Ingersoll-Rand VR638 User manual

VR638
Cab
S/N 3650 12001
& above
VR638
Canopy
S/N 3651 12001
& above
Operation and
Maintenance
Manual
CPN 22806483 (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.
1 of 99

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
I
ncorrec
t
I
ncorrec
t
I
ncorrec
t
I
ncorrec
t
I
ncorrec
t
I
ncorrec
t
I
ncorrec
t
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.
2 of 99
Find manuals at https://best-manuals.com

CPN 22806483 II-R VR-638
Operation and Maintenance Manual
CONTENTS
CONTENTS
CONTENTS .......................................................................................................................................................................I
FOREWORD....................................................................................................................................................................III
SAFETY ............................................................................................................................................................................1
RATED CAPACITY CHARTS .........................................................................................................................................15
OPERATING INSTRUCTIONS .......................................................................................................................................19
PREVENTIVE MAINTENANCE ......................................................................................................................................47
OPTIONS ........................................................................................................................................................................77
SPECIFICATIONS VR638 ..............................................................................................................................................83
MATERIAL HANDLER WARRANTY ..............................................................................................................................89
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:
3 of 99
Find manuals at https://best-manuals.com

I-R VR-638 II CPN 22806483
Operation and Maintenance Manual
CONTENTS
4 of 99
Find manuals at https://best-manuals.com

CPN 22806483 III I-R VR-638
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.
5 of 99
Find manuals at https://best-manuals.com

I-R VR-638 IV CPN 22806483
Operation and Maintenance Manual
FOREWORD
6 of 99
Find manuals at https://best-manuals.com

CPN 22806483 VI-R VR-638
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.
xxx
S0780
S0430
7 of 99
Find manuals at https://best-manuals.com

I-R VR-638 VI CPN 22806483
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
8 of 99
Find manuals at https://best-manuals.com

CPN 22806483 VII I-R VR-638
Operation and Maintenance Manual
FOREWORD
Identification Of The Telescopic Handler
Figure 5
Reference Designation
1 Telescopic boom
2 Boom
3 Fuel tank
4 Mirror
5 Operator Cab
6 Battery compartment
7 Boom stop
8 Engine exhaust
9 Lights (opt.)
10 Engine cover
11 Rotating beacon (opt.)
12 Forks
13 Angle indicator
14 Lateral Operator Restraint Bar (LORS™)
(only on canopy models)
! ' %
#
!
$
""
& 


'
S1820
This figure shows the cab version.
9 of 99
Find manuals at https://best-manuals.com

I-R VR-638 VIII CPN 22806483
Operation and Maintenance Manual
FOREWORD
Options and Accessories
The VR638 Telescopic Handlers Have The Following
Basic Equipment:
• Hydrostatic transmission
• ROPS/FOPS operator canopy
• Hydraulic Joystick Control
• Two-way auxiliary hydraulic supply at the end of the
boom
• Hydraulic system
• 4 equal-size drive and steering wheels with
TITAN 13.00 x 24 12 PR G2 LIFT RIGGER tires
• Back up alarm
• Mirrors
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.
Two mounts are possible:
Options
•Tires
• Cab with air conditioning and heating
• Rotating beacon
• Roof windscreen wiper
• Hydraulic lock of accessories
• Mudguards
APPROVED TIRES & INFLATION PRESSURES
VR638
Manufacturer Model Size Load
Range Pressure (PSI)
TITAN
(standard) Lift Rigger 13.00-24 12 PR 75
MITAS
(option) Traction TR-01 15.5/80-24 159 A8 73
10 of 99
Find manuals at https://best-manuals.com