Ingersoll-Rand VR518 User manual

VR518
Cab
S/N 3646 12001
& above
VR518
Canopy
S/N 3647 12001
& above
Operation and
Maintenance
Manual
CPN 22806467 (12-05) Revised (6-12)
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Bobcat Company or the products of
either.
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Safety instructions
WARNING
Operators must read and understand instructions
before running the machine. Untrained operators can
cause injury or death.
• SEAT BELT: Check belt fasteners and check for damaged strap
or buckle.
• OPERATOR CAB (ROPS & FOPS): It must be on the machine with
all fasteners tight. Never use the machine without the right side
window.
• OPERATOR'S HANDBOOK: Must be in cab.
• MACHINE SIGNS (Decals): Replace if Damaged
• SAFETY TREADS: Replace if Damaged
• GRAB HANDLES: Replace if Damaged
• PARKING BRAKE
• WINDOWS AND MIRRORS: Clean and check for broken window
or mirror. Replace if Damaged
Never use the telescopic handler without instructions. See the
machine signs (decals), Operation & Maintenance Manual, AEM
Safety Manual and data sheets located in the cab.
Safety Alert Symbol: This symbol with a warning statement means: “Warning, be alert! Your safety is involved!” Care-
fully read the message that follows.
Always fasten seat belt securely.
Do not have any part of your body out-
side the cab
Never use the telescopic handler with-
out operator cab (ROPS & FOPS). Never use the machine as a working platform or an elevator unless it is
equipped with a IR-approved platform.
Do not use the machine where exhaust
can contact flammable material, explo-
sive dust or gases.
Check for underground or overhead
lines in the area before operating the
machine.
Keep a minimum distance of 8 m
between the nearest line and the
machine arm, attachment, or load.
Never transport a load when raised.
Do not travel or turn with the lift arms
up.
Load, unload and turn on flat level
ground.
Never exceed rated operating capacity.
Keep to the limits of the machine's
Rated Capacity Chart and/or the attach-
ment's nominal capacity.
Never leave telescopic handler with
engine running or with lift arms up.
To park, engage parking brake and put
attachment flat on the ground.
Never modify equipment.
Only use attachments that are approved
by IR for this type of telescopic handler.
Correct Incorrect
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SAFETY EQUIPMENT
The IR telescopic handler must be equipped with safety systems necessary for each job. Ask your dealer for information on the safe use
of attachments and accessories.
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CPN 22806467 IIR VR518
Operation and Maintenance Manual
CONTENTS
CONTENTS
CONTENTS .......................................................................................................................................................................I
FOREWORD....................................................................................................................................................................III
SAFETY ............................................................................................................................................................................1
RATED CAPACITY CHARTS .........................................................................................................................................15
OPERATING INSTRUCTIONS .......................................................................................................................................19
PREVENTIVE MAINTENANCE ......................................................................................................................................45
OPTIONS ........................................................................................................................................................................81
SPECIFICATIONS VR518 ..............................................................................................................................................89
MATERIAL HANDLER WARRANTY ..............................................................................................................................95
REFERENCE INFORMATION
INGERSOLL - RAND
Material Handling Equipment
312 Ingersoll Dr.
SHIPPENSBURG, PA 17257
Write the correct information for your IR telescopic handler in the spaces below. Always use these numbers
when referring to your machine.
Telescopic Handler Serial Number
Engine Serial Number
Notes:
Your IR Dealer:
Address:
Telephone:
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IR VR518 II CPN 22806467
Operation and Maintenance Manual
CONTENTS
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CPN 22806467 III IR VR518
Operation and Maintenance Manual
FOREWORD
Intro
FOREWORD
This manual was written to give the owner/operator instructions on the safe operation and maintenance of the
IR telescopic handler. READ AND UNDERSTAND THIS MANUAL BEFORE OPERATING YOUR MACHINE. If you
have any questions, see your IR dealer.
Contents
Serial Number Locations.................................................................................................................................................. V
Telescopic Handler Serial Number ........................................................................................................................ V
Engine Serial Number............................................................................................................................................ V
Other Serial Numbers ............................................................................................................................................ V
Delivery Report ............................................................................................................................................................... VI
Warranty Registration ..................................................................................................................................................... VI
Identification Of The Telescopic Handler ....................................................................................................................... VII
Options and Accessories .............................................................................................................................................. VIII
CAUTION
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.
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IR VR518 IV CPN 22806467
Operation and Maintenance Manual
FOREWORD
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CPN 22806467 VIR VR518
Operation and Maintenance Manual
FOREWORD
Serial Number Locations
Telescopic Handler Serial Number
Always use the type, model and serial number of the
machine when requesting service information or when
ordering parts.
Early or later models (identified by the serial number) may
use different parts or require a specific maintenance
procedure.
The machine name plate is riveted to the right side of the
frame, near the front right wheel. The serial number is
etched on the top of the frame, on the front right end.
Figure 1
Engine Serial Number
The engine serial number is etched on a plate located
beneath the alternator belt [Figure 2]. The belt cover must
first be removed. Always use the complete serial number
when requesting information or when ordering parts.
Figure 2
Other Serial Numbers
Other components may also have serial numbers and an
identification plate. Always use these serial numbers when
ordering parts.
96118
S0430
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IR VR518 VI CPN 22806467
Operation and Maintenance Manual
FOREWORD
Delivery Report
The Delivery Report must be filled out by the dealer and
signed by the owner or operator when the Telescopic Han-
dler is delivered. An explanation of the form must be given
to the owner. Make sure it is filled out correctly.
Figure 3
Warranty Registration
The Warranty Registration must be filled out by the dealer
and signed by the owner or operator when the Telescopic
Handler is delivered. Make sure it is filled out correctly.
This document has 4 copies (Division copy - Customer
copy - Seller Distributor copy - Servicing Distributor copy).
Figure 4
S0002 S0776
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CPN 22806467 VII IR VR518
Operation and Maintenance Manual
FOREWORD
Identification Of The Telescopic Handler
Figure 5
Reference Designation
1 Telescopic boom
2 Cab air filter
3 Fuel tank
4 Mirror
5 Operator Cab
6 Battery compartment
7 Boom stop (option)
8 Engine exhaust
9 Lights
10 Working lights
11 Engine cover
12 Rotating beacon
13 Pallet forks
910
9 8 11 4310
14
13
2
4
5
7
6
12
S1297
This figure shows the cab version.
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IR VR518 VIII CPN 22806467
Operation and Maintenance Manual
FOREWORD
Options and Accessories
The VR518 Telescopic Handlers Have The Following
Basic Equipment:
• Hydrostatic transmission
• ROPS/FOPS operator cab
• Heating, demisting, windscreen washer
• Hydraulic Joystick Control
• Two-way auxiliary hydraulic supply at the end of the
boom
• Hydraulic system
• Mechanical lock of accessories
• 4 Four TITAN 400/70x20 150B Lift Rigger II tires
• Mudguards
• Narrow bracket (mounting of the equipment)
Below is a list of equipment available from your dealer as
Dealer and/or Factory Installed Accessories. Please see
your IR dealer for more information.
Tires
The machine is fitted with 4 identical tires.
Four mounts are possible:
Options
• Aggravating Movements Arrester (AMA) device with key
switch to disable this function
•Tires
• Reverse drive alarm
• Cab air conditioning
• Rear hydraulic hook + mirror
• Transmission disengagement
• Rear hydraulic connection
• Trailer brake valve
• Fan reverse (for clearing out dust)
• Set of blue lights for hen houses
• Hydraulic lock of equipment
• Rotating beacon
• Windscreen grill
• Work light on boom
• Tow hitch + electrical plug
• Roof windscreen wiper
• 2nd hydraulic function on boom
Brand Dimensions Pressure
(bar)
TITAN
(standard)
400/70 - 20 4 bar
DUNLOP
(option)
400/70 - 20 150B 4 bar
DUNLOP
(option)
400/80 - 24 153B 4,25
DUNLOP
(option)
400/80 - 24 T37 156B 4,25
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CPN 22806467 1IR VR518
Operation and Maintenance Manual
SAFETY
SAFETY
Contents
General Safety Information ...............................................................................................................................................3
Safety Information In This Manual ....................................................................................................................................4
Operator Protection Equipment.........................................................................................................................................4
ROPS (Rollover Protective Structure).....................................................................................................................4
FOPS (Falling Object Protective Structure) ............................................................................................................4
Seat Belt .................................................................................................................................................................4
LORS™ (Lateral Operator Restraint System) (Canopy only) .................................................................................4
Boom Safety Stop ...................................................................................................................................................4
Safety Instructions For Operation .....................................................................................................................................5
Before You Operate, Maintain, Or In Any Other Way Use This Telescopic Material Handler: ...............................5
Pre-Start Inspection ................................................................................................................................................5
Starting....................................................................................................................................................................5
Operating ................................................................................................................................................................5
Load Handling.........................................................................................................................................................7
Stopping..................................................................................................................................................................7
Safety Instructions For Maintenance.................................................................................................................................8
Fire Prevention..................................................................................................................................................................8
Safety Instructions For Transporting And Hauling ............................................................................................................9
Safety Related Decals.....................................................................................................................................................10
Location Of The Decals ........................................................................................................................................10
Safety Related Decals Overview ..........................................................................................................................11
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IR VR518 2CPN 22806467
Operation and Maintenance Manual
SAFETY
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CPN 22806467 3IR VR518
Operation and Maintenance Manual
SAFETY
General Safety Information
Carefully follow the operating and maintenance instruc-
tions in this manual.
All IR telescopic handlers and attachments are designed to
ensure maximum safety to the operator. However, in spite
of very careful design, this machine can be dangerous if
not used and serviced according to the instructions in this
manual.
A certificate of compliance is issued on delivery of the
machine. This must be kept and shown at each periodic
inspection of the machine and handed over to the pur-
chaser if the machine is resold.
The IR telescopic handler is highly maneuverable and
compact. It is rugged and useful under a wide variety of
conditions. The operator will still face hazards associated
with various types of applications.
Subject to compliance with operating and maintenance
instructions, and use of the specially designed original
equipment, this machine:
• can be used for lifting operations with variable-length
load suspension components, which allow the load to
swing freely in all directions;
This machine is not designed for:
• use under weather conditions with a risk of lightning,
storm or winds faster than 12.5 m/s (force 6 on the Beau-
fort scale);
• use in explosive atmosphere;
• carrying out work on live power lines;
• carrying out underground work.
The dealer explains the capabilities and restrictions of the
IR telescopic handler for each application. The dealer
demonstrates the safe operation according to IR instruc-
tions, which are made available to operators.
The dealer can also identify unsafe modifications or use of
non-approved attachments.
The attachments and buckets are designed for rated
capacities and secure fastening to the IR telescopic
handler.
The user should check with the dealer, or refer to IR docu-
mentation, to determine safe loads of materials of
specified densities for the Telescopic Handler/Attachment
combination.
The user must adhere to the Rated Capacity Charts rela-
tive to each mounting of tires.
The user should use only the tires listed in “Tyres” on
page 94 and should ensure that the machine is equipped
with 4 identical tires.
The following publications and training materials provide
information on the safe use and maintenance of the tele-
scopic handler and attachments:
• The Delivery Report ensures that complete instructions
have been given to the new owner and that the IR Tele-
scopic Handler and equipment are in safe operating con-
dition.
• The Operation & Maintenance Manual delivered with the
IR telescopic handler or attachment provides operating
information as well as routine maintenance and service
procedures. It is a p art of the telescopic handler and
must be stored in the container provided inside the oper-
ator cab. Replacement Operation & Maintenance Manu-
als are available from your IR dealer.
• Machine signs (decals) instruct on the safe operation
and maintenance of your IR telescopic handler or attach-
ment. The signs and their locations are shown in the Op-
eration & Maintenance Manual. Replacement signs are
available from your IR dealer.
• The AEM Safety Manual
On delivery, the dealer checks the recommended applica-
tions of the product with the owner / operator. If the
machine is to be used for other applications, the owner/
operator should check the relevant recommendations with
the dealer.
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IR VR518 4CPN 22806467
Operation and Maintenance Manual
SAFETY
Safety Information In This Manual
DANGER
DANGER indicates a imminently hazardous situation
which, if not avoided, could result in death or serious
injury.
WARNING
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
CAUTION
CAUTION indicates a potentially hazardous situation
which, if not avoided, could result in minor or moder-
ate injury.
CAUTION
CAUTION used without the Safety Alert Symbol indi-
cates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE
NOTICE is used to notify people of installation, operation,
or maintenance information which is important but not haz-
ard related.
The IR telescopic handler and attachment must be in good
operating condition before use.
Operator Protection Equipment
ROPS (Rollover Protective Structure)
The cab/canopy incorporates a ROPS (rollover protective
structure) with overhead guard. When used in conjunction
with seat belts, the cab/canopy 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.
FOPS (Falling Object Protective Structure)
The cab/canopy protects the operator against the impact
of falling objects (e.g. a falling part of the load).
Seat Belt
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 stitching is found.
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 sub-
stantially 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.
LORS™ (Lateral Operator Restraint System)
(Canopy only)
The LORS™ requires the operator to be seated in the
operating position with the restraint bar lowered and
engine running before the machine can be operated.
Boom Safety Stop
The Variable Reach Telescopic Material Handler is
equipped with a boom stop 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.
See “Approved Boom Stop” on page 49 for more
information.
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CPN 22806467 5IR VR518
Operation and Maintenance Manual
SAFETY
Safety Instructions For Operation
Before You Operate, Maintain, Or In Any Other Way
Use This Telescopic Material Handler:
Read and study both this Manual and the AEM 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 oper-
ating 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 mainte-
nance of this telescopic material handler, ask your
supervisor or contact any Ingersoll-Rand distributor.
NEVER GUESS ALWAYS CHECK!
Pre-Start Inspection
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.
Clean any foreign material from the steps and operator’s
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 autho-
rized personnel.
ALWAYS know the capability and limitations of your equip-
ment: 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.
Check for any conditions that could be dangerous: holes,
banks, underground culverts, manhole covers, water
meter pits, curb and/or street boxes.
Starting
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.
The parking brake is ON.
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.
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 opera-
tion, before beginning work.
Operating
CAUTION
A qualified operator must not use drugs or alcoholic
drinks which impair his/her alertness or coordination
while working. An operator who is taking prescription
drugs must get medical advice to determine if he/she
can safely operate a machine.
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.
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IR VR518 6CPN 22806467
Operation and Maintenance Manual
SAFETY
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.
DO NOT work over or near electric power lines. The tele-
scopic material handler is not insulated. DO NOT operate
this machine in any location where any part of it will come
within 12 feet (3.66 meters) of any high-voltage lines.
DANGER
Hazardous voltage will cause severe injury or death.
Keep away from power lines.
Know the area in which you are working. Familiarize your-
self 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 signalling. 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 neces-
sary, use extreme caution and make the turn wide and
slow.
Keep your seat belt fastened at all times when operating
the machine.
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 direc-
tion 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 low-
ered. Rearward tilt of the carriage and load, off-center
loads, and uneven or soft ground will aggravate these
conditions.
Keep a safe distance from the edge of docks, ramps, plat-
forms, 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 han-
dler does not suddenly slide and tip over.
Coordinated steering provides the greatest maneuverabil-
ity and is the mode of steering most often used. 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.
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 pedestri-
ans 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.
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, con-
tact our IR dealer for towing instructions.
DO NOT run the engine in a closed building for an
extended length of time. EXHAUST FUMES CAN KILL.
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CPN 22806467 7IR VR518
Operation and Maintenance Manual
SAFETY
Load Handling
CAUTION
Make sure you understand the Rated Capacity
Chart(s) before a load is lifted.
Refer to the chapter “RATED CAPACITY CHARTS” on
page 15
WARNING
Only attachments which have been fully tested for
stability and have had Rated Capacity Charts estab-
lished 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.
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 repre-
sents 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 attach-
ments, 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 indi-
cator 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.
Inspect the load to be lifted. Lift the load and lower the load
only on stable level ground. If a load must be handled sev-
eral times, put stacking blocks under the load. Handle only
stable loads. A load can have unstable items that can eas-
ily 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.
Stopping
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 run-
ning. 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.
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IR VR518 8CPN 22806467
Operation and Maintenance Manual
SAFETY
Safety Instructions For Maintenance
Machine maintenance and compliance are obligatory. For
any intervention other than normal maintenance, consult
your IR dealer.
Only wear suitable clothing, AVOID loose clothing. Tie
back and protect your hair, if necessary.
Clean the machine or at least the relevant area before any
maintenance work. Protect against water, steam or clean-
ing agents any components likely to be damaged
(particularly electric components) during this operation.
Turn off the engine before any maintenance work. If any
maintenance work requires the engine to be running, take
all the necessary safety measures and precautions. There
may be moving parts, high temperatures, hydraulic circuits
under pressure, electric circuits under voltage. Such oper-
ations must be carried out by trained, qualified personnel.
Make any necessary repairs immediately even if they DO
NOT seem important. Immediately repair any leaks, even
if they DO NOT seem important.
Make sure that the area is adequately ventilated before
starting the engine.
DO NOT operate the machine without hydraulic fluid in the
hydraulic system.
DO NOT run the engine without complete fuel and exhaust
systems, without oil or coolant, or in case of fuel leakages.
AVOID, whenever possible, servicing or providing mainte-
nance 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
engine cooling system has cooled down. Use care when
removing hydraulic tank breather cap. Hydraulic tank is
pressurized. Hot oil can cause severe burns. DO NOT take
apart, tighten or loosen any connections, hoses or any
hydraulic component when the system is under pressure.
Such operations must be carried out by trained, qualified
personnel.
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 dam-
age to the electronic engine control module (ECM) will
occur if battery cables are connected.
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 con-
necting to a battery charger or jumper cable.
Clean up all traces of fuel, oil, grease or impurities.
Use only recommended lubricants. DO NOT use polluted
lubricants or lubricants whose filtration state is not pre-
cisely known.
DO NOT smoke or approach the machine with a bare
flame if the fuel tank is open or when filling it. Fill the tank
in a suitable place. DO NOT fill the tank while the engine is
running.
Fire Prevention
The machines and some attachments have components
that are at high temperatures under normal operating con-
ditions. The primary source of high temperatures is the
engine and exhaust system. The electrical system, if dam-
aged or incorrectly maintained, can be a source of arcs or
sparks.
• Stop the engine and let it c ool before adding fuel.
No smoking!
• Use the procedure in the Operation & Maintenance Man-
ual for connecting the battery and for jump starting.
• Know where fire extinguishers and first aid kits are locat-
ed and how to use them. Replacement fire extinguishers
are available from your IR dealer.
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CPN 22806467 9IR VR518
Operation and Maintenance Manual
SAFETY
Safety Instructions For Transporting And
Hauling
DO NOT attempt to load the Variable Reach Telescopic
Material Handler onto the transporter without knowledge
and experience with the operation of the telescopic mate-
rial 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 Tele-
scopic 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 dis-
tance 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.
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IR VR518 10 CPN 22806467
Operation and Maintenance Manual
SAFETY
Safety Related Decals
Follow the instructions on all the Machine Signs (Decals) that are on the telescopic handler. Replace any damaged
machine signs and be sure they are in the correct locations. Machine signs are available from you IR loader dealer.
Location Of The Decals Figure 1
10 314 44
3
8
7
6
5
812 5
13
621 4
1
9
4
S0798
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