . 6-19
Check Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Check Hydraulic Oil Level . . . . . . . . . . . . . . . . . . 5-15
Check Oil Level in Axle Differential
Planetary Wheel Ends . . . . . . . . . . . . . . . . . . . . . 5-22
Check Oil Level in Axle Differentials . . . . . . . . . . 5-23
Check Park Brake . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Check Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Check Tire Pressure and Condition . . . . . . . . . . 5-18
Check Transmission Fluid Level . . . . . . . . . . . . . . 5-8
Clean Heater / A-C Filter . . . . . . . . . . . . . . . . . . . 5-26
Cleaning the Air Cleaner Element . . . . . . . . . . . . 5-11
Coolant Level, Check . . . . . . . . . . . . . . . . . . . . . . 5-8
Coordinated Steering . . . . . . . . . . . . . . . . . . . 1, 4-24
Crab Steering . . . . . . . . . . . . . . . . . . . . . . . . . 1, 4-23
D
Daily Routine Maintenance, 10 Hour or . . . . . . . 5-19
Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Diagnostic Port . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Difficult Starting & Poor/Irregular Performance . . . 6-4
Direction Control Lever . . . . . . . . . . . . . . . . . . . . . 3-3
Dry Wall Handler . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Dry Wall Handler Installation . . . . . . . . . . . . . . . . 4-45
Dynamic Forces . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
E
Electrical Circuit Malfunctions . . . . . . . . . . . . . . . . 6-6
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . 10-1
Engine Belts, Check . . . . . . . . . . . . . . . . . . . . . . 5-44
Engine Diagnostic Port . . . . . . . . . . . . . . . . . . . . 3-10
Engine Fuel Filter, Change . . . . . . . . . . . . . . . . . 5-40
Engine Making Excessive Fumes . . . . . . . . . . . . . 6-5
Engine Oil and Filter, Change . . . . . . . . . . . . . . . 5-39
Engine Oil Level, Check . . . . . . . . . . . . . . . . . . . 6-19
Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . 3-5
Engine Overheats - Stop Engine Immediately . . . 6-5
Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . 6-3
Ether Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Extreme Pressure Multi-purpose Grease . . . . . . . 8-7
C
Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Center of Gravity (CG) . . . . . . . . . . . . . . . . . . . . . 4-2
Chain Sheave Bearings, Grease . . . . . . . . . . . . 5-19
Chains, Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Change Engine Fuel Filter . . . . . . . . . . . . . . . . . 5-40
Change Engine Oil and Filter . . . . . . . . . . . . . . . 5-39
Change Hydraulic Oil Filters . . . . . . . . . . . . . . . . 5-41
Change In Line Filter . . . . . . . . . . . . . . . . . . . . . . 5-29
Change Transmission Oil . . . . . . . . . . . . . . . . . . 5-46
Change Transmission Oil Filter . . . . . . . . . . . . . . 5-48
Check Air Cleaner Connections and Ducts For Leaks . . . . . . . . . . . . . . . . . . . . . . . 5-7
VR-642C
12-1
I
F
WORD INDEX
Factors (of CG) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Fasteners, Inspect . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Fill Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Fork Pins, Grease . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Frame Level Pivot Bushings and
Stabilizer Pivot Bushings, Grease . . . . . . . . . . . . 5-25
Front Wheel Steering . . . . . . . . . . . . . . . . . . . . . 4-23
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Fuel Level, Check . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Fuel Tank, Fill . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Fuel/Water Separator . . . . . . . . . . . . . . . . . . . . . 5-15
Fuse Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
G
Gauge, Battery (Voltmeter) . . . . . . . . . . . . . . . . . . 3-1
Gauge, Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . 3-1
Gauge, Transmission Oil Temperature . . . . . . . . 3- 2
Gauge, Water Temperature . . . . . . . . . . . . . . . . . 3-2
General Identification . . . . . . . . . . . . . . . . . . . . . . . 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . 1
General Maintenance Information . . . . . . . . . . . . . 5-1
Grease Axle King Pins . . . . . . . . . . . . . . . . . . . . 5-24
Grease Axle Pivot Bearings . . . . . . . . . . . . . . . . 5-24
Grease Boom Pivot and Boom Cylinders . . . . . . 5-26
Grease Chain Sheave Bearings . . . . . . . . . . . . . 5-19
Grease Fork Pins . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Grease Frame Level Pivot Bushings and
Stabilizer Pivot Bushings . . . . . . . . . . . . . . . . . . 5-25
Grease Steering Cylinder Pin Bearings . . . . . . . 5-29
J
Joystick, Boom Control . . . . . . . . . . . . . . . . . . . . . 3-7
Joystick, Level and Fork Control . . . . . . . . . . . . . . 3-7
K
Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
L
Left and Right Stabilizer Switches . . . . . . . . . . . . . 3-2
Level and Fork Control Joystick . . . . . . . . . . . . . . 3-7
Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Lever, Direction Control . . . . . . . . . . . . . . . . . . . . . 3-3
Lever, Turn Signal Control . . . . . . . . . . . . . . . . . . 3-4
Lifting, Lowering, and Tilting . . . . . . . . . . . . . . . . 4-27
Light, Check Engine . . . . . . . . . . . . . . . . . . . . . . . 3-5
Light, Service Engine . . . . . . . . . . . . . . . . . . . . . . 3-5
Light, Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Load Capacity Charts . . . . . . . . . . . . . . . . . . . . . 1-11
Load Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . 5-48
Low Engine Oil Pressure . . . . . . . . . . . . . . . . . . . 6- 5
M
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . 7-1
Machine Serial Number . . . . . . . . . . . . . . . . . . . . . . 2
Machine Weights and Figures . . . . . . . . . . . . . . . . 7-2
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . 5-3
Manual Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Metric Conversion . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
N
Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
H
Handling Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Hazardous Substance Precaution . . . . . . . . . . . 1-15
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Heater and Air Conditioner Controls . . . . . . . . . . 3-11
Heater / A-C Filter, Clean . . . . . . . . . . . . . . . . . . 5-26
Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Hydraulic Oil Filters, Change . . . . . . . . . . . . . . . 5-41
Hydraulic Oil Level, Check . . . . . . . . . . . . . . . . . 5-15
Hydraulic Oil Temperature Gauge . . . . . . . . . . . . 3-5
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . 10-1
O
Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . 4-1
Operating the Machine . . . . . . . . . . . . . . . . . . . . . 4-4
Operator Protection Equipment . . . . . . . . . . . . . . . 1-3
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 1
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
In Line Filter, Change . . . . . . . . . . . . . . . . . . . . . 5-29
Indicator, Angle . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Indicator, Level . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Initial Break-in Maintenance . . . . . . . . . . . . . . . . . 5-5
Inspect Chains . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Inspect Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Inspect Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
International Machine Symbols . . . . . . . . . . . . . . . 2-1
ISO Metric Torque Chart . . . . . . . . . . . . . . . . . . . . 9-1
P
Park Brake, Check . . . . . . . . . . . . . . . . . . . . . . . 5-17
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Park Brake Test Switch . . . . . . . . . . . . . . . . . . . . . 3-6
Park Brake Test Procedure . . . . . . . . . . . . . . . . . 4-15
Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Pedal, Accelerator . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Pedal, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Pintle Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Power Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Prototype Models . . . . . . . . . . . . . . . . . . . . . . . . . . 2
12-2
VR-642C
Q
Quarterly Routine Maintenance, 250 Hour or . . 5-39
Quick Attachment Apron . . . . . . . . . . . . . . . . . . . 4-40
R
WORD INDEX
Rated Capacity Chart . . . . . . . . . . . . . . . . . . . . . . 1-8
Recommended Lubricants . . . . . . . . . . . . . . . . . 11-9
Recommended Spare Parts . . . . . . . . . . . . . . . . 11-1
Replacing The Air Cleaner Element . . . . . . . . . . 6-10
Routine Maintenance, 10 Hour or Daily . . . . . . . 5-19
Routine Maintenance, 1000 Hour or Annual . . . . 5-39
Routine Maintenance, 250 Hour or Quarterly . . . 5-39
Routine Maintenance, 50 Hour or Weekly . . . . . 5-27
Torque Axle Mounting Bolts . . . . . . . . . . . . . . . . 5-30
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Transmission Fluid Level, Check . . . . . . . . . . . . . 5-8
Transmission Oil, Change . . . . . . . . . . . . . . . . . 5-46
Transmission Oil Filter . . . . . . . . . . . . . . . . . . . . . . 5-5
Transmission Oil Filter, Change . . . . . . . . . . . . . 5-48
Transmission Oil Temperature Gauge . . . . . . . . 3- 2
Transmission Range Selector . . . . . . . . . . . . . . . . 3-3
Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Transporting and Hauling . . . . . . . . . . . . . . . . . . 1-10
Traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Truss Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Turn Signal Control Lever . . . . . . . . . . . . . . . . . . . 3-4
Two Wheel Steering . . . . . . . . . . . . . . . . . . . . . . . . 1
S
SAE Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Safety Related Decals . . . . . . . . . . . . . . . . . . . . 1-18
Scrap Grapple Bucket . . . . . . . . . . . . . . . . . . . . . 4-42
Seat Belt, Check . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Service Engine Light . . . . . . . . . . . . . . . . . . . . . . . 3-5
Side Tilt Carriage . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Single Joystick Control . . . . . . . . . . . . . . . . . . . . . 3-8
Stabilizer Switches, Left and Right . . . . . . . . . . . . 3-2
Stabilizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Steering, Coordinated . . . . . . . . . . . . . . . . . . 1, 4-24
Steering, Crab . . . . . . . . . . . . . . . . . . . . . . . . . 1, 4-23
Steering, Front Wheel . . . . . . . . . . . . . . . . . . . 1, 4-23
Steering and Turning . . . . . . . . . . . . . . . . . . . . . 4-21
Steering Cylinder Pin Bearings, Grease . . . . . . . . 5-2
Steering Mode Selector Switch . . . . . . . . . . . . . . . 3-5
Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Stop Engine Light . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Swing Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Switch, Auxiliary Function . . . . . . . . . . . . . . . . . . . 3-2
Switch, Ballast / Ignition Kill . . . . . . . . . . . . . . . . . 6-9
Switch, Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Switch, Boom Light . . . . . . . . . . . . . . . . . . . . . . . 3-4
Switch, Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Switch, Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Switch, Park Brake . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Switch, Steering Mode Selector . . . . . . . . . . . . . . 3-5
Switch, Windshield Washer . . . . . . . . . . . . . . . . . 3-6
Switch, Work Light . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Switches, Left and Right Stabilizer . . . . . . . . . . . . 3-2
V
Vacuator Valve, Air Cleaner . . . . . . . . . . . . . . . . 5-14
Vandal Protection Cover - Option . . . . . . . . . . . . 4-39
Voltmeter Indicates Low or Negative Voltage . . . . 6-5
VR-642C Recommended Spare Parts . . . . . . . . 11-1
W
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Water Temperature Gauge . . . . . . . . . . . . . . . . . . 3-2
Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Weekly Routine Maintenance, 50 Hour or . . . . . . 5-27
Weighted Ballast Box . . . . . . . . . . . . . . . . . . . . . . 6-9
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Windshield Washer Switch . . . . . . . . . . . . . . . . . . 3-6
Work Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
T
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Three-Speed Transmission . . . . . . . . . . . . . . . . . 4-19
Tighten Loose Bolted Connections . . . . . . . . . . . . 5-6
Tire Pressure and Condition, Check . . . . . . . . . . 5-18
VR-642C
12-3
Ingersoll-Rand Company (“IR”) warrants to its and its affiliates’ authorized distributors, who in turn warrant to the initial user only, that each new Ingersoll-Rand material handler sold by the distributor will be free from proven defects in material and workmanship for the following period:
• VR Series and RT-700G and H Series limited to 1 year or 1,000 hours of operation, from date of entry into service, or twenty-four (24) months from the date of delivery from the factory to the distributor, whichever occurs first.
• RT-700J Series limited to 3 years or 3,000 hours of operation from date of entry into service, or forty-eight (48) months from date of delivery from the factory to the distributor, whichever occurs first
During the warranty period, the authorized distributor shall repair or replace, at IR’s option, any part that is found upon inspection to be defective in material or workmanship. Such part will be repaired or replaced without charge for parts and labor to the initial user by the authorized distributor. The initial user shall provide the authorized distributor with prompt notification of the defect and allow reasonable time for repair or replacement. IR may require failed parts to be returned to the factory. Transportation of the product to the authorized distributor is the responsibility of the user. The remedies provided in this warranty are exclusive.
This warranty does not apply to failures occurring as a result of abuse, misuse, negligent repairs, corrosion, erosion and normal wear and tear, alterations or modifications made to the product without the express written consent of IR, or failure to follow the recommended operating practices and maintenance procedures as provided in the product’s operating and maintenance publications. This warranty does not cover replacement of scheduled service items such as oil, filters, and wear items. This warranty does not apply to engines (including engine electrical components) and tires or other accessories and equipment furnished by IR, but manufactured by others. The initial user shall rely solely on the warranty, if any, of the respective manufacturers thereof.
THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES AND
CONDITIONS (EXCEPT FOR THE WARRANTY OF TITLE), EXPRESS OR IMPLIED. IR
DISCLAIMS ALL OTHER WARRANTIES AND CONDITIONS, EXPRESS OR IMPLIED,
INCLUDING ANY IMPLIED WARRANTIES OR CONDITIONS OF MERCHANTIBILITY OR
FITNESS FOR A PARTICULAR PURPOSE.
IN NO EVENT SHALL IR OR ANY OF ITS AFFILIATES, SUBSIDIARIES OR AUTHORIZED
DISTRIBUTORS BE LIABLE FOR ANY SPECIAL, INCIDENTAL, INDIRECT OR
CONSEQUENTIAL DAMAGES WHATSOEVER, INCLUDING, BUT NOT LIMITED TO, LOSS OR
INTERRUPTION OF BUSINESS, LOST PROFITS, OR LOSS OF MACHINE USE, WHETHER
BASED ON CONTRACT, WARRANTY, TORT, NEGLIGENCE, STRICT LIABILITY, STATUTE
OR OTHERWISE, EVEN IF IR OR ANY OF ITS AFFILIATES, SUBSIDIARIES OR AUTHORIZED
DISTRIBUTORS HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. THE
TOTAL LIABILITY OF IR, ITS AFFILIATES, SUBSIDIARIES AND AUTHORIZED
DISTRIBUTORS WITH RESPECT TO THE PRODUCT FURNISHED HEREUNDER SHALL NOT
EXCEED THE PURCHASE PRICE OF THE PRODUCT UPON WHICH SUCH LIABILITY IS
BASED, EXCEPT FOR CLAIMS FOR PERSONAL INJURY.
13851266
Road Development
© 2006 Ingersoll-Rand Company
Printed in the U.S.A.
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Variable Reach
Turbocharged Diesel Engine
Three-Speed Powershift Transmission
Hydraulic Brakes on All Four Wheels
Spring Applied Parking Brake
Load Sensing Hydraulic Pump
The VR-642C is powered by a direct injected 4 cylinder diesel engine.
The VR-642C has a turbocharged 110 hp (82 kW) at 2500 rpm engine.
The VR-642C has a three-speed, powershift transmission with torque converter.
The VR-642C uses hydraulic brakes on all four wheels. The service brakes are a hydraulically operated power brake to oil immersed discs in both axles.
The VR-642C's parking brake is controlled by a toggle switch on the operator’s control panel and will apply when the engine is shut down.
The VR-642C has a closed circuit hydraulic pump with load sensing to the hydraulic functions.
How is 4-wheel steering mode selected on the VR-642C?
Use the steering mode selector switch to select coordinated steering (4-wheel mode). This mode is commonly used as it allows all four wheels to steer the Telescopic Material Handler and enables smaller radius turns. It is recommended that the machine be stopped and the wheels straightened before changing steering modes to ensure proper alignment.
How to adjust the parking brake?
To adjust the parking brake, follow these steps: 1. Rotate the set screw clockwise to apply the brake. 2. Replace and tighten the cylinder locknut until the lever arm is tight against the nut. 3. Rotate the setscrew counterclockwise clear of the lever arm and tighten the locknut.
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