OPERATION AND MAINTENANCE

MANUAL for VR-843C

Variable Reach Material Handler
Effective with Serial Number 175806

CPN 13858303 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-843C
TITLE PAGE
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

VR-843C i
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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

ii VR-843C
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VR-843C
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

iv VR-843C
 TABLE OF CONTENTS
VR-843C
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-843C RECOMMENDED SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

RECOMMENDED LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9

WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-1

VR-843C v
 INTRODUCTION

INTRODUCTION

GENERAL
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-843C 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-843C machine. A three-speed, power-
shift 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.

STEERING
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.

OPTIONAL EQUIPMENT
The VR-843C 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
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.
It is important that any procedure not specifically recommended in this manual be thoroughly
evaluated from the standpoint of safety before it is implemented.

VR-843C 1
 INTRODUCTION

! 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

2 VR-843C
 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-843C 3
 INTRODUCTION

4 VR-843C
SAFETY SECTION 1

SECTION 1 - SAFETY

BE AWARE OF SAFETY INFORMATION

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.

UNDERSTAND SIGNAL WORDS

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-843C 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.

NOTICE
BLUE BACKGROUND

NOTICE is used to notify people of installation, operation, or maintenance information

which is important but not hazard related.

OVERVIEW
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!

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 operators platform to reduce the danger of
slipping.

1-2 VR-843C
SAFETY SECTION 1

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.

OPERATOR PROTECTION EQUIPMENT

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.

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.

VR-843C 1-3
 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.

OPERATING
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

1-4 VR-843C
SAFETY SECTION 1

! 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

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-843C 1-5
 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.
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.

1-6 VR-843C
SAFETY SECTION 1

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, off-
center 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 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.
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.

VR-843C 1-7
 SECTION 1 SAFETY

! 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.

LOAD HANDLING
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.
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.

1-8 VR-843C
SAFETY SECTION 1

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 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.

MAINTENANCE
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.
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.

VR-843C 1-9
 SECTION 1 SAFETY

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 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.

1-10 VR-843C
SAFETY SECTION 1

LOAD CAPACITY CHARTS

! 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-843C 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

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.

1-12 VR-843C
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-843C 1-13
 SECTION 1 SAFETY

ANGLE INDICATOR
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-843C
SAFETY SECTION 1

HAZARDOUS SUBSTANCE PRECAUTION

The following substances are contained in this machine and may be hazardous to 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 Avoid injestion, skin contact, and breathing fumes.
Rust Preventative Avoid injestion, skin contact, and breathing fumes.
Engine Fuel Avoid injestion, skin contact, and breathing fumes.
Battery Fluid Avoid injestion, skin contact, and breathing fumes.
SAE Gear Oil 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.
Electric Motor Dust Avoid breathing during maintenance.
(Brushes/Insulation)
Break Lining Dust * Avoid breathing during maintenance.

* Only on machines with dry axle brakes.

VR-843C 1-15
 SECTION 1 SAFETY

SAFETY DECALS (SHEET 1 of 2)

Table 2: Decal Reference Numbers

REF
DESCRIPTION QTY. LOCATION
NO.
1 WARNING: Moving Machine 2 Top of Frame
2 WARNING: Crush Area 1 Counter Weight Box
3 WARNING: Pressure Hazard 1 Rear Engine Cover
4 WARNING: Carriage 2 Upright Carriage
7 WARNING: Rollover Tire Inflation 1 Front Engine Cover
8 WARNING: Improper Operation 2 Front Engine Cover
9 WARNING: Rotating Fan 2 Rear Engine Cover
10 WARNING: Falling Load 2 Counter Weight Box
19 NOTICE: Unmetered Ether 1 Top of Frame
20 WARNING: Runover 1 Fuel Tank

1-16 VR-843C
SAFETY SECTION 1

SAFETY DECALS (SHEET 2 of 2)

VR-843C 1-17
 SECTION 1 SAFETY

Table 3: Decal Reference Numbers

REF
DESCRIPTION QTY. LOCATION
NO.
4 WARNING: Carriage 2 Upright Carriage
5 WARNING: Block Axle Frame 2 Frame Level Cylinder
6 WARNING: Crush Area 5 Behind Each Wheel
8 WARNING: Improper Operation 2 Front Engine Cover
10 WARNING: Falling Load 2 Counter Weight Box
11 WARNING: Fall from Forks 1 Upright Carriage
12 WARNING: Rollover 2 Operator’s Console
13 DANGER: Electrical Hazard 1 Operator’s Console
14 WARNING: No Riders 1 Operator’s Cab
15 NOTICE: OSHA 1 Operator’s Cab
16 WARNING: Frame Level 1 Operator’s Cab
17 NOTICE: Parking Brake Test 1 Operator’s Console
18 WARNING: Unpinned Attachment 1 Operator’s Console

SAFETY RELATED DECALS

1. WARNING: Moving Machine

1-18 VR-843C
SAFETY SECTION 1

2. WARNING: Crush Area

3. WARNING: Pressure Hazard

4. WARNING: Carriage

VR-843C 1-19
 SECTION 1 SAFETY

5. WARNING: Block Axle Frame

6. WARNING: Crush Area

7. WARNING: Rollover Tire Inflation

1-20 VR-843C
SAFETY SECTION 1

8. WARNING: Improper Operation

9. WARNING: Rotating Fan

10. WARNING: Falling Load

VR-843C 1-21
 SECTION 1 SAFETY

11. WARNING: Fall from Forks

12. WARNING: Rollover

13. DANGER: Electrical Hazard

1-22 VR-843C
SAFETY SECTION 1

14. WARNING: No Riders

15. NOTICE: OSHA

16. WARNING: Frame Level

VR-843C 1-23
 SECTION 1 SAFETY

17. NOTICE: Parking Brake Test

18. WARNING: Unpinned Attachment

19. NOTICE: Unmetered Ether

1-24 VR-843C
SAFETY SECTION 1

20. WARNING: Runover

VR-843C 1-25
 SECTION 1 SAFETY

1-26 VR-843C
SYMBOL IDENTIFICATION/METRIC CONVERSION SECTION 2

SECTION 2 - SYMBOL IDENTIFICATION/METRIC

CONVERSION

INTERNATIONAL MACHINE SYMBOLS

This section contains symbols that may be used on the VR-843C Variable Reach Material
Handler. The following explains the meaning of international symbols that may appear on your
machine.

1. On/Start 7. Transmission Oil 13. Fuel (Diesel)

Temperature

2. Off/Stop 8. Engine Oil 14. Fuel Level

3. Horn 9. Coolant Temperature 15. Work Lights

4. Battery Condition 10. Ether Inject (Cold Start) 16. Flashing Beacon

5. Hourmeter 11. Parking Brake 17. Remote Cylinder Extent

and Retract

6. Grease 12. Hydraulic Oil 18. Control Lever -

Multidirectional

VR-843C 2-1
 SECTION 2 SYMBOL IDENTIFICATION/METRIC CONVERSION

INTERNATIONAL HIGHWAY SYMBOLS

The following symbols may also appear in a yellow square instead of in a red triangle.

2-2 VR-843C
SYMBOL IDENTIFICATION/METRIC CONVERSION SECTION 2

METRIC CONVERSION

TO CONVERT INTO MULTIPLY BY

bars pounds per sq. in. 14.5
bars kilopascals 100
Celsius Fahrenheit (°C X 9/5) + 32
centimeters inches 0.3937
centimeters millimeters 10
circumference radians 6.283
cubic centimeters cubic inches 0.06102
degrees (angle) radians 0.1745
degrees per second revolutions per minute 0.1667
Fahrenheit Celsius (°F - 32) x 5/9
feet meters 0.3048
feet per minute meters per minute 0.3048
gallons liters 3.785
Hertz vibrations per minute 60
horsepower kilowatts 0.7457
inches centimeters 2.54
inches millimeters 25.4
kilograms pounds 2.205
kilograms-meter pounds-foot 7.233
kilopascals pounds per sq. in. 0.145
kilopascals bars 0.01
kilowatts horsepower 1.341
liters gallons (U.S. liquid) 0.2642
liters pints (U.S. liquid) 2.113
liters quarts (U.S. liquid) 1.057

VR-843C 2-3
 SECTION 2 SYMBOL IDENTIFICATION/METRIC CONVERSION

TO CONVERT INTO MULTIPLY BY

meters feet 3.281
meters inches 39.37
meters per minute feet per second 0.05468
miles per hour kilometers per hour 1.609
millimeters inches 0.03937
Newtons pounds 4.448
Newtons-meter pounds-foot 0.737
pints (liquid) liters 0.4732
pounds kilograms 0.4536
pounds Newtons 0.225
pounds-foot kilograms-meter 0.138
pounds-foot Newtons-meter 1.356
pounds per square inch bars 0.06895
pounds per square inch kilopascals 6.895
quarts (liquid) liters 0.9463
radians degrees 57.30
radians per second revolutions per minute 9.549
revolutions per minute degrees per second 6.0
revolutions per minute radians per second 0.1047
tons (short) tons (metric) 0.9078
vibrations per minute Hertz 0.0167

2-4 VR-843C
OPERATING CONTROLS AND INSTRUMENTS SECTION 3

SECTION 3 - OPERATING CONTROLS AND

INSTRUMENTS
The following individual controls and instruments are used on the VR-843C 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

FUEL GAUGE
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.

BATTERY GAUGE (VOLTMETER)

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.

ENGINE OIL PRESSURE GAUGE

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-843C 3-1
 SECTION 3 OPERATING CONTROLS AND INSTRUMENTS

TRANSMISSION OIL TEMPERATURE GAUGE

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.

HOURMETER
The Hourmeter (5, Figure 3-1) indicates the operating hours for the engine. Maintenance
recommendations are based on the engine operating hours.

WATER TEMPERATURE GAUGE

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.

AUXILIARY FUNCTION SWITCH (OPTION)

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.

LEFT AND RIGHT STABILIZER SWITCHES

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.

ETHER SWITCH (OPTION)

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.

SPARES
These slots (11, Figure 3-1) are spares and are not used currently.

3-2 VR-843C
OPERATING CONTROLS AND INSTRUMENTS SECTION 3

Figure 3-2

DIRECTION CONTROL LEVER

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.

TRANSMISSION RANGE SELECTOR

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.

HORN BUTTON
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-843C 3-3
 SECTION 3 OPERATING CONTROLS AND INSTRUMENTS

Figure 3-3

WORK LIGHT SWITCH (OPTION)

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.

BOOM LIGHT SWITCH

The Boom Light Switch (16, Figure 3-3) controls the optional light at the end of the boom.

SPARE
Slot (17, Figure 3-3) is a spare and are not used currently.

TURN SIGNAL CONTROL LEVER (OPTION)

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.

BEACON SWITCH
The Beacon Switch (19, Figure 3-3) controls the optional beacon.

3-4 VR-843C
OPERATING CONTROLS AND INSTRUMENTS SECTION 3

PARK BRAKE SWITCH

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

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

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.

STOP ENGINE LIGHT

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.

STEERING MODE SELECTOR SWITCH

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.

BRAKE PEDAL
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-843C 3-5
 SECTION 3 OPERATING CONTROLS AND INSTRUMENTS

WINDSHIELD WASHER
The Windshield Washer Switch (26, Figure 3-3) activates the pump for the windshield washer.
Press and hold the switch to activate.

PARK BRAKE TEST SWITCH

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.

KEY SWITCH
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.

ACCELERATOR PEDAL
The Accelerator Pedal (29, Figure 3-3) is operated by the operator’s right foot and controls the
engine speed.

FUSE PANEL
The fuse block is located inside the control panel housing behind panel (30, Figure 3-3).

3-6 VR-843C
OPERATING CONTROLS AND INSTRUMENTS SECTION 3

Figure 3-4

BOOM CONTROL JOYSTICK

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.

LEVEL AND FORK CONTROL JOYSTICK

! 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-843C 3-7
 SECTION 3 OPERATING CONTROLS AND INSTRUMENTS

Figure 3-5

LEVEL INDICATOR
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

SINGLE JOYSTICK CONTROL - OPTION

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.

3-8 VR-843C
OPERATING CONTROLS AND INSTRUMENTS SECTION 3

Figure 3-7

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-843C 3-9
 SECTION 3 OPERATING CONTROLS AND INSTRUMENTS

ENGINE DIAGNOSTIC PORT

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

12 VOLT POWER PORT

A convenient 12 volt power port (1, Figure 3-9) is located in front of the joystick control console.

Figure 3-9

3-10 VR-843C
OPERATING CONTROLS AND INSTRUMENTS SECTION 3

HEATER AND AIR CONDITIONER CONTROLS - OPTION

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-843C 3-11
 SECTION 3 OPERATING CONTROLS AND INSTRUMENTS

3-12 VR-843C
OPERATING INSTRUCTIONS SECTION 4

SECTION 4 - OPERATING INSTRUCTIONS

! 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.

GENERAL
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-843C 4-1
 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.

STABILITY AND CENTER OF GRAVITY

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

4-2 VR-843C
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-843C 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

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.

INSPECTION BEFORE OPERATION

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.

4-4 VR-843C
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-843C 4-5
 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

4-6 VR-843C
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-843C 4-7
 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

4-8 VR-843C
OPERATING INSTRUCTIONS SECTION 4

7. Check condition of the drive belt (1, Figure 4-13). Replace belt if cracked or
worn.

Figure 4-13

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-843C 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-843C
OPERATING INSTRUCTIONS SECTION 4

STARTING PROCEDURES

! 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-843C 4-11
 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 4-16).

Figure 4-16

4-12 VR-843C
OPERATING INSTRUCTIONS SECTION 4

3. Put the direction control lever (12, Figure 4-17) in the "Neutral" (N) position.

Figure 4-17

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-843C 4-13
 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.

PRE-OPERATION CHECKS
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

4-14 VR-843C
OPERATING INSTRUCTIONS SECTION 4

Figure 4-20

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.

PARK BRAKE TEST 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-843C 4-15
 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).

4-16 VR-843C
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.

BASIC OPERATING PROCEDURES

! 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-843C 4-17
 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-843C 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.

4-18 VR-843C
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-843C 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-843C 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

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).

4-20 VR-843C
OPERATING INSTRUCTIONS SECTION 4

STEERING AND TURNING

! 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-843C 4-21
 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.

4-22 VR-843C
OPERATING INSTRUCTIONS SECTION 4

The VR-843C 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-843C 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

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.

HANDLING AND MOVING LOADS

! WARNING
Serious Personal Injury

Improper operation cab 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.

4-24 VR-843C
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-843C 4-25
 SECTION 4 OPERATING INSTRUCTIONS

Figure 4-31

Figure 4-32

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.

4-26 VR-843C
OPERATING INSTRUCTIONS SECTION 4

LIFTING, LOWERING, AND TILTING

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-843C 4-27
 SECTION 4 OPERATING INSTRUCTIONS

Figure 4-33

Figure 4-34

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.

4-28 VR-843C
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-843C 4-29
 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

4-30 VR-843C
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.

TRAVELING
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-843C 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

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.

4-32 VR-843C
OPERATING INSTRUCTIONS SECTION 4

ATTACHMENTS

! 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.

PARKING
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-843C 4-33
 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.

TOWING
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.

4-34 VR-843C
OPERATING INSTRUCTIONS SECTION 4

If the machine has no power:

! 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. Shutdown 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-843C 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 (3).

c. Remove cylinder rod nut (4, Figure 4-38).

d. Loosen set-screw (2, Figure 4-38) to allow the park brake arm to swing
free of the cylinder rod (5) and release the park brake.

Figure 4-38

7. Remove the chocks from wheels and tow the machine.

4-36 VR-843C
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. Position arm (3, Figure 4-38) onto cylinder rod (5).

b. Tighten set-screw (2, Figure 4-38) enough to allow nut (4) to be installed
onto rod (5).

c. Tighten nut (4, Figure 4-38) until park brake arm (3) is tight against rod
lock nut (6).

d. Back out set-screw (2, Figure 4-38) and tighten lock nut (1).

9. Reconnect the drive shafts.

STABILIZERS
Stabilizers (1, Figure 4-39) are available as optional equipment on the VR-843C Material
Handler. The stabilizers should be used whenever you are picking up or placing a load with
the boom raised.

Figure 4-39

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.

VR-843C 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

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.

4-38 VR-843C
OPERATING INSTRUCTIONS SECTION 4

TRANSPORTATION

! 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.

VANDAL PROTECTION COVER - OPTION

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-843C 4-39
 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).

OPTIONS
The following options affect the load capacity and CG of the VR-843C. 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.

QUICK ATTACHMENT APRON

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

4-40 VR-843C
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-843C 4-41
 SECTION 4 OPERATING INSTRUCTIONS

SCRAP GRAPPLE BUCKET -- OPTION

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 DESCRIPTION

1 Scrap Grapple Bucket

2 Adapter
3 Coupler
4 Quick Disconnect Nipple
5 Quick Connect Couple Dust Cap
6 Quick Connect Nipple Dust Cap

4-42 VR-843C
OPERATING INSTRUCTIONS SECTION 4

BUCKET LOADER INSTALLATION — OPTION

The Bucket Loader (1, Figure 4-44) mounts as shown in Figure 4-44.

Figure 4-44

TRUSS BOOM INSTALLATION — OPTION

The Truss Boom (1, Figure 4-45) mounts as shown in Figure 4-45.

Figure 4-45

VR-843C 4-43
 SECTION 4 OPERATING INSTRUCTIONS

PINTLE HOOK INSTALLATION — OPTION

The Pintle Hook (1, Figure 4-46) mounts and connects to a tapped plate located at the rear of
the VR-843C 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 DESCRIPTION

1 Pintle Hook Plate

2 Pintle Hook
3 Washer
4 H.H.C.S.
5 Washer
6 H.H.C.S.

4-44 VR-843C
OPERATING INSTRUCTIONS SECTION 4

DRY WALL HANDLER INSTALLATION — OPTION

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-843C 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

6 1
3 2
4
5

ITEM DESCRIPTION

1 Wing Screw M12 x 1.75 x 60 mm (Qty 4)

NOTE: Apply Never Seize before installing.
2 Left Hand Fork Rest (Right Hand Similar)
3 Left Hand Plate Catch (Right Hand Similar)
4 Left Hand Float Stop (Right HandSimilar)
5 Retaining Ring
6 Wing Nut (Qty 2) M12 x 1.75 x 60 mm

4-46 VR-843C
OPERATING INSTRUCTIONS SECTION 4

SIDE TILT CARRIAGE — OPTION

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

ITEM DESCRIPTION

1 S/T QA Carriage (1219 mm [48 in.], 1524

mm [60 in.], or 1829 mm [72 in.])
2 Not Used with VR series
3 Adapter (Qty 2)
4 Coupler (Quick Disconnect)
5 Nipple (Quick Disconnect)
6 Dust Cap (used with item 4)
7 Dust Cap (used with item 5)

VR-843C 4-47
 SECTION 4 OPERATING INSTRUCTIONS

SWING CARRIAGE -- OPTION

The Swing Carriage allows carriage to swivel to either side. The carriage mounts and connects
as shown in Figure 4-49.

Figure 4-49

ITEM DESCRIPTION

1 Swing Carriage Assembly

2 Load Arm
3 Adapter
4 Coupler (Quick Disconnect)
5 Nipple (Quick Disconnect)
6 Dust Cap (used with item 4)
7 Dust Cap (used with item 5)
8 Hex Head Cap Screw
9 Lockwasher
10 Plate
11 Load Chart / VR Attachment Chart
12 Metal Tack

4-48 VR-843C
MAINTENANCE INSTRUCTIONS SECTION 5

SECTION 5 - MAINTENANCE INSTRUCTIONS

! 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.

GENERAL MAINTENANCE INFORMATION

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-843C 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-843C
MAINTENANCE INSTRUCTIONS SECTION 5

MAINTENANCE SCHEDULE
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

INITIAL MAINTENANCE
Powershift Transmission Oil Filter Page 5-5
Wheel Nut Tightness 599 N-m (442 lb.-ft.) Page 5-6
Tighten Loose Bolted Connections Page 5-6
10 HOUR OR DAILY MAINTENANCE
Check Engine Oil Level Page 5-7
Check Coolant Level, Radiator, and Hoses Page 5-8
Check Transmission Fluid Level Page 5-9
Check Air Cleaner Connections and Ducts for Leaks Page 5-10
Check Air Cleaner Restriction Page 5-10
Cleaning and Replacing the Air Cleaner Element Page 5-11
Air Cleaner Vacuator Valve Page 5-14
Check Hydraulic Oil Level Page 5-15
Fuel/Water Separator Page 5-15
Fill Fuel Tank Page 5-16
Check Park Brake Page 5-17
Check Tire Pressure and Condition Page 5-18
Check Seat Belt and Mounting Hardware Page 5-19

VR-843C 5-3
 SECTION 5 MAINTENANCE INSTRUCTIONS

Function Specification Page

50 HOUR OR WEEKLY MAINTENANCE
Grease Chain Sheave Bearings MPG-EP 2 grease Page 5-19
Check Lug Nut Torque 599 N-m (442 lb.-ft.) Page 5-21
Check Oil Level in Axle Differential Planetary Wheel Page 5-22
Ends
Check Oil Level in Axle Differentials Page 5-23
Grease Axle Pivot Bearings MPG-EP 2 grease Page 5-24
Grease Axle King Pins MPG-EP 2 grease Page 5-24
Grease Fork Pins MPG-EP 2 grease Page 5-25
Grease Frame Level Pivot Bushings and Stabilizer MPG-EP 2 grease Page 5-25
Pivot Bushings
Grease Boom Pivot and Boom Cylinders MPG-EP 2 grease Page 5-26
Clean Heater/A-C Filter Page 5-26
250 HOUR OR QUARTERLY MAINTENANCE
Change Engine Oil and Filter Page 5-27
Change Fuel Filters Page 5-29
Change In Line Filter Page 5-29
Clean Hydraulic Tank Breather Page 5-30
Torque Axle Mounting Bolts 597 N-m (440 lb.-ft.) Page 5-30
Inspect Chains Page 5-31
Check Boom Wear Pad Clearances Page 5-33
Adjust Boom Chains and Hoses Page 5-36
1000 HOUR OR ANNUAL MAINTENANCE
Change Hydraulic Oil Filter Page 5-39
Change Hydraulic Oil and Clean Suction Strainer Page 5-40
Change Axle Differential Oil Page 5-41
Change Axle Planetary Oil Page 5-43
Engine Coolant Page 5-44
Change Transmission Oil Page 5-46
Change Transmission Oil Filter Page 5-48

5-4 VR-843C
MAINTENANCE INSTRUCTIONS SECTION 5

INITIAL MAINTENANCE SCHEDULE

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-843C 5-5
 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.

5-6 VR-843C
MAINTENANCE INSTRUCTIONS SECTION 5

10 HOUR OR DAILY ROUTINE MAINTENANCE

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

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-843C 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

2. Check radiator fins and clean as necessary using compressed air or water.

3. Check radiator hoses for leaks or damage.

5-8 VR-843C
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-843C 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

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.

5-10 VR-843C
MAINTENANCE INSTRUCTIONS SECTION 5

Cleaning and Replacing the Air Cleaner Element

The VR-843C 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-843C 5-11
 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

5-12 VR-843C
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-843C 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

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.

5-14 VR-843C
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-843C 5-15
 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

5-16 VR-843C
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-843C 5-17
 SECTION 5 MAINTENANCE INSTRUCTIONS

Check Tire Pressure and Condition

! 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

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.

5-18 VR-843C
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).

50 HOUR OR WEEKLY ROUTINE MAINTENANCE

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-843C 5-19
 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

5-20 VR-843C
MAINTENANCE INSTRUCTIONS SECTION 5

7. Apply four shots of MPG-EP2 grease to fitting (1, Figure 5-24) on the extend
chain sheave bearing.

Figure 5-24

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 eight-
hour check, the interval for checking with a torque wrench can be extended to 250 hours.

Figure 5-25

VR-843C 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

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.

5-22 VR-843C
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 8 for the correct lubricant.

4. Replace plug and repeat step procedure for the remaining axle.

VR-843C 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

1. Wipe each fitting clean.

2. Apply four (4) shots of MPG-EP2 grease to each fitting (2, Figure 5-30).

5-24 VR-843C
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-843C 5-25
 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.

5-26 VR-843C
MAINTENANCE INSTRUCTIONS SECTION 5

250 HOUR OR QUARTERLY ROUTINE MAINTENANCE

Change Engine Oil and Filter

! 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-843C 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

11. Start the engine. Check the engine oil pressure and for any leaks.

5-28 VR-843C
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-843C 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

1. Torque front axle mounting bolts to 895 N•m (660 lb.-ft.).

2. Repeat procedure for rear axle.

5-30 VR-843C
MAINTENANCE INSTRUCTIONS SECTION 5

Inspect Chains

! 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-843C 5-31
 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).

5-32 VR-843C
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-843C 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

c. Repeat above steps for pad locations 2, 3, & 4.

5-34 VR-843C
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. Shut down 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. Shut down 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-843C 5-35
 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.

5-36 VR-843C
MAINTENANCE INSTRUCTIONS SECTION 5

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

Figure 5-52

4. Start the engine and fully retract the boom.

5. Stop the engine.

VR-843C 5-37
 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.

5-38 VR-843C
MAINTENANCE INSTRUCTIONS SECTION 5

1000 HOUR OR ANNUAL ROUTINE MAINTENANCE

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-843C 5-39
 SECTION 5 MAINTENANCE INSTRUCTIONS

Change Hydraulic Oil and Clean Suction Strainer

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

5-40 VR-843C
MAINTENANCE INSTRUCTIONS SECTION 5

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

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-843C 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

4. Place a drain pan capable of holding approximately 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.

5-42 VR-843C
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-843C 5-43
 SECTION 5 MAINTENANCE INSTRUCTIONS

Engine Coolant

! 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

1. Open the radiator cap (1, Figure 5-61) to ensure proper draining.

5-44 VR-843C
MAINTENANCE INSTRUCTIONS SECTION 5

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

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-843C 5-45
 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

5-46 VR-843C
MAINTENANCE INSTRUCTIONS SECTION 5

! 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

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-843C 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

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).

LONG TERM STORAGE

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.

5-48 VR-843C
TROUBLESHOOTING SECTION 6

SECTION 6 - TROUBLESHOOTING

! 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.

FUSES AND RELAYS

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-843C 6-1
 SECTION 6 TROUBLESHOOTING

Figure 6-2

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 ENGINE ECM

BATTERY +
F22 7.5 AMP ENGINE ECM
BATTERY +
F23 7.5 AMP ENGINE ECM
BATTERY +
F24 10 AMP ENGINE ECM
(FUEL PUMP)
F25 10 AMP ENGINE ECM
(FUEL PUMP)

6-2 VR-843C
TROUBLESHOOTING SECTION 6

Relays are also included on this machine. They are identified in Table 6-2.
Table 6-2

RELAY CHART
RELAY FUNCTION
NO.
CR1 POWER RELAY
CR2 BRAKE TEST
(ALT DROOP)
CR3 BRAKE TEST (NEUTRAL)
CR4 BRAKE TEST (LATCHING)
CR5 BRAKE TEST
(REVERSE LOCKOUT)
CR6 (STARTER)
CR7 BRAKE TEST
(PRESS SWITCH)

ENGINE WILL NOT START

Starter does not rotate

• Fuse F1 defective • Check console fuse and replace
• Battery discharged • Check battery, charge if necessary
• Battery cable connections loose • Clean and tighten terminal
or disconnected connections
• In-line fuse to starter blown • Call for service to correct fault
• Starter relay fault • Call for service to correct fault
• Ignition Switch defective • Call for service to correct fault
• Starter solenoid or starter • Call for service to correct fault
defective
• Ballast kill switch defective • Call for service to correct fault
• Park Brake not switched on • Turn on Park Brake
• Transmission shifter lever NOT in • Place shifter in NEUTRAL
NEUTRAL

VR-843C 6-3
 SECTION 6 TROUBLESHOOTING

Starter does rotate

• Empty Fuel Tank • Fill fuel tank
• Clogged Fuel Filter • Call for service to clean/replace
• Fuel solenoid at fuel pump • Call for service to test/replace
defective
• Check fuel solenoid with test lamp
• Defective wiring • Call for service to correct fault

DIFFICULT STARTING & POOR/IRREGULAR PERFORMANCE

• Low battery power • Check battery

• Batteries discharged • Charge battery, if necessary
• Battery cable connections loose • Clean and tighten terminal
or corroded connections, cover with acid-free
grease
• Using too high a viscosity oil in • Use appropriate oil grade for the
low ambient temps. ambient temperature conditions
• Fuel line blockage due to wax • Change fuel filters, and bleed fuel
separation in winter system, check for fuel line leaks and
loose connection. Always use winter
grade fuel in winter
• Incorrect valve clearances • Call for service to adjust
• Loose or badly adjusted throttle • Adjust or replace control cable
cable
• Defective fuel injectors • Call for specialist service
• Defective turbocharger • Call for specialist service
• Blocked air cleaner element • Clean or replace element

6-4 VR-843C
TROUBLESHOOTING SECTION 6

ENGINE MAKING EXCESSIVE FUMES

• Engine oil level too high • Drain engine oil to correct level on
the dip stick
• Blocked air cleaner element • Clean or replace element
• Low compression due to poor • Call for specialist service
condition of the valve or incorrect
valve clearance

ENGINE OVERHEATS - STOP ENGINE IMMEDIATELY

• Excessive dirt on cooling system • Clean the radiator/cooling fins

• Engine belt broken • Call for service to correct fault
• Defective injector nozzle • Call for service to correct fault
• Incorrect fuel pump calibration • Call for service to correct fault
• Blocked cooling air flow • Clear blockage

LOW ENGINE OIL PRESSURE

• Low engine oil level • Fill oil level to dipstick mark

• Defective oil pressure switch • Check with test lamp.
• Leaks from lubrication system • Stop engine and check for leaks,
and tighten any loose fittings on the
system oil lines

VOLTMETER INDICATES LOW OR NEGATIVE VOLTAGE

• Speed of alternator too low • Check belt tensions, change belt if

required
• Battery discharged or dead • Check battery, charge if necessary.
• Not charging due to defective • Call for service to correct fault
alternator or regulator

VR-843C 6-5
 SECTION 6 TROUBLESHOOTING

ELECTRICAL CIRCUIT MALFUNCTIONS

IGNITION, RELAY, LIGHTS RELAY,

FRAME LEVEL, ETHER (OPT), BEACON
(OPT)
• Fuse F1 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

TRANS, BACKUP ALARM, PARK BRAKE

• Fuse F2 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

STEER SELECTION, FUEL SOLENOID

• Fuse F3 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

GAUGES, HORN
• Fuse F4 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

ENGINE INDICATOR LAMPS, ECM

SWITCH POWER
• Fuse F5 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

REAR AXLE STABILIZER (RAS)

• Fuse F6 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

POWER PORT
• Fuse F7 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

6-6 VR-843C
TROUBLESHOOTING SECTION 6

WIPER (REAR)
• Fuse F8 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

WORK LIGHTS
• Fuse F9 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

STABILIZERS
• Fuse F10 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

AUXILIARY HYDRAULICS
• Fuse F11 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

TURN, HAZARD, BRAKE LIGHTS

• Fuse F12 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

BOOM LIGHTS
• Fuse F13 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

WIPER (FRONT)
• Fuse F14 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

WIPER (TOP)
• Fuse F15 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

VR-843C 6-7
 SECTION 6 TROUBLESHOOTING

WASHER, FAN, INTERIOR LIGHT

• Fuse F16 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

HEATER VALVE, AIR CONDITIONING

• Fuse F17 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

BLOWER
• Fuse F18 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

OPEN
• Fuse F19

OPEN
• Fuse F20

ENGINE ECM (BATTERY +)

• Fuse F21 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

ENGINE ECM (BATTERY +)

• Fuse F22 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

ENGINE ECM (BATTERY +)

• Fuse F23 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

6-8 VR-843C
TROUBLESHOOTING SECTION 6

ENGINE ECM (FUEL PUMP)

• Fuse F24 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

ENGINE ECM (FUEL PUMP)

• Fuse F25 defective • Check console fuse and replace
• Defective wiring/parts • Call for service to correct fault

NOTE
Fuses F21 to F25 (Engine ECM) are located on the chassis harness next to the
engine.

BALLAST / IGNITION KILL SWITCH

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-843C 6-9
 SECTION 6 TROUBLESHOOTING

Figure 6-4

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

6-10 VR-843C
TECHNICAL SPECIFICATIONS SECTION 7

SECTION 7 - TECHNICAL SPECIFICATIONS

GENERAL IDENTIFICATION
Name of machine VR-843C
Type of machine Vertical Reach Material Handler
Serial number and product range Effective with Serial Number 175806
Name and address of manufacturer Ingersoll Rand Construction Technologies
Road Development
312 Ingersoll Drive
Shippensburg, Pennsylvania 17257

MACHINE DIMENSIONS

VR-843C 7-1
 SECTION 7 TECHNICAL SPECIFICATIONS

VR-843C DESCRIPTION DESIGNATION DIMENSION

mm in.

Overall Length (less forks) A 6400 252.0

Overall Width B 2590 102.0
Overall Height C 2413 95.0
Wheelbase Reach D 3251 128.0
Drive Axle to Carriage Front E 1430 56.3
Ground Clearance F 406 16.0
Overall Length (w/forks) G 7670 302.0
Carriage Width Maximum: H 1490 58.5
Minimum: H 290 9.0
Carriage Length I 1220 48.0
Carriage Height J 1210 47.8
Drive Axle to Rear K 1240 49.0

MACHINE WEIGHTS AND FIGURES

Tread Width mm (in.) 2210 (87.0)

Frame Leveling > 70° 10° each side
< 70° 4° each side
Shipping Weight kg (lbs.) 12,542 (27,650)
Turning Radius:
Inside mm (in.) 2184 (86.0)
Outside mm (in.) 3726 (146.7)
Steering Wheel Turns:
Stop to Stop 6.25 turns
Travel Speeds:
Range 1 km/h (mph) 1 - 7 (0 - 4)
Range 2 km/h (mph) 8 - 13 (5 - 8)
Range 3 km/h (mph) 14 - 32 (9 - 20)

7-2 VR-843C
TECHNICAL SPECIFICATIONS SECTION 7

VR-843C MACHINE STANDARD EQUIPMENT

ENGINE:
Standard Cummins 4BT3.9 “Elite” Diesel
Cylinders 4
Capacity cm3 (cu. in.) 3917 (239)

Power @ 2500 RPM kW (HP) 82 (110)

Torque @ 1500 RPM N-m (lb.-ft.) 397 (293)

TRANSMISSION:
Type Powershift with Soft Shift
Range 3 speeds forward and reverse
Make Ingersoll Rand

DRIVE AXLES:
Front & Back All Wheel Drive
Type Planetary Steering
Make Ingersoll Rand

BRAKES:
Service Internal wet disk
Parking Brake Internal - SAHR

TIRES:
Front 13.00 x 24 14PR/G2
Rear 13.00 x 24 14PR/G2
Ballast Not Required

VR-843C 7-3
 SECTION 7 TECHNICAL SPECIFICATIONS

ELECTRICAL:
Negative Ground 12 volts
Alternator 62 Amps
Battery 900 Amps
Backup Alarm 107 DBM

STEERING:
3 modes 2-wheel, 4-wheel, or Crab
HYDRAULIC SYSTEM:
129 Lpm @ 241 bar
Pump, Variable displacement piston
34 gpm @ 3500 psi

GAUGES:
Oil Pressure Water Temperature
Fuel Level Voltmeter
Transmission Oil Temperature 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

7-4 VR-843C
FUEL AND LUBRICANT INSTRUCTIONS SECTION 8

SECTION 8 - FUEL AND LUBRICANT INSTRUCTIONS

GENERAL INFORMATION
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-843C 8-1
 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.

8-2 VR-843C
FUEL AND LUBRICANT INSTRUCTIONS SECTION 8

LUBRICATION CHART

VR-843C 8-3
 SECTION 8 FUEL AND LUBRICANT INSTRUCTIONS

SERVICE FUNCTIONS:
S - CHECK T - TORQUE CL - CLEAN D - DRAIN
C - CHANGE G - GREASE AR - AS REQUIRED
F - FILL A - ADD FTLH - FILL TO LEVEL HOLE/MARK

SERVICE
REF. NO DESCRIPTION SERVICE PART NO. OR LUBRICANT COMMENTS
INTERVAL

1 ENGINE OIL S, A * FULL ON DIPSTICK

2 ENGINE COOLANT S, A WATER/ANTI-FREEZE AR
TRANSMISSION OIL
3
LEVEL
S, A ** FULL ON DIPSTICK

4 AIR CLEANER INDICATOR S AR 1 PLACE

10 HRS. OR
5 HYDRAULIC OIL LEVEL S, A ** FILL TO SIGHT GAUGE
DAILY
FUEL/WATER
6 D COLLECTED WATER AR 1 PLACE
SEPARATOR
7 FUEL TANK S, A #2 DIESEL FUEL AR
8 PARKING BRAKE S SEE SECTION 3
9 TIRES S, A PRESSURE / CONDITION SEE INFLATION DECAL
CHAIN SHEAVE
12 G EP-2 GREASE 2 FITTINGS
BEARINGS
14 WHEEL LUGS S, T 619 N-M/442 LB.-FT. 40 PLACES
AXLE DIFFERENTIAL OIL
15 S, A *** 2 PLUGS
LEVEL
AXLE PLANETARY
16 S, A *** 4 PLUGS
WHEEL ENDS
50 HRS. OR
WEEKLY 17 AXLE PIVOT BEARINGS G EP-2 GREASE 4 FITTINGS
18 AXLE KING PINS G EP-2 GREASE 8 FITTINGS
20 FORK PINS G EP-2 GREASE AR
21 FRAME LEVEL PIVOT EP-2 GREASE 2 FITTINGS
G
BUSHINGS
22 BOOM PIVOT AND EP-2 GREASE 13 FITTINGS
G
CYLINDERS
31 ENGINE OIL TURBO D, F * 11 L (11.6 QUARTS)
32 ENGINE OIL FILTER C SEE PARTS MANUAL 1 REQUIRED
33 FUEL FILTER C SEE PARTS MANUAL 1 REQUIRED
250 HRS. OR
34 HYD. TANK BREATHER C 1 REQUIRED
QUATERLY
35 BOOM CHAINS S CHAIN LUBRICANT AR
36 BOOM WEAR PADS G EP-2 GREASE 30 PADS
37 CHAIN AND BOOM HOSE T SEE SECTION 5 ADJUST

8-4 VR-843C
FUEL AND LUBRICANT INSTRUCTIONS SECTION 8

SERVICE
REF. NO DESCRIPTION SERVICE PART NO. OR LUBRICANT COMMENTS
INTERVAL

51 HYD. TANK BREATHER c SEE PARTS MANUAL 1 REQUIRED

52 AXLE DIFFERENTIAL OIL D, F *** 31 L (32.8 QUARTS)
53 BOOM CHAINS S CHAIN LUBRICANT AR
HYD. OIL SUCTION
54 CL, A (3)
STRAINER
1000 HRS.
OR 55 HYDRAULIC OIL C ** FILL TO SIGHT GAUGE
ANNUALLY
56 ENGINE COOLANT D, F WATER/ANTI-FREEZE 18.9 L (20 QUARTS)
57 AXLE PLANETARY D, F *** 0.9 L (1 QUART)
58 TRANSMISSION OIL (1) D, F ** 11.3 L (12 QUARTS)
TRANSMISSION OIL
59 C SEE PARTS MANUAL 1 REQUIRED
FILTER (1)

* 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

FLUID CAPACITIES
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) 132 Liter (35 Gallon)
Engine Oil (SAE 15W40) 11 Liter (11.6 Quart) - Turbocharged
Transmission Oil (Multipurpose ATF) 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-843C 8-5
 SECTION 8 FUEL AND LUBRICANT INSTRUCTIONS

HYDRAULIC OIL REQUIREMENTS AND SPECIFICATIONS

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.
Table 8-2
Viscosity : 60 SUS minimum at operating temperature
7500 SUS maximum at starting temperature
150 TO 225 SUS AT 38° C (100° F) (generally)
44 TO 48 SUS AT 99° C (210° F) (generally)
Viscosity Index : 90 minimum
Aniline Point : -175 minimum
API gravity : 28 minimum

Paraffinic oils: 28 OR MORE

Mixed base: 24 TO 28
Napthanic or asphaltic base: 24 or less
Recommended Additives : Rust and oxidation inhibitors
Foam depressant
Desirable Characteristics : 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 Type F
Mobil Oil Company Mobil DTE 15M
Sun Oil Company Sun Oil 2105

For temperatures below -12° C (10° F), the following examples meet specifications.

Auto Transmission Fluid Type F

Mobil Oil Company Mobil DTE 13
Shell Oil Company Tellus T-27

8-6 VR-843C
FUEL AND LUBRICANT INSTRUCTIONS SECTION 8

LUBRICATING OIL/GREASE SPECIFICATIONS (EXCEPT ENGINE)

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. MIN. AMBIENT TEMP °C (°F)

75W -40°C (-40°F)
80W -26°C (-15°F)
85W -12°C (+10°F)
90 -7°C (+20°F)
140 +4°C (+40°F)
250 +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 18 kg (40 lb.) Minimum

Dropping Point 177° C (350° F) Minimum
Oil Viscosity 75 SUS Minimum at 99° C (210° F)
Water Resistance 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).

ENGINE LUBE OIL SPECIFICATIONS

NOTE
For latest applicable engine lubricating oil specifications, contact engine
manufacturer, engine distributor or your Ingersoll Rand distributor.

VR-843C 8-7
 SECTION 8 FUEL AND LUBRICANT INSTRUCTIONS

CUMMINS FUEL OIL SPECIFICATIONS

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

1.3 to 5.8 mm per second at 40° C

Viscosity (ASTM D-445)
(1.3 to 5.8 centistokes per second at 104° F)
40 minimum except in cold weather or in service
Cetane Number (ASTM D-613) with prolonged idle, a higher cetane number is
desirable.
Sulfur Content (ASTM D-129 or 1552) Not to exceed 1 percent by weight.
Water and Sediment (ASTM D-1796) Not to exceed 0.1 percent by volume.
Carbon Residue (Ramsbottom, ASTM-D-524 Not to exceed 0.25 percent by weight on 10
or Conradson, ASTM D-189) percent volume residue.
At least 52° C (125° F) or legal temperature if
Flash Point (ASTM D-93)
higher than 52° C (125° F).
-1 to 6° C (30 to 42° F ) API gravity at 16° C
Density (ASTM D-287)
(60° F) (0.816 to 0.876 Sp. Gr.).
6° C (10° F) below lowest ambient temperature
Cloud Point (ASTM D-97)
at which the fuel is expected to operate.
Copper strip corrosion not to exceed No. 2 rating
Active Sulfur
after 3 hours at 49° C (122° F).
Ash (ASTM D-482) Not to exceed 0.02 percent by weight.
The distillation curve must be smooth and
continuous. At least 90 percent of the fuel must
Distillation (ASTM D-86)
evaporate at less than 360° C (680° F). All of the
fuel must evaporate at less than 385° C (725° F).

8-8 VR-843C
FUEL AND LUBRICANT INSTRUCTIONS SECTION 8

HAZARDOUS SUBSTANCE PRECAUTION

HAZARDOUS SUBSTANCE PRECAUTION

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

The following substances may be produced during the operation of this machine and
may be hazardous to health.

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.

The following substances are used in the manufacturing of this machine and may be
hazardous to health if used incorrectly.

SUBSTANCE PRECAUTION
Antifreeze (Water-cooled engine) Avoid ingestion, skin contact and breathing fumes.
Hydraulic Oil Avoid ingestion, skin contact and breathing fumes.
Engine Lubricating Oil Avoid ingestion, skin contact and breathing fumes.
Preservative Grease Avoid ingestion, skin contact and breathing fumes.
Rust Preventative Avoid ingestion, skin contact and breathing fumes.
Engine Fuel Avoid ingestion, skin contact and breathing fumes.
Battery Avoid ingestion, skin contact and breathing fumes.
SAE Gear Oil Avoid ingestion, skin contact and breathing fumes.

VR-843C 8-9
 SECTION 8 FUEL AND LUBRICANT INSTRUCTIONS

8-10 VR-843C
TORQUE SPECIFICATIONS SECTION 9

SECTION 9 - TORQUE SPECIFICATIONS

ISO METRIC TORQUE CHART

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.

TORQUE
BOLT SIZE (MM) GRADE 8.8 N-m GRADE 10.9 N-m
(POUNDS-FOOT) (POUNDS-FOOT)

6 11 (8) 15 (11)
8 28 (20) 37 (27)
10 53 (39) 72 (53)
12 92 (68) 126 (93)
14 145 (107) 201 (148)
16 212 (156) 312 (230)
20 415 (306) 609 (449)
24 717 (529) 1054 (777)
30 1424 (1050) 2094 (1544)
36 2488 (1835) 3656 (2696)

VR-843C 9-1
 SECTION 9 TORQUE SPECIFICATIONS

SAE TORQUE CHART

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.

CLAMP LOAD TORQUE

BOLT SIZE
kg lbs. N•m lb.-ft

1/4 - 20 916 2020 11 96 lb.-in.

1/4 - 28 1052 2320 14 120 lb.-in.

5/16 - 18 1515 3340 23 17

5/16 - 24 1678 3700 26 19

3/8 - 16 2241 4940 41 30

3/8 - 24 2540 5600 47 35

7/16 - 14 3084 6800 68 50

7/16 - 20 3425 7550 75 55

1/2 - 13 4105 9050 102 75

1/2 - 20 4853 10700 122 90

9/16 - 12 5262 11600 149 110

9/16 - 18 5874 12950 163 120

5/8 - 11 6532 14400 203 150

5/8 - 18 7688 16950 240 180

3/4 - 10 9661.5 21300 353 260

3/4 - 16 10795.5 23800 407 300

7/8 - 9 12247 27000 542 400

7/8 - 14 13517 29800 597 440

1-8 16102.5 35500 786 580

1 - 12 17599 38800 868 640

1 1/8 - 7 19187 42300 1085 800

1 1/8 - 12 21546 47500 1193 880

1 1/4 - 7 24403 53800 1519 1120

1 1/4 - 12 27034 59600 1681 1240

1 3/8 - 6 29075 64100 1460 1980

1 3/8 - 12 33112 73000 1680 2278

1 1/2 - 6 35380 78000 1940 2631

1 1/2 - 12 39780 87700 2200 2983

9-2 VR-843C
TORQUE SPECIFICATIONS SECTION 9

USE OF LOCTITE
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-843C 9-3
 SECTION 9 TORQUE SPECIFICATIONS

9-4 VR-843C
SCHEMATICS SECTION 10

SECTION 10 - SCHEMATICS

GENERAL INFORMATION
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-843C
Vertical Reach Material Handlers are outlined below.

Electrical Schematics

• Electrical Schematic for the VR-843C Vertical Reach Material Handler, Drawing No.
13443197, pages 10-3 to 10-5.

Hydraulic Schematics

• Hydraulic Schematic for the VR-843C Vertical Reach Material Handler, Drawing No.
18006643, page 10-6.

VR-843C 10-1
 SECTION 10 SCHEMATICS

10-2 VR-843C
SCHEMATICS SECTION 10

Electrical Schematic for VR-843C Vertical Reach Material Handler (13443197 Sheet 1 of 3)

VR-843C 10-3
 SECTION 10 SCHEMATICS

Electrical Schematic for VR-843C Vertical Reach Material Handler (13443197 Sheet 2 of 3)

10-4 VR-843C
SCHEMATICS SECTION 10

Electrical Schematic for VR-843C Vertical Reach Material Handler (13443197 Sheet 3 of 3)

VR-843C 10-5
 SECTION 10 SCHEMATICS

Hydraulic Schematic VR-843C Vertical Reach Material Handler (18006643)

10-6 VR-642C
SPARE PARTS SECTION 11

SECTION 11 - RECOMMENDED SPARE PARTS

VR-843C 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-843C 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-843C Vertical Reach Material Handler

Service Interval (Hours) Component

Description CPN
0 - 1000 1000 - 3000 3000 +
Air Cleaner
1 Air Cleaner 54524418
1 1 1 Air Cleaner Primary Filter Element 54484092
1 1 1 Air Cleaner Secondary Filter 54493259
Element
Axle and Wheels
1 Front Drive Shaft Assembly 54568522
1 Rear Drive Shaft Assembly 54479878
1 Frame Level Cylinder 13224969
1 Frame Level Cylinder Locknut 59644465
1 Rim (Standard) 59182097
1 Tire (Standard) 59158345
1 Air Valve (Foamless Wheel & Tire 59254447
Assemblies)
20 Wheel Nut 59163758

VR-843C 11-1
 SECTION 11 SPARE PARTS

Service Interval (Hours) Component

Description CPN
0 - 1000 1000 - 3000 3000 +
Boom and Carriage
4 Bearing 50268127
2 Anchor 59455154
1 Tilt Compensation Cylinder 59221895
4 Cylinder Pivot Pin 13232244
1 Lift Cylinder 59221721
1 Fork Tilt Cylinder 59221770
2 Anchor Pin 59001891
2 Anchor Chain 59101170
1 Chain Anchor Rod 59101048
1 Chain Extension 59157339
2 Anchor Chain Pin 59456962
1 Base Ring 59462895
1 Pin 59454801
1 Crowd Cylinder 59282715
2 Wear Pad 13156799
1 Bushing 59455204
1 Bracket Guide Plate 59116459
1 Anchor Guide 59116467
2 Chain Sheave Guard 59135087
1 Chain Sheave 59169953

11-2 VR-843C
SPARE PARTS SECTION 11

Service Interval (Hours) Component

Description CPN
0 - 1000 1000 - 3000 3000 +
Outer Boom Section
2 Wear Pad 13156799
2 Wear Pad 13156781
2 Shim Plate 59269134
6 Wear Pad 59182196
2 Block 59451641
2 Bearing 13232277
1 Boom Cowling 13351135
Intermediate Boom Section
2 Hose Sheeve 13334552
2 Block 59157099
2 Shim Plate 59100941
2 Wear Pad 13156799
2 Wear Pad 13243639
2 Wear Pad 59182196
1 Finger 13183074
2 Shim Plate 59135194
4 Shim Plate 59136804
Inner Boom Section
2 Wear Pad 13156799
2 Spacer Plate 59116491
2 Shim Plate 59100941
2 Shim Plate 59135194
2 Shim Plate 59136804

VR-843C 11-3
 SECTION 11 SPARE PARTS

Service Interval (Hours) Component

Description CPN
0 - 1000 1000 - 3000 3000 +
Quick-Attach Carriage
1 Cylinder Pivot Pin 13232251
1 48 in. Load Arm 58793209
1 60 in. Load Arm 58793191
1 72 in. Load Arm 58793183
2 Plate 59451815
2 Pin 59101758
1 Apron Handle 13199393
1 Quick-Attach Apron 13187364
1 Rubber Stop Pin 13195862
1 12 Ft. Truss Boom 59199513
Electrical
1 1 1 Power Relay with Diodes 13316831
1 1 1 Relay 59436899
1 Battery 59436931
1 Battery Hold Down 59181875
1 Horn 13111422
1 Switch 59112011
1 Backup Alarm 13273354
1 Fuse, 10 A 59325712
1 Fuse, 15 A 59483339
1 Fuse, 20 A 59398016
1 Diode Assembly 59149146

11-4 VR-843C
SPARE PARTS SECTION 11

Service Interval (Hours) Component

Description CPN
0 - 1000 1000 - 3000 3000 +
Engine
1 1 1 Engine Oil Filter 13284716
1 1 1 Fuel Filter 13284708
1 1 1 Inline Fuel Filter 58827932
1 Fan Belt 13284732
1 Starter 13284724
1 Alternator 54726948
1 Transmission Temperature Sender 59302554
1 Engine Oil Pressure Sender 58878000
1 Suction Fan 59023747
1 Engine Coolant Temperature 59816322
Sender
1 Engine Oil Pressure Switch 59124578
1 Muffler 58933623
2 Exhaust Clamp 59179218
1 Tail Pipe 13195912
1 1 1 Radiator Cap 13281571
1 Upper Radiator Hose 13267067
1 Lower Radiator Hose 13307863
Frame
1 Cable 59436741
1 Fuel Level Sender 59129528
1 Fuel Cap 59182428
1 Magnetic Plug 59144428
1 Hydraulic Tank 13258470
1 Hydraulic Tank Cap 59182410
1 Fuel Tank 13258355

VR-843C 11-5
 SECTION 11 SPARE PARTS

Service Interval (Hours) Component

Description CPN
0 - 1000 1000 - 3000 3000 +
Hydraulics
1 Hydraulic Pump 54535646
1 1 1 Hydraulic Filter 13173802
1 Steering Unit 13267596
1 Brake Valve 59113480
1 Steering Selector Valve 13163274
1 Pressure Switch 13259189
2 Pressure Reducer 13284633
1 Fuel Tank 13258355
Stabilizer
1 Stabilizer Cylinder 59221812
1 Stabilizer Valve 13173331
2 Bearing 58951674
2 Anchor 59455154
Instrument Panel
1 Ignition Switch 13316849
1 1 1 Ignition Switch Key 58917261
1 Ignition Switch Cover 58892902
1 Cable 59436741
1 Fuel Level Gauge 59046920
1 Voltmeter 59044297
1 Oil Pressure Gauge 59046904
1 Transmission Temperature Gauge 59113761
1 Water Temperature Gauge 59132324
1 Hourmeter 59165001
1 Brake Test Switch 54666102
1 Parking Brake Switch 54666094
1 Indicator Light 59816447

11-6 VR-843C
SPARE PARTS SECTION 11

Service Interval (Hours) Component

Description CPN
0 - 1000 1000 - 3000 3000 +
Operator Compartment
1 Horn Button 59159558
1 Spinner Kit 59199141
1 Transmission Shifter 59113696
1 Level Gauge 59181545
1 Heater Valve 13200027
Open Cab
1 Rear Wiper Arm 59072694
1 Wiper Blade 59194514
1 Wiper Motor Kit 59194548
Enclosed Cab
1 Front Window 13174081
1 Sliding Window 59154641
1 Rear Wiper Arm 59072694
1 Wiper Blade 59194514
1 Wiper Motor Kit 59194548
1 Level Gauge 59181545
1 Armrest 54473004
1 Defrost Fan 59154757
1 Door Seal 59072702
1 Door Strap 59142851
1 Outside Door Latch 59142661
1 Inside Latch Handle 59154955
1 Door Key 59155598

VR-843C 11-7
 SECTION 11 SPARE PARTS

Service Interval (Hours) Component

Description CPN
0 - 1000 1000 - 3000 3000 +
Kits
1 VR-843C Decal Kit 13341581
1 Frame Level Cylinder Seal Kit 13248505
1 Tilt Compensation Cylinder Seal Kit 13421896
1 Lift Cylinder Seal Kit 13268271
1 Fork Tilt Cylinder Seal Kit 13281431
1 Crowd Cylinder Seal Kit 13284104
1 Hydraulic Pump Seal Kit 59154310
1 Brake Valve Seal Kit 59154617
1 Stabilizer Cylinder Seal Kit 13284120
Optional Equipment
Wheel and Tire Assemblies
1 Foam Filled Tire 54503016
72 in. Swing Carriage
2 Hydraulic Cylinder 13170147
2 Counterbalance Valve 58874751
1 Seal Kit 54728886
1 Bearing 50275395
1 Flow Control Valve 13170188
2 Cover Plate 59583450
Load Bucket
1 Load Bucket 59149484
Tapered Forks
1 48 in. Tapered Fork 59272583
1 60 in. Tapered Fork 59272591

11-8 VR-843C
SPARE PARTS SECTION 11

Service Interval (Hours) Component

Description CPN
0 - 1000 1000 - 3000 3000 +
Scrap Grapple Bucket
1 Cylinder 59110932
1 Seal Kit 59231282
Block Heater
1 Block Heater 59118521
Worklights
2 Work Lamp 58837949
2 Work Lamp Light Bulb 58875543
3 Cable Seal 59854877
Stop/Turn Signal
1 Brake Light Switch 59157792
Single Function Auxiliary Hydraulics
2 Sheave 13334552
1 Lift/Crowd Valve 13315387
1 Lift/Crowd Valve 13315361

RECOMMENDED LUBRICANTS
This section of the manual contains a list of the recommended Ingersoll Rand lubricants for
the VR-843C Vertical Reach Material Handler.
Table 11-2: Recommended Lubricants

1 Qt. 1 Gal. 5 Gal. 55 Gal.

IR All-Season Premium Hydraulic Oil N/A N/A 59045179 59045187

IR Multi-Purpose Premium Engine Oil 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 13248430 13248448 58977597 59022459

IR Synthetic Plus Component Lubricant 13248414 13248422 59046177 59046165

VR-843C 11-9
 SECTION 11 SPARE PARTS

11-10 VR-843C
 WORD INDEX

Numerics Check Air Cleaner Restriction . . . . . . . . . . . . . . . 5-10

10 Hour or Daily Routine Maintenance . . . . . . . . 5-19 Check Air Cleaner Restriction Indicator . . . . . . . 5-22
1000 Hour or Annual Routine Maintenance . . . . 5-39 Check Boom Wear Pad Clearances . . . . . . . . . . 5-33
250 Hour or Quarterly Routine Maintenance . . . 5-39 Check Coolant Level . . . . . . . . . . . . . . . . . . . . . . . 5-8
50 Hour or Weekly Routine Maintenance . . . . . . 5-27 Check Engine Belts . . . . . . . . . . . . . . . . . . . . . . . 5-44
Check Engine Light . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Check Engine Oil Level . . . . . . . . . . . . . . . . . . . . 6-19
A
Check Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Check Hydraulic Oil Level . . . . . . . . . . . . . . . . . . 5-15
Adjust Boom Chains and Hoses . . . . . . . . . . . . . 5-36
Check Oil Level in Axle Differential
Air Cleaner Element, Cleaning the . . . . . . . . . . . 5-11
Planetary Wheel Ends . . . . . . . . . . . . . . . . . . . . . 5-22
Air Cleaner Restriction, Check . . . . . . . . . . . . . . 5-10
Check Oil Level in Axle Differentials . . . . . . . . . . 5-23
Air Cleaner Restriction Indicator, Check . . . . . . 5-22
Check Park Brake . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Air Cleaner Vacuator Valve . . . . . . . . . . . . . . . . . 5-14
Check Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Air Conditioner Controls . . . . . . . . . . . . . . . . . . . 3-11
Check Tire Pressure and Condition . . . . . . . . . . 5-18
Angle Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Check Transmission Fluid Level . . . . . . . . . . . . . . 5-8
Annual Routine Maintenance, 1000 Hour or . . . . 5-39
Clean Heater / A-C Filter . . . . . . . . . . . . . . . . . . . 5-26
Apron, Quick Attachment . . . . . . . . . . . . . . . . . . 4-40
Cleaning the Air Cleaner Element . . . . . . . . . . . . 5-11
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Coolant Level, Check . . . . . . . . . . . . . . . . . . . . . . 5-8
Auxiliary Function Switch . . . . . . . . . . . . . . . . . . . 3-2
Coordinated Steering . . . . . . . . . . . . . . . . . . . 1, 4-24
Axle Differential Planetary Wheel Ends,
Crab Steering . . . . . . . . . . . . . . . . . . . . . . . . . 1, 4-23
Check Oil Level in . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Axle Differentials, Check Oil Level in . . . . . . . . . 5-23
Axle King Pins, Grease . . . . . . . . . . . . . . . . . . . . 5-24 D
Axle Mounting Bolts, Torque . . . . . . . . . . . . . . . . 5-30 Daily Routine Maintenance, 10 Hour or . . . . . . . 5-19
Axle Pivot Bearings, Grease . . . . . . . . . . . . . . . . 5-24 Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Diagnostic Port . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Difficult Starting & Poor/Irregular Performance . . . 6-4
B
Direction Control Lever . . . . . . . . . . . . . . . . . . . . . 3-3
Ballast / Ignition Kill Switch . . . . . . . . . . . . . . . . . . 6-9
Dry Wall Handler . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Battery Gauge (Voltmeter) . . . . . . . . . . . . . . . . . . . 3-1
Dry Wall Handler Installation . . . . . . . . . . . . . . . . 4-45
Battery Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Dynamic Forces . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Beacon Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Boom Chains and Hoses, Adjust . . . . . . . . . . . . 5-36
Boom Control Joystick . . . . . . . . . . . . . . . . . . . . . 3-7 E
Boom Light Switch . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Electrical Circuit Malfunctions . . . . . . . . . . . . . . . . 6-6
Boom Pivot and Boom Cylinders, Grease . . . . . 5-26 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . 10-1
Boom Safety Stop . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Engine Belts, Check . . . . . . . . . . . . . . . . . . . . . . 5-44
Boom Stop Installation . . . . . . . . . . . . . . . . . . . . . 4-5 Engine Diagnostic Port . . . . . . . . . . . . . . . . . . . . 3-10
Boom Wear Pad Clearances, Check . . . . . . . . . 5-33 Engine Fuel Filter, Change . . . . . . . . . . . . . . . . . 5-40
Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Engine Making Excessive Fumes . . . . . . . . . . . . . 6-5
Bucket Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43 Engine Oil and Filter, Change . . . . . . . . . . . . . . . 5-39
Button, Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Engine Oil Level, Check . . . . . . . . . . . . . . . . . . . 6-19
Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . 3-5
Engine Overheats - Stop Engine Immediately . . . 6-5
C
Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . 6-3
Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Ether Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Center of Gravity (CG) . . . . . . . . . . . . . . . . . . . . . 4-2
Extreme Pressure Multi-purpose Grease . . . . . . . 8-7
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-843C 12-1
 WORD INDEX

F J
Factors (of CG) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Joystick, Boom Control . . . . . . . . . . . . . . . . . . . . . 3-7
Fasteners, Inspect . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Joystick, Level and Fork Control . . . . . . . . . . . . . . 3-7
Fill Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Fork Pins, Grease . . . . . . . . . . . . . . . . . . . . . . . . 5-25 K
Frame Level Pivot Bushings and Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Stabilizer Pivot Bushings, Grease . . . . . . . . . . . . 5-25
Front Wheel Steering . . . . . . . . . . . . . . . . . . . . . 4-23
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 L
Fuel Level, Check . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Left and Right Stabilizer Switches . . . . . . . . . . . . . 3-2
Fuel Tank, Fill . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Level and Fork Control Joystick . . . . . . . . . . . . . .3-7
Fuel/Water Separator . . . . . . . . . . . . . . . . . . . . . 5-15 Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Fuse Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Lever, Direction Control . . . . . . . . . . . . . . . . . . . . . 3-3
Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Lever, Turn Signal Control . . . . . . . . . . . . . . . . . . 3-4
Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Lifting, Lowering, and Tilting . . . . . . . . . . . . . . . . 4-27
Light, Check Engine . . . . . . . . . . . . . . . . . . . . . . . 3-5
Light, Service Engine . . . . . . . . . . . . . . . . . . . . . . 3-5
G Light, Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Gauge, Battery (Voltmeter) . . . . . . . . . . . . . . . . . . 3-1 Load Capacity Charts . . . . . . . . . . . . . . . . . . . . . 1-11
Gauge, Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . 3-1 Load Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Gauge, Transmission Oil Temperature . . . . . . . . 3- 2 Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Gauge, Water Temperature . . . . . . . . . . . . . . . . . 3-2 Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . 5-48
General Identification . . . . . . . . . . . . . . . . . . . . . . . 1 Low Engine Oil Pressure . . . . . . . . . . . . . . . . . . . 6- 5
General Information . . . . . . . . . . . . . . . . . . . . . . . . 1
General Maintenance Information . . . . . . . . . . . . . 5-1
Grease Axle King Pins . . . . . . . . . . . . . . . . . . . . 5-24 M
Grease Axle Pivot Bearings . . . . . . . . . . . . . . . . 5-24 Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . 7-1
Grease Boom Pivot and Boom Cylinders . . . . . . 5-26 Machine Serial Number . . . . . . . . . . . . . . . . . . . . . . 2
Grease Chain Sheave Bearings . . . . . . . . . . . . . 5-19 Machine Weights and Figures . . . . . . . . . . . . . . . . 7-2
Grease Fork Pins . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . 5-3
Grease Frame Level Pivot Bushings and Manual Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Stabilizer Pivot Bushings . . . . . . . . . . . . . . . . . . 5-25 Metric Conversion . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Grease Steering Cylinder Pin Bearings . . . . . . . 5-29
N
H Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Handling Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Hazardous Substance Precaution . . . . . . . . . . . 1-15 O
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Heater and Air Conditioner Controls . . . . . . . . . . 3-11 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . 4-1
Heater / A-C Filter, Clean . . . . . . . . . . . . . . . . . . 5-26 Operating the Machine . . . . . . . . . . . . . . . . . . . . . 4-4
Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Operator Protection Equipment . . . . . . . . . . . . . . . 1-3
Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hydraulic Oil Filters, Change . . . . . . . . . . . . . . . 5-41 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Hydraulic Oil Level, Check . . . . . . . . . . . . . . . . . 5-15
Hydraulic Oil Temperature Gauge . . . . . . . . . . . . 3-5 P
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . 10-1 Park Brake, Check . . . . . . . . . . . . . . . . . . . . . . . 5-17
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
I Park Brake Test Switch . . . . . . . . . . . . . . . . . . . . . 3-6
In Line Filter, Change . . . . . . . . . . . . . . . . . . . . . 5-29 Park Brake Test Procedure . . . . . . . . . . . . . . . . . 4-15
Indicator, Angle . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Indicator, Level . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Pedal, Accelerator . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Initial Break-in Maintenance . . . . . . . . . . . . . . . . . 5-5 Pedal, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Inspect Chains . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 Pintle Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Inspect Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Power Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Inspect Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . 1-2
International Machine Symbols . . . . . . . . . . . . . . . 2-1 Prototype Models . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ISO Metric Torque Chart . . . . . . . . . . . . . . . . . . . . 9-1

12-2 VR-843C
 WORD INDEX

Q Torque Axle Mounting Bolts . . . . . . . . . . . . . . . . 5-30

Quarterly Routine Maintenance, 250 Hour or . . 5-39 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Quick Attachment Apron . . . . . . . . . . . . . . . . . . . 4-40 Transmission Fluid Level, Check . . . . . . . . . . . . . 5-8
Transmission Oil, Change . . . . . . . . . . . . . . . . . 5-46
Transmission Oil Filter . . . . . . . . . . . . . . . . . . . . . . 5-5
R
Transmission Oil Filter, Change . . . . . . . . . . . . . 5-48
Rated Capacity Chart . . . . . . . . . . . . . . . . . . . . . . 1-8
Transmission Oil Temperature Gauge . . . . . . . . 3- 2
Recommended Lubricants . . . . . . . . . . . . . . . . . 11-9
Transmission Range Selector . . . . . . . . . . . . . . . . 3-3
Recommended Spare Parts . . . . . . . . . . . . . . . . 11-1
Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Replacing The Air Cleaner Element . . . . . . . . . . 6-10
Transporting and Hauling . . . . . . . . . . . . . . . . . . 1-10
Routine Maintenance, 10 Hour or Daily . . . . . . . 5-19
Traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Routine Maintenance, 1000 Hour or Annual . . . . 5-39
Truss Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Routine Maintenance, 250 Hour or Quarterly . . . 5-39
Turn Signal Control Lever . . . . . . . . . . . . . . . . . . . 3-4
Routine Maintenance, 50 Hour or Weekly . . . . . 5-27
Two Wheel Steering . . . . . . . . . . . . . . . . . . . . . . . . 1

S V
SAE Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Vacuator Valve, Air Cleaner . . . . . . . . . . . . . . . . 5-14
Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . 1-1
Vandal Protection Cover - Option . . . . . . . . . . . . 4-39
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Voltmeter Indicates Low or Negative Voltage . . . . 6-5
Safety Related Decals . . . . . . . . . . . . . . . . . . . . 1-18
VR-843C Recommended Spare Parts . . . . . . . . 11-1
Scrap Grapple Bucket . . . . . . . . . . . . . . . . . . . . . 4-42
Seat Belt, Check . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Service Engine Light . . . . . . . . . . . . . . . . . . . . . . . 3-5 W
Side Tilt Carriage . . . . . . . . . . . . . . . . . . . . . . . . 4-47 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Water Temperature Gauge . . . . . . . . . . . . . . . . . . 3-2
Single Joystick Control . . . . . . . . . . . . . . . . . . . . . 3-8 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Stabilizer Switches, Left and Right . . . . . . . . . . . . 3-2 Weekly Routine Maintenance, 50 Hour or . . . . . . 5-27
Stabilizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 Weighted Ballast Box . . . . . . . . . . . . . . . . . . . . . . 6-9
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Windshield Washer Switch . . . . . . . . . . . . . . . . . . 3-6
Steering, Coordinated . . . . . . . . . . . . . . . . . . 1, 4-24 Work Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
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

T
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Three-Speed Transmission . . . . . . . . . . . . . . . . . 4-19
Tighten Loose Bolted Connections . . . . . . . . . . . . 5-6
Tire Pressure and Condition, Check . . . . . . . . . . 5-18

VR-843C 12-3
 MATERIAL HANDLER WARRANTY
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
Ingersoll-Rand Construction Technologies
Road Development
312 Ingersoll Drive
Shippensburg,PA 17257

© 2006 Ingersoll-Rand Company

Printed in the U.S.A.