c3100 carrier operation & safety manual carrier operation & safety manual ... it is good...

C3100 Carrier Operation& Safety Manual

Keep this manual with vehicle at all times.

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Truck Number T00519 & LaterRevised

November 15, 2012

Part Number990001-016

CALIFORNIA PROPOSITION 65

Battery posts,terminals and relatedaccessories contain

lead and lead compounds,chemical known to the

State of Californiato cause cancer andreproductive harm.

WASH HANDSAFTER HANDLING!

CALIFORNIA PROPOSITION 65

Diesel Engine exhaust and some of its constituents

are known to the State of California to cause cancer,

birth defects and other reproductive harm.

Revision Log
Revision Log REVISION LOG12 March, 2010 - A - Original Issue of Manual
12 September, 2012 - B - Updated contact information

15 November, 2012 - C - Revised Section 9.1 “Coolant Type” to include SCA

a990001-016

Read This First
Read This FirstThis manual is a very important tool. Keep it with the vehicle at all times.
The purpose of this manual is to provide owners, users and operators with relevantinformation concerning the safety and daily operation of this vehicle. It is theoperator’s responsibility to read this manual thoroughly; paying particularattention to hazard labels that have been included to draw attention toimportant issues of operator safety and overall performance.

The information, specifications and illustrations contained in this manual are basedon data that was current at the time of publication. Kimble Custom Chassis reservesthe right to make changes and/or improvements at any time without notification orliability, or without applying those changes or improvements to vehicles previouslymanufactured.

Operator Qualifications

Personnel must not operate the vehicle until this manual has been read, training isaccomplished and operation of the vehicle has been completed under thesupervision of an experienced and qualified operator.

Operators of this equipment must possess a valid, applicable driver’s license,(Commercial Driver License), be in good physical and mental condition, have normalreflexes and reaction time, good vision and depth perception and normal hearing.Operator must not be using medication which could impair abilities nor be under theinfluence of alcohol or any other intoxicant during the work shift.

This manual is not a training manual, Kimble Custom Chassis cannot anticipateeverything the operator needs to know about operating a Kimble vehicle. A goodtraining program or a truck driving school can provide proper education. Receiveproper training before operating this vehicle. Only qualified drivers should drive thisvehicle.

The operator must also read, understand and comply with all applicable Employer,Industry and Governmental rules, standards and regulations, which apply to theoperation of this vehicle.

Event Data Recorder

This vehicle is equipped with one or more devices that record specific data. The typeand amount of data recorded varies depending on how the vehicle is equipped (suchas the brand of engine).

Environmental Concerns and Recommendations

Any instructions in this manual to discard materials, a first attempt to reclaim andrecycle them should be made. To preserve the environment, follow environmentalrules and regulations when disposing of materials.

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Read This First
Modifications
Any modification to this vehicle must be approved by Kimble CustomChassis.

Product Safety & Reliability

Every new Kimble vehicle is designed to conform to all Federal Motor Vehicle SafetyStandards applicable at the time of manufacture. However, even with these safetyfeatures, continued safe and reliable operation depends greatly upon correctoperation and regular vehicle maintenance, See Section 7 - Lubrication andMaintenance. The vehicle must be operated within the range of its mechanicalcapabilities and the limits of its load ratings.

Kimble Custom Chassis must be notified immediately in all instances where Kimbleproducts have been involved in an accident involving bodily injury or death ofpersonnel or when damage has occurred to personal property or the Kimbleproduct.

For:• Accident Reporting and Product Safety Publications

• Questions Regarding Product Modifications, Product Applications and Safety

Contact:Product Safety & Reliability DepartmentKimble Custom Chassis1951 Reiser Ave SENew Philadelphia, OH 44663

Phone: 1-330-308-6766

Reporting Safety Defects

United StatesIf you believe that your vehicle has a defect which could cause a crash or causeinjury or death, immediately inform the National Highway Traffic SafetyAdministration (NHTSA) in addition to notifying Kimble Custom Chassis.

If NHTSA receives similar complaints, it may open an investigation, and if it findsthat a safety defect exists in a group of vehicles, it may order a recall and remedycampaign.

To contact NHTSA, call the Auto Safety Hotline toll-free at 1-800-424-9393 or writeto: U.S. Department of Transportation, NHTSA, Office of Defects Investigation(NVS-210), 1200 New Jersey Avenue, S.E., Washington, D.C. 20590. Otherinformation about auto safety can be received from the Hotline.

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Read This First
Canada
Canadian customers who wish to report a safety-related defect to TransportCanada, Defect Investigation and Recalls, may telephone the toll-free hotline 1-800-333-0510, or contact Transport Canada by mail at: Transport Canada, ASFAD,Place de Ville Tower C, 330 Sparks Street, Ottawa ON, K1A ON5.

For additional road safety information, visit the Road Safety website at:http://www.tc.gc.ca/roadsafety/menu.htm

Emergency Equipment

It is good practice to carry an emergency equipment kit with the vehicle including:window scraper, snow brush, container of sand or salt, emergency light, smallshovel, first aid kit and a fire extinguisher.

Vehicle Repair

This is not a repair or workshop manual. The Kimble vehicle is a complex machine.Anyone attempting repairs needs good mechanical training, knowledge of vehiclespecifications and proper tools. If you are not an experienced mechanic or do nothave the right equipment, allow the repairs to be done by a qualified mechanic. Theyare equipped to do the job safely and correctly.

The Preventive Maintenance section in this manual contains general serviceinformation for the operator. This is summary information only, used for generalmaintenance of major components installed on the Kimble vehicle.

Additional information on major component suppliers to Kimble also supplyoperation manuals specific to their products. Additional manuals and other pieces ofliterature are included in the vehicle.

Other Publications Available

Illustrated Parts Manual............................................. 990001-017

WARNINGEQUIPMENT DAMAGE/PERSONAL INJURY. Do NOT attempt repair workwithout sufficient training, parts and service manuals and the proper tools. Failureto comply could cause equipment damage or result in death or serious injury.

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Table of ContentsTable of Contents

TABLE OF CONTENTSRevision LogRead This First

Operator Qualifications ......................................................bEvent Data Recorder .........................................................bEnvironmental Concerns and Recommendations..............bModifications ...................................................................... cProduct Safety & Reliability................................................ cReporting Safety Defects ................................................... cEmergency Equipment.......................................................dVehicle Repair....................................................................dOther Publications Available ..............................................d

Table of ContentsSection 1 - General Safety Practices

1.1 Hazard Classification System ..............................................1-1Safety Alert System and Safety Signal Words................1-1

1.2 General Precautions ............................................................1-11.3 Operation Safety..................................................................1-2

Electrical Hazards ...........................................................1-2Tip Over Hazard..............................................................1-2Travel Hazard .................................................................1-4Vehicle Loading Hazard..................................................1-4Riding Personnel Hazard ................................................1-5Driving Hazards on Slopes .............................................1-5Pinch Points and Crush Hazards ....................................1-6Fall Hazard......................................................................1-7Chemical Hazards...........................................................1-8

Section 2 - Pre-Operation and Inspection2.1 Pre-Operation Check and Inspection...................................2-12.2 Safety Precautions...............................................................2-22.3 Walk-Around Inspection.......................................................2-42.4 Cab and Platform Access ....................................................2-62.5 Warm-Up and Operational Checks......................................2-7

Warm-Up Check .............................................................2-7Operational Check ..........................................................2-7

Section 3 - Operators Cab3.1 Operators Cab .....................................................................3-13.2 Cab Layout ..........................................................................3-23.3 Operator Seat ......................................................................3-4

Adjustments ....................................................................3-4Seat Belt .........................................................................3-5

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Table of Contents
3.4 Cab Door & Windows.......................................................... 3-6
Cab Door ........................................................................ 3-6

Section 4 - Controls & Indicators4.1 General................................................................................ 4-14.2 Instrument Panel ................................................................. 4-2

Driver Information Center ............................................... 4-4Front Panel ..................................................................... 4-6Right Console ................................................................. 4-6Heating/Cooling Panel.................................................... 4-7

4.3 Steering Column Adjuster ................................................... 4-84.4 Ignition Switch ..................................................................... 4-94.5 Transmission Shifter.......................................................... 4-10

Travel Direction ............................................................ 4-10Push-button Gear Selection ......................................... 4-10Shifting Suggestions Under Normal Operation............. 4-11

4.6 Transmission Filter Indicator ............................................. 4-124.7 Power Outlet...................................................................... 4-134.8 Park Brake......................................................................... 4-144.9 Pusher/Tag Axle Regulators ............................................. 4-154.10 Transfer Gear Shifter......................................................... 4-16

Section 5 - Operation5.1 Engine ................................................................................. 5-1

Starting the Engine......................................................... 5-1Cold Weather Operation................................................. 5-2Battery Boosted Starting................................................. 5-3Normal Engine Operation ............................................... 5-4Shut-Down Procedure .................................................... 5-4

5.2 Battery Disconnect .............................................................. 5-5

Section 6 - Vehicle Recovery6.1 Freeing the Vehicle ............................................................. 6-16.2 Towing a Disabled Vehicle .................................................. 6-2

Moving Short Distances.................................................. 6-2Moving Longer Distances ............................................... 6-2

6.3 Loading and Securing for Transport.................................... 6-3

Section 7 - Lubrication and Maintenance7.1 Introduction.......................................................................... 7-1

Clothing and Safety Gear ............................................... 7-17.2 General Maintenance Instructions....................................... 7-27.3 Service and Maintenance Schedules .................................. 7-3

10, 50 & 250 Hour Maintenance Schedule..................... 7-3500, 2000 & 3000 Hour Maintenance Schedule............. 7-4

7.4 Lubrication Schedules ......................................................... 7-6

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Table of Contents
50 Hour Lubrication Schedule.........................................7-6
7.5 Operator Maintenance Instructions......................................7-8Fuel System ....................................................................7-8Air Intake System..........................................................7-10Engine Oil .....................................................................7-12Power Steering Fluid.....................................................7-13Tires ..............................................................................7-14Engine Cooling System.................................................7-16Battery...........................................................................7-17

Section 8 - Additional Information8.1 Air Brake System .................................................................8-18.2 Air Dryer...............................................................................8-28.3 Anti-lock Braking System.....................................................8-38.4 Engine Exhaust Brake .........................................................8-48.5 Operating the Transmission.................................................8-58.6 Inter-Axle Differential Lock...................................................8-68.7 Main Differential Lock ..........................................................8-78.8 Pusher/Tag Axle ..................................................................8-8

Section 9 - Specifications9.1 Vehicle Specifications..........................................................9-1

Fluid and Lubrication Capacities.....................................9-1Tires ................................................................................9-2Dimensions .....................................................................9-2

Section 10 - Troubleshooting10.1 Power Panel Layout...........................................................10-110.2 ABS Diagnostic..................................................................10-210.3 Air Schematic.....................................................................10-310.4 Power Steering Schematic.................................................10-4

Troubleshooting Guide..................................................10-510.5 Fuel System Schematic .....................................................10-610.6 Tag/Pusher Axle Instructions.............................................10-7

Trouble Shooting...........................................................10-710.7 Major Components ............................................................10-8

IndexInspection, Maintenance and Repair Log

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Table of Contents

iv 990001-016

Section 1 - General Safety Practices

SECTION 1 - GENERAL SAFETY PRACTICES

1.1 HAZARD CLASSIFICATION SYSTEM

Safety Alert System and Safety Signal Words

DANGER indicates an imminently hazardous situation which, if not avoided, willresult in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, couldresult in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, mayresult in minor or moderate injury.

1.2 GENERAL PRECAUTIONS

WARNINGBefore operation, read & understand this manual. Failure to comply with thesafety precautions listed in this manual could result in vehicle damage, propertydamage, personal injury or death.

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1.3 OPERATION SAFETY

Electrical Hazards

• This vehicle is not insulated and does not provide protection from contact orbeing near electrical current.

• NEVER operate the vehicle in an area where overhead power lines, overhead orunderground cables, or other power sources may exist without ensuring theappropriate power or utility company de-energizes the lines.

• Always check for power lines before operating.

Tip Over Hazard

• Be sure that the ground conditions are able to support the vehicle.

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If the vehicle starts to tip over:

• DO NOT JUMP

• BRACE YOURSELF and STAY WITH THE VEHICLE

• KEEP YOUR SEAT BELT FASTENED

• HOLD ON FIRMLY

• LEAN AWAY FROM THE POINT OF IMPACT

Trying to escape from a tipping vehicle could result in death or serious injury.

• MAINTAIN proper tire pressure at all times. If proper tire pressures are notmaintained, the vehicle could tip over. See “Tires” on page 7-14 for details.

• Always wear the seat belt. See page 3-5 for details.

• Keep head, arms, hands, legs and all other body parts inside operator’s cab at alltimes.

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Travel Hazard
• Look out for and avoid other personnel, machinery and vehicles in the area. Usea spotter if you DO NOT have a clear view.

• Before moving on jobsite be sure of a clear path and sound horn.

• Always look in the direction of travel.

Vehicle Loading Hazard

Work within the vehicles load capacity. An overloaded vehicle is unsafe to drive. Thecomponents of the vehicle are designed to operate within the gross vehicle weightrating (GVWR), and the maximum front and rear gross axle weight rating (GAWR).

• GVWR: the MAXIMUM WEIGHT the vehicle is allowed to carry, including theweight of the empty vehicle, platform, occupant, fuel and any load. NEVERexceed the GVWR of the vehicle.

• GAWR: the total weight that one axle or axle set is designed to transmit to theground. A load too heavy over one axle can affect the braking and handling ofthe vehicle. Even if the load is under the legal limits, be sure it is distributedevenly.

WARNINGDo NOT exceed the load rating specified on the vehicle’s door verification label.Overloading can cause component failure or affect vehicle handling resulting inloss of vehicle control and personal injury. Exceeding load ratings can alsoshorten the service life of the vehicle.

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Riding Personnel Hazard
• DO NOT drive vehicle when personnel are on platform.

• No riders permitted in vehicle. Operator only in cab while driving.

Driving Hazards on Slopes

To maintain sufficient traction and braking capabilities, travel on slopes as follows:

• To avoid overspeeding the engine and drivetrain when driving down slopes,downshift to a lower gear and use the service brake as necessary to maintain aslow speed. DO NOT shift into neutral and coast downhill.

• Avoid excessively steep slopes or unstable surfaces. To avoid tip over DO NOTdrive across excessively steep slopes under any circumstances.

• Avoid sharp turning on a slope.

• DO NOT park on a slope.

WARNINGDo NOT allow personnel to remain on work platform while driving. Unrestrainedriders can be thrown from the vehicle resulting in personal injury or death.

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Pinch Points and Crush Hazards
• Stay clear of pinch points and rotating parts on the vehicle.

• Stay clear of moving parts while engine is running.

• Keep all guards and covers secured in place.

• Keep clear of steering tires and frame or other objects.

• Keep others away while operating.

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Fall Hazard
• Enter using the proper hand holds and steps provided. Always maintain 3-pointcontact when entering or exiting the vehicle. Never grab control levers orsteering wheel when entering or exiting the vehicle. See page 2-6 for details.

• DO NOT exit the vehicle until the shutdown procedure on page 5-4 has beenperformed.

• DO NOT jump from vehicle when exiting.

• DO NOT carry riders. Riders could fall off vehicle causing death or serious injury.

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Chemical Hazards
Exhaust Fumes

• DO NOT operate vehicle in an enclosed area without proper ventilation.

• DO NOT operate the vehicle in hazardous environments unless approved forthat purpose by Kimble Custom Chassis and site owner. Sparks from theelectrical system and the engine exhaust can cause an explosion.

Flammable Fuel

• DO NOT fill the fuel tank or service the fuel system near an open flame, sparksor smoking materials. Engine fuel is flammable and can cause a fire and/orexplosion.

Pressurized Systems (Air & Fluid)

• DO NOT attempt to repair or tighten any hoses or fittings while the engine isrunning or when the system is under pressure.

• Stop engine and relieve trapped pressure. The system is under enough pressurethat it can penetrate the skin.

• DO NOT use your hand to check for leaks. Use a piece of cardboard or paper tosearch for leaks. Wear gloves to protect hands from spraying fluid.

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Section 2 - Pre-Operation and Inspection

SECTION 2 - PRE-OPERATION AND INSPECTION

2.1 PRE-OPERATION CHECK AND INSPECTIONNote: Complete all required maintenance before operating vehicle.

The pre-operation check & inspection, performed at beginning of each work shift orat each change of operator, should include the following:

1. Cleanliness - Check all surfaces for leakage (oil, fuel or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel.

2. Structure - Inspect the vehicle structure for dents, damage, weld or parent metal cracks or other discrepancies.

3. Operation and Safety Manual - Make sure operator has read and is familiar with Operation & Safety Manual located in cab.

4. Walk-Around Inspection - See page 2-4 for details.

5. Fluid Levels - Check fluids, including fuel, engine oil and coolant. When adding fluids, refer to Section 9 - Specifications to determine proper type and intervals. Before removing filler caps or fill plugs, wipe all dirt and grease away from the ports. If dirt enters these ports, it can severely reduce component life.

6. Operational Check - Once the walk-around inspection is complete, perform a warm-up and operational check (see page 2-7) of all systems. See Section 4 - Controls & Indicators for more specific operating instructions.

7. Any discrepancies or problems identified during inspection should be resolved before start-up.

WARNINGFALL HAZARD. Use extreme caution when checking items beyond your normalreach. Use an approved ladder. Failure to comply could result in death or seriousinjury.

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2.2 SAFETY PRECAUTIONS

Read and understand all safety precautions that could cause possible productdamage and/or harmful situations.

DANGER1. Avoid high voltage lines. Contacting electric lines may result in death or

serious injury.

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WARNING2. No riders permitted on vehicle. Operator only in cab while driving. Riders

could fall off vehicle causing serious injury or death.

3. Stay clear of any pinch point area anytime engine is running. Being in a pinch point area could cause serious injury or death.

4. The protection offered by this cab will be impaired if it has been subjected to any modification, structural damage or has been involved in an accident.

5. Keep away from exhaust system when hot. Hot exhaust components can cause severe burns.

6. Stay clear of moving parts while engine is running. Moving parts can cause serious injury.

7. Diesel fuel is flammable. Extinguish all open flame and smoking material when refueling injury or death could result from fire.

8. Do NOT engage park brake while vehicle is in motion. Abrupt stop could cause serious injury and damage to the vehicle.

9. Always replace guards, covers, secure panels and access doors upon completion of inspection, service or maintenance tasks. Failure to comply could result in death or serious injury.

10. Do NOT spray starting aid into air intake. Vehicle is equipped with a air intake grid heater that can ignite the starting aid causing serious injury.

CAUTION11. Cooling system is pressurized. Allow unit to cool before servicing. Remove

cap slowly, hot fluid can cause burns.

12. Turbocharger damage can result from quick startup and shutdown. For longer turbocharger life and to minimize turbocharger damage idle engine at least 3-5 minutes after startup and before shutdown.

13. Vehicle must be in neutral and park brake set to start.

14. Disconnect positive and negative sides of battery before welding on unit. Failure to do so could permanently damage electronic controls on engine.

15. Do NOT push or tow another vehicle or object other than approved trailers. This use could result in damage to the vehicles or persons nearby.

16. Do NOT push or pull vehicle sideways. The vehicle is not designed for side loading or opposing pressures and could result in damage to the vehicle.

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2.3 WALK-AROUND INSPECTION

It is the driver’s responsibility to perform an inspection and ensure the completeroad-worthiness of the vehicle before operating.

Begin your walk-around inspection at item 1, as noted below. Continue to your left(clockwise when viewed from top) checking each item in sequence.

INSPECTION NOTE: On all components, make sure there are no loose or missingparts, that they are securely fastened and no visible leaks or excessive wear existsin addition to any other criteria mentioned. Inspect all structural members for cracks,excessive corrosion and other damage.

1. Mirrors - Clean and undamaged, adjust for maximum visibility.

2. Steps & Handles - Clean and unobstructed.

3. Wiper blade - Check condition and replace as required.

4. Headlights & Turn Signals - Clean, undamaged and work properly.

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5. Coolant System - See inspection note.
6. Engine -

• Drive belts, check condition and replace as required.

• Hoses, inspect for leaks and replace as required.

• See inspection note.

7. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug nuts. Inspect for worn tread, cuts, tears or other discrepancies.

8. Transmission - See inspection note.

9. Platform - Clean and walkways clear of objects.


11. Tail Lights & Turn Signals - Clean, undamaged and work properly.


13. Platform - Clean and walkways clear of objects.

14. Fuel Tank - Inspect for leaks, structural damage, excessive corrosion or other damage. Ensure fill cap is secured.

15. Power Steering Reservoir - See inspection note.

16. Air Cleaner - Air cleaner restriction indicator, check for clogged condition. Replace element as required.

17. Battery - Cables tight, no visible damage or corrosion. Cover properly secured.


19. Cab & Electrical -

• General appearance; no visible damage.

• Window glass undamaged and clean.

• Gauges, switches, shifter, foot controls and horn operational.

• Check seat belt for damage, replace belt if frayed or cut webbing, damagedbuckles or loose mounting hardware.

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2.4 CAB AND PLATFORM ACCESS

Entry and Exit

1. Keep hands and shoes clean, checking for grease, mud etc. before entering and exiting.

2. Face operators cab and platform when entering and exiting.

3. Place papers, coats, etc in operators cab and platform before entering, take out after exiting. Keep hands free to grip hand holds.

4. Use three points of contact with the vehicle or ground at all times. This means that a minimum of two hands and one foot, or one hand and two feet must be in firm contact with the vehicle or ground.

WARNINGFALL HAZARD. Keep all stations, handrails, floors, steps, etc. wiped free offoreign substances. Metal surfaces become extremely slippery when oily, greasy,muddy, etc. Failure to comply could result in death or serious injury.

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2.5 WARM-UP AND OPERATIONAL CHECKS

Warm-Up Check

During warm-up period, check:

1. Heater, defroster and windshield wiper.

2. All lighting systems for proper operation.

3. Voltmeter should show 12 to 14 volts.

4. Clean and adjust mirrors for maximum visibility.

Operational Check

When engine warms, check:

1. Service brake and parking brake operation.

2. Forward and reverse travel.

3. Engage and disengage front drive axle, (if equipped).

4. All gauges working properly.

5. Turn PTO switch on and off (if equipped).

6. Engage and disengage transfer case, (if equipped).

7. Steering in both directions with engine at low idle.

8. Horn and back-up alarm. Must be audible from inside operators cab with engine running.

9. All other vehicle functions - operate smoothly and correctly.

10. Perform any additional checks described in Section 7.

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Section 3 - Operators Cab

SECTION 3 - OPERATORS CAB

3.1 OPERATORS CAB

The vehicle is equipped with a standard operator cab.

Note: Each Kimble Chassis is custom made, cab layout may not look exactly like illustrations.

WARNINGNever operate vehicle unless the cab structure is in good condition. Anymodification to this vehicle must be approved by Kimble Custom Chassis toassure compliance with this carrier configuration. If damaged, the CAB CANNOTBE REPAIRED. It must be REPLACED. Failure to comply could result in death orserious injury.

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3.2 CAB LAYOUT

1. Fire Extinguisher: Portable container used for extinguishing minor fires.

2. Steering Wheel: Turning the steering wheel to the left or right steers the vehicle in the corresponding direction.

3. Cab Door: See page 3-6 for details.

4. Brake Pedal: Operates the service brakes. The further the pedal is depressed, the greater the braking.

5. Accelerator Pedal: Pressing down on the pedal increases engine speed.

6. Front Panel: See page 4-6 for details.

7. Mirror: Adjust properly to view side of vehicle and rear view.

8. Grab Handle: Handle to assist in entry/exit of operators cab.

9. Air Horn Lanyard: Pull lanyard to sound air horn.

10. Defroster Vent: Defroster and defogging louver directing air to windshield.

11. Sun Visor: Screens sunlight from operator, change angle as needed.

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12. Instrument Panel: See page 4-2 for details.
13. Courtesy Light & Map Light: Illuminates when door opens. Press switch left to illuminate both, right to illuminate map light.

14. Parking Brake: See page 4-13 for details.

15. Heating & Cooling Panel: See page 4-7 for details.

16. Power Outlets: See page 4-13 for details.

17. Right Console: See page 4-6 for details.

18. Fuse Panel Box: See page 10-1 for details.

19. Windshield Washer Fluid Reservoir: Fill when washer fluid level is low.

20. Horn Button: Depress button to sound horn.

21. Operator Seat: See page 3-4 for details.

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3.3 OPERATOR SEAT

Adjustments

Prior to starting engine adjust seat for position and comfort as follows:

• Press the switch (1) on the side of seat to adjust the air suspension height.

• Slide handle (2) to move seat fore and aft.

• Press lever (3) to adjust backrest angle.

• Pull handle (4) to adjust height of shoulder strap.

A two inch seat belt (5) is standard equipment. See page 3-5 for details.

Tether belts (6) are installed on suspension seat. The belts secure the seat to thefloor to restrain it in case of a sudden stop or an accident.

WARNINGBefore driving the vehicle, ensure that there is adequate head clearance atmaximum upward travel of seat. Serious head or neck injury can occur.

WARNINGDo NOT remove, modify or replace the tether belt system with a different tethersystem. A failed or missing tether belt could allow the seat base to fully extend inthe event of an accident leading to greater injuries or death.

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Seat Belt
Fasten seat belt as follows:

1. Grasp both free ends of the belt making certain that belt webbing is not twisted or entangled.

2. With back straight in the seat, couple the retractable end (7) of the belt into the receptacle end (8) of the belt.

3. With belt positioned in correct location (see below), pull the retractable end (9) of the belt away from the buckle until it is tight across the lap.

4. To reduce belt rubbing against the neck or pressure to shoulder adjust Komfort Latch (10) to relieve the seat belt tension.

5. To release belt latch, depress red button (11) on the receptacle and pull free end from receptacle.

Note: Always disengage Komfort Latch when removing seat belt.

WARNINGAdding too much slack to the seat belt will reduce the seat belt’s effectivenessduring a crash. Failure to comply could result in injury or death.

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3.4 CAB DOOR & WINDOWSNote: Keep all windows and mirrors clean and unobstructed.

Cab Door

• Pull handle (1) to close door after entry.

• Pull door lever (2) to open door for exit.

• Turn window crank handle (3) clockwise to raise, counterclockwise to lower.

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WARNINGKeep limbs in vehicle at all times. Do NOT attempt to open door while vehicle ismoving. If the door were to open the force of the air could pull door from hand andswing open. Failure to comply could result in death or serious injury.

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Section 4 - Controls & Indicators

SECTION 4 - CONTROLS & INDICATORS

4.1 GENERALThis section provides the necessary information needed to understand controlfunctions and indicator lights. See supplemental manufacturer’s material for furtherinformation.

Note: Kimble Custom Chassis has no direct control over vehicle application and operation. The owner and operator are responsible for conforming with good safety practices.

CAUTIONEQUIPMENT DAMAGE. When a stop engine telltale or a gauge red lightilluminates, safely bring vehicle to a stop and preform shut down procedure.Determine cause and correct before continued use.

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4.2 INSTRUMENT PANELNote: Each Kimble Chassis is custom made. Instrument panel may not look exactly like the one illustrated.

1. Voltmeter Gauge: Displays the battery voltage. The proper operating range should show 12 to 14V (volts).

2. Fuel Level Gauge: Level gauge for diesel fuel tank.

3. Tachometer: Indicates the engine speed in revolutions per minute (rpm).

4. Driver Information Center: See page 4-4 for details.

5. Speedometer: Indicates vehicle speed in miles per hour (mph) and kilometers per hour (kph).

6. Front Brake Air Pressure Gauge: Indicates air pressure in the front brake system. Normal operating pressure is 120 psi.

7. Rear Brake Air Pressure Gauge: Indicates air pressure in the rear brake system. Normal operating pressure is 120 psi.

8. Transmission Temperature Gauge: Indicates the transmission fluid temperature. See specific manufacturer’s manual for normal operating ranges.

9. Parking Brake Switch: See page 4-13 for details.

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10. Air Vent: Adjustable air vent.
11. Engine Brake Switch: On/Off switch. See page 8-4 for details.

12. Engine Brake Select Switch: Press switch to third position to activate 1st stage engine brake. Press switch to second position to activate 2nd engine brake. Press switch to first position to activate 3rd stage.

13. Hazard Warning Switch: On/Off switch for hazard flashers.

14. Steering Column Tilt/Tele Lever: See page 4-8 for details.

15. Turn Signal/High Beam lever: Press lever downward to activate left turn signal. Press lever upward to activate right turn signal. Pull lever to activate/deactivate high beam lights.

16. Instrument Panel Dimmer Switch: Slide switch to adjust instrument panel brightness.

17. Headlight Switch: Press switch to second position to activate parking lights. Press switch to third position to activate headlights. Return switch to first position to turn off lights.

18. Oil Pressure Gauge: Indicates engine oil pressure. See specific manufacturer’s manual for normal operating range.

19. Intermittent Windshield Wiper/Washer Fluid Knob: Turn knob clockwise to activate intermittent wipers. Adjust long to short delay, low or high speed wiper. Push knob to activate windshield wash function.

20. Engine Temperature Gauge: Indicates the engine coolant temperature. See specific manufacturer’s manual for normal operating ranges.

21. Transmission Filter Indicator: See page 4-12 for details.

22. Fan Override Switch: On/Off switch. Turning switch to the “ON” position, the fan clutch will be overridden and the engine fan will stay on and will remain on till the switch is manually turned to the “OFF” position.

23. Fast Idle Switch: On/Off switch. Turning switch to the “ON” position, the engine idle speed will increase to 1000 RPM and will remain at high idle until switch is manually turned to the “OFF” position. This may be used to warm engine, increase air pressure or accessories etc.

4-3990001-016

Driver Information Center
The Driver Information Center displays messages and notifies driver of vehiclestatus. The center also uses notifying telltales that illuminate when a fault messagehas been received. See specific manufacturer’s manual for additional information.

1. Left Turn Signal: Illuminates and flashes when left hand turn signal is activated.

2. Stop Engine: Illuminates when there is a fault in the engine system. Audible alarm will sound. Determine cause and correct before continued use.

3. Check Engine: Illuminates when there is a fault in the engine system. Audible alarm will sound. Determine cause and correct before continued use.

4. Park Brake: Illuminates when park brake is activated. Park brake must be applied to start engine.

5. High Beams: Illuminates when high beam headlights are activated.

6. Low Oil Pressure: Illuminates when oil pressure is below safe operating level. Audible alarm will sound. Determine cause and correct before continued use.

7. Coolant Temperature: Illuminates when coolant temperature exceeds manufacturer’s recommendations. Determine cause and correct before continued use.

8. Transmission Temperature: Illuminates when transmission temperature exceeds manufacturer’s recommendations. Determine cause and correct before continued use.

9. Right Turn Signal: Illuminates and flashes when right hand turn signal is activated.

10. Front Axle (if equipped): Illuminates when Front Axle is activated.

11. Differential Lock: Illuminates when Inter Axle or Main Differential Lock is activated.

12. Low Coolant: Illuminates when coolant level is below safe operating level. Determine cause and correct before continued use.

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4-4 990001-016

13. Power Take-Off (if equipped): Illuminates when Power Take-Off is activated.
14. Neutral: Illuminates when park brake is set and transmission is in neutral.

15. Automatic Traction Control (if equipped): Illuminates when Automatic Traction Control is activated.

16. Anti Lock Brakes: Illuminates when there is a fault in the ABS system. Determine cause and correct before continued use. See “Anti-lock Braking System” on page 8-3 for additional infromation.

17. Check Transmission: Illuminates when there is a fault in the transmission system. Determine cause and correct before continued use.

18. Exhaust Regeneration (if equipped): Illuminates when diesel particulate filter regeneration is in process.

19. Scroll Right: Scroll right through menu on the information screen.

20. Scroll Down: Scroll down through menu on the information screen.

21. Information Screen: Review and receive messages regarding vehicle status.

WARNINGDo NOT scroll Information Screen while driving vehicle. Removing concentrationand vision from road could cause an accident. Failure to comply could result indeath or serious injury.

4-5990001-016

Front Panel
1. Heated Mirror Switch: On/Off switch. If mirrors are covered with frost or mist, turn switch to the “ON” position to heat the mirrors. Turn to “OFF” once cleared.

2. Ignition Switch: See page 4-9 for details.

3. PTO Switch: On/Off switch. Turning switch to the “ON” position, the PTO will be in “REAR MODE”, power will be transferred from cab throttle and shifter to rear controls and chassis lights will be disconnected. The switch must be manually turned to the “OFF” position, to return to “ROAD MODE” for cab controls.

Right Console

4. Power Outlets: See page 4-13 for details.

5. Transmission Shifter: See page 4-10 for details.

6. Inter Axle Lock: Move control right to engage inter axle operation, move control left to disengage inter axle operation. See “Inter-Axle Differential Lock” on page 8-6 for additional infromation. Light on dash will illuminate.

7. Main Differential Lock: Move control right to engage main differential operation, move control left to disengage main differential operation. See “Main Differential Lock” on page 8-7 for additional infromation. Light on dash will illuminate.

8. Tag/Pusher Axle Control: Move control to raise and lower pusher and tag axles at the same time. See “Pusher/Tag Axle” on page 8-8 for additional information. Regulators located behind cab in enclosure see page 4-15 for details.

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Heating/Cooling Panel
9. Heater Blower Switch: Press switch to second position to activate heater blower. Return switch to first position to turn off heater blower.

10. Blower Mode Switch: Press switch to first position to activate defrost. Press switch to second position to activate floor. Return switch to first position to turn off heater.

11. Blower Speed Switch: Press switch to first position for low blower speed.Press switch to second position to activate medium blower speed. Press switch to third position to activate high blower speed.

12. Temperature Control: Turn the adjustable rotary control to the desired temperature.

Heating/Cooling

Turn the temperature control to the desired temperature and set the fan speed.Adjust the air flow through the air louvers.

Defrosting

Once engine reaches operating temperature turn the control to HOT, turn heaterblower switch to “ON”. Turn blower mode switch to “DEFROST” and select “HIGH”on the blower speed switch.

WARNINGUse extreme caution while adjusting HVAC controls when driving vehicle.Removing concentration and vision from road could cause an accident. Failure tocomply could result in death or serious injury.

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4.3 STEERING COLUMN ADJUSTER

• Before adjusting steering column follow “Shut-Down Procedure” on page 5-4.

• Push adjuster lever (1) to telescope (2) the column.

• Place the steering column in the desired position.

• Pull adjuster lever to tilt (3) the column.

• Place the steering column in the desired position.

WARNINGDo NOT adjust steering column while driving vehicle. A sudden change indirection of travel could cause an accident. Failure to comply could result in deathor serious injury.

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4-8 990001-016


4.4 IGNITION SWITCH

In the “OFF” position (4) the key can be inserted and removed, only in this position.Some electrical functions can be operated in the “OFF” position.

• Full clockwise rotation to “START” (5) engages starter motor.

• Counter-Clockwise rotation to “OFF” stops engine and removes voltage fromcertain electrical functions.

• See “Starting the Engine” on page 5-1 for details.

Note: In “IGN” or “START” position, the vehicle power is available for all electrical functions.

CAUTIONEQUIPMENT DAMAGE. Do NOT engage starter motor while engine is running.Failure to comply could result in damage to the starter or engine.

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4.5 TRANSMISSION SHIFTER

Travel Direction

The automatic transmission has six gears for forward travel, a single gear forreverse travel and a push button shifter.

Push-button Gear Selection

1. Digital Display - Contains two digital displays, “Select” and “Monitor”. During normal operation the select display shows the highest forward range attainable. The monitor display shows the lowest available forward range.

2. Mode Display - Displays special function in the “Mode ID” label.

3. Mode Button - Press “Mode” button to enable a secondary shift schedule, PTO enable or other functions.

4. Up Arrow Button - Press the up arrow when in “Drive” to request the next higher range. Continually pressing the up arrow will request the highest range.

5. Down Arrow Button - Press the down arrow when in “Drive” to request the next lower range. Continually pressing the up arrow will request the lowest range.

6. Reverse Button - Press “R” to select reverse.

7. Neutral Button - Press “N” to select neutral.

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8. Drive Button - Press “D” to select drive. The highest forward range available
will appear in the digital display window. The transmission will start out in the lowest available forward range and advance automatically to the highest range.

9. Diagnostic Mode - Push both arrow buttons simultaneously to enter diagnostic mode and fluid level check.

Shifting Suggestions Under Normal Operation

• With an automatic transmission equipped vehicle, it is not necessary to selectthe right moment to upshift or downshift during changing road and trafficconditions. The automatic transmission does it for the operator.

• Knowledge of the shift selector positions, available ranges and when to selectthem vehicle control easier.

• To reduce wear on the service brakes, select lower ranges when descendinglong grades (with or without retarder).

• Refer to transmission’s operators manual for additional knowledge.

• There is no speed limitation on upshifting, but there is a limitation on downshiftingand for shifts that cause a directional change.

• Directional shifts will not occur if selected when throttle position, engine speed ortransmission output speed is above the shift limit.

See “Operating the Transmission” on page 8-5 for additional infromation.

CAUTIONEQUIPMENT DAMAGE. Do NOT idle in “R” (reverse) or “D” Drive for more thanfive minutes. Extended idling in reverse or drive can cause transmissionoverheating and damage. Always select “N” (neutral) and set the service orparking brake whenever time exceeds five minutes.

4-11990001-016


4.6 TRANSMISSION FILTER INDICATOR

• Transmission filter light (1) is located on the instrument panel.

• Light will illuminate (2) when transmission filter is dirty and causing too muchrestrictions with the fluid flow.

• Transmission will be in by-pass mode when light is illuminate and will remain thatway until the filter is changed.

• Transmission filters (3) are remote mounted and located on the right-hand framerail. Dispose of fluid and filters properly.

• Replace with new filters and refill transmission fluid back to the full level. Checkfor leaks and recheck fluid level after running through gears.

CAUTIONEQUIPMENT DAMAGE. Do NOT operate vehicle for a prolonged period with thetransmission filter light illuminated. Fluid will not be filtered when transmission isin by-pass mode, which could allow particles into the transmission. Failure tocomply could result in damage to the transmission or transfer case.

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4.7 POWER OUTLET

Note: The power outlet will operate with the ignition switch in either the OFF, IGN (ignition) or START position.

The outlet (4) may be used to operate 12 volt, 15 ampere devices, such as aspotlight or mobile phone charger.

Replace cap after use to keep debris from entering the outlet.

WARNINGDo NOT exceed the voltage/amperage capacity of the power outlet. Failure tocomply could result in a fire or personal injury. Follow all warnings andinstructions in the operator’s manual of the device being used.

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4.8 PARK BRAKE

• The parking brake valve (1) controls the activation and deactivation of theparking brake.

• Pull the valve out to apply the parking brake and press the valve to release theparking brake.

• This applies and releases air pressure in brake chambers which engages anddisengages rear axle spring brake mechanism.

WARNINGDo NOT leave the cab without applying the parking brake. Failure to complycould cause the vehicle to roll resulting in death or serious injury.

WARNINGDo NOT manually apply parking brake while the vehicle is moving. Stopping withthe parking brake can cause a sudden wheel lock-up or loss of control. Failure tocomply could result in death or serious injury.

WARNINGIf the air pressure falls below 60 psi red light illuminates in gauge and a audiblealarm will sound. Safely bring vehicle to a stop and perform shut down procedure.If pressure continues to drop, at 40 psi parking brake will set and stop the vehicleabruptly, which could cause an accident resulting in death or serious injury.

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4.9 PUSHER/TAG AXLE REGULATORS

The air ride, air lift suspension is operated from a control panel consisting of a togglevalve, (in cab), pressure gauge and a pressure regulator, (both in enclosure). Usedto regulate the air pressure in the load bags for the proper load on the auxiliary andto be able to lift auxiliary axle to the up position when unit is not required.

• Locate pusher/tag axle regulator enclosure (2) behind cab.

• Adjust pusher axle air pressure by turning regulator knob (3). Pressure isincreased by turning the knob clockwise and decreased counter-clockwise.

• Adjust tag axle air pressure by turning regulator knob (4).Pressure is increasedby turning the knob clockwise and decreased counter-clockwise.

• Use air pressure gauges (5) to view pressure in load bags.

• Secure enclosure door when finished.

Note: Chassis air pressure must be built up to 65 psi minimum before operation. Pressure is required to operate the brake protection valve, which maintains a safe air brake pressure in the event of an air loss in the suspension system.

WARNINGEQUIPMENT DAMAGE. Never exceed assigned gross axle weight ratings(GAWR) of each axle. Exceeding the specified weight rating of any axle couldresult in equipment damage or serious injury.

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4.10 TRANSFER GEAR SHIFTER

To shift transfer gear from “Road Mode” to “Rear Mode” or vice versa, transmissionmust be in “Neutral” and parking brake set. A shifter shaft extending from the clutchhousing is used to manually engage or disengage the output shafts.

To manually engage:

• Ensure transmission is in “Neutral” and parking brake is set.

• Pull shifter shaft (1) away from transmission (2) to engage “Rear Mode”.

• Push shifter shaft towards transmission (3) to engage “Road Mode”.

Note: Rear mode is for final stage manufacturer’s use.

WARNINGEQUIPMENT DAMAGE. Do NOT shift output shafts with transmission in gear.Trying to shift output shafts while transmission is operating will cause damageand potentially a hazardous situation. The driveshafts have rotating parts andshafts. Failure to comply could result in product damage or serious injury.

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4-16 990001-016

Section 5 - Operation

SECTION 5 - OPERATION

5.1 ENGINE

Starting the Engine

This vehicle can be operated under normal conditions in temperatures of 0° F to110° F (-17° C to 43° C). Consult Kimble Custom Chassis for operation outside thisrange or under abnormal conditions.

1. Make sure shifter is in “Neutral” and all electrical components (lights, heater, defroster, etc.) are turned off. Ensure parking brake is set.

2. Turn ignition switch to “START” to engage starting motor. Release key immediately when engine starts. If engine fails to start within 15 seconds, release key and allow starting motor to cool for a few minutes before trying again.

3. After engine starts, observe engine oil pressure gauge. If gauge remains on zero for more than ten seconds, stop engine and determine cause before restarting engine. Reference engine manual for minimum pressure at operating temperature.

4. Allow engine to idle, increasing air pressure within the air brake system reservoir.

Note: Engine will not start unless transmission is in “Neutral” and park brake applied.

CAUTIONEQUIPMENT DAMAGE Failure to allow starter to cool could result in seriousdamage or premature failure of the starter motor. Do NOT engage the startingmotor when flywheel is turning.

WARNINGUNEXPECTED MOVEMENT HAZARD. Always ensure that transmission is inneutral and the service brake is applied before releasing park brake. Releasingpark brake in either forward or reverse could cause the vehicle to move abruptly,causing an accident resulting in death or serious injury.

5-1990001-016

Cold Weather Operation
Use these cold weather starting guidelines when the air temperature falls. CheckEngine Operation manual for further details on when cold weather starting aids areneeded. Engine manufacturer and Kimble Custom Chassis must approve additionalstarting aids.

Using special cold-starting equipment will help the engine start easier. In coldweather, fast engine starting helps relieve the loads on the electrical system andcranking motor. Follow these simple guidelines to extend the service life of vehicle’sengine.

• Vehicle is equipped with a air intake grid heater, do NOT use ether or startingfluid as a starting aid

• Keep the electrical system in top condition

• Use best quality and recommended grade of fuel (see Engine Operation manual)

• Use the recommended engine lubricating oil

WARNINGEXPLOSION HAZARD. Never spray a starting aid into the air intake. Vehicle isequipped with a air intake grid heater and the starting aid could explode. Failureto comply could result in death or serious injury.

5-2 990001-016

Battery Boosted Starting
If battery-boost starting (jump-start) is necessary, proceed as follows:

• Never allow vehicles to touch.

• Connect the positive (+) jumper cable to positive (+) post of discharged battery.

• Connect the opposite end of positive (+) jumper cable to positive (+) post ofbooster battery.

• Connect the negative (-) jumper cable to negative (-) post on booster battery.

• Connect opposite end of negative (-) jumper cable to ground point on vehicleaway from discharged battery.

• Follow standard starting procedures.

• Remove cables in reverse order after vehicle has started.

WARNINGBATTERY EXPLOSION HAZARD. Never jump start or charge a frozen batteryas it could explode. Keep sparks, flames and lighted smoking materials awayfrom the battery. Lead acid batteries generate explosive gases when charging.Wear safety glasses. Failure to comply could result in death or serious injury.

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Normal Engine Operation
• Observe gauges frequently to be sure all engine systems are functioningproperly.

• Be alert for unusual noises or vibration. When an unusual condition isnoticed, park vehicle in a safe position and perform shut-down procedure. Reportcondition to your supervisor or maintenance personnel.

• Avoid prolonged idling. If the engine is not being used, turn it off.

Shut-Down Procedure

Individual applications may have different shutoff procedures. Ensure the shutoffprocedures are understood. Use the following general guideline in order to stop theengine.

When parking the vehicle, park in a safe location away from other equipment and/ortraffic lanes.

1. Bring the vehicle safely to a complete stop.

2. Apply the park brake.

3. Shift the transmission to “Neutral.”

4. Operate engine at low idle for 3 to 5 minutes to allow circulating coolant and lubricating oil to carry away heat. DO NOT over rev engine. Refer to Engine Manufacturers Operation Manual for additional information.

5. Shut off engine and remove ignition key.

6. Exit vehicle properly. Refer to page 2-6 for details.

7. Block wheels (if necessary).

Note: If vehicle will be shut down for extended period, disconnect battery. See page 5-5 for details.

5-4 990001-016


5.2 BATTERY DISCONNECT

• The battery disconnect switch (1) is located on the side of the battery box.

• The disconnect switch removes all battery power to the vehicle when turned tothe “OFF” position (2).

• The disconnect should also be used whenever the vehicle is placed out ofservice for extended periods, to prevent battery discharge.

• Turn switch back to the “ON” position (3) to return vehicle power.

Note: During operation and the vehicle is suddenly without power, first ensure that the battery disconnect switch is in the “ON” position.

CAUTIONEQUIPMENT DAMAGE. The batteries must be disconnected if the vehicle is notto be used for a period exceeding two weeks, or the vehicle may not start andpermanent battery damage could occur.

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5-6 990001-016

Section 6 - Vehicle Recovery

SECTION 6 - VEHICLE RECOVERY

6.1 FREEING THE VEHICLEAlways look ahead for wet, muddy or icy patches in path, stop vehicle and engageInter-Axle Lock ahead of time.

If the vehicle gets stuck in sand, mud, snow or ice:

• Engage Axle Locks, see page 4-6 for details

• Move the shift lever to “First” or “Reverse”

• Apply light pressure on the accelerator pedal while the transmission is in gear

• Remove foot from the accelerator while shifting

• Do NOT race the engine

• For best traction and safety, avoid spinning the wheels

Rocking Out1. Shift to D (Drive) and apply steady, light throttle, NEVER full throttle.

2. When the vehicle has rocked forward as far as it will go, apply and hold vehicle service brake.

3. When engine has returned to idle, select R (Reverse).

4. Release the brakes and apply a steady, light throttle allowing the vehicle to rock in reverse as far as it will go.

5. Again, apply and hold service brakes and allow engine to return to idle.

This procedure may be repeated in drive and reverse if each directional shift continues to move the vehicle a greater distance. NEVER make Neutral to Drive or directional shift changes when the engine RPM is above idle.

WARNINGDo NOT spin wheels, spinning wheels can be dangerous - tires can explode fromspinning too fast. Under some conditions, a tire may be spinning at a speed twicethat shown on the speedometer. Any resulting tire explosion could cause severeinjury or death to a bystander or passenger, as well as extensive vehicle damageincluding: tire, transmission and/or rear axle malfunction.

WARNINGDo NOT engage the Axle Locks while the wheels are spinning freely (slipping),failure to comply could cause loss of vehicle control or axle damage.

6-1990001-016


6.2 TOWING A DISABLED VEHICLEThe following information assumes the vehicle cannot be moved under itsown power.

• Before moving the vehicle, read all of the following information to understandoptions available. Then select the appropriate method.

• The steering system permits manual steering if engine or power assist featurefails; however, steering will be slow and will require much greater force.

Moving Short Distances

• If it is only necessary to move vehicle a short distance, less than 100 ft (30 m), itis permissible to use a vehicle of sufficient capacity to tow the unit withtransmission in “Neutral” and “Inter-Axle Lock” disengaged.

Moving Longer Distances

• If the vehicle must be moved longer distances, it must be loaded onto a trailer ofsufficient capacity. See “Loading and Securing for Transport” on page 6-3.

• If towing DO NOT attempt to tow a vehicle long distances without disconnectingthe drive-line.

Note: All federal, state and local regulations applicable to a vehicle in tow must be followed.

WARNINGOnly qualified personnel should attempt to tow the vehicle, and only withequipment properly sized for this type of vehicle to avoid damage to personneland/or equipment.

WARNINGDo NOT tow an un-braked vehicle if the combined weight of both vehicles is morethan the sum of the gross axle weight rating of the towing vehicle. Brake capacitywill be inadequate, which could result in personal injury or death.

CAUTIONDo NOT use the unit’s frame in any way to tow the vehicle. Failure to complycould result in damage to personnel and/or equipment.

6-2 990001-016


6.3 LOADING AND SECURING FOR TRANSPORTThe following information contains suggestions only, Kimble Custom Chassiscannot anticipate everything the operator needs to know about loading andsecuring a Kimble vehicle. Only qualified personnel should attempt loadingand securing the vehicle.

1. Clean deck, ramps and vehicle tires, ensuring they are free of mud, snow and ice.

2. Using a spotter, slowly load the vehicle. All hand signals should be agreed upon prior to loading by the operator and the signalman. See Hand Signals on rear cover for details.

3. Once loaded, apply parking brake, move all controls to “Neutral,” stop engine and remove ignition key.

4. Do not tie down on drive shafts, pivot arms, steering cylinders or other components unable to withstand stresses caused from tiedowns.

Note: The user assumes all responsibility for choosing the proper method of transportation and tie-down devices, making sure the equipment used is capable of supporting the weight of the vehicle being transported and that all manufacturer’s instructions and warnings, regulations and safety rules of their employer, the Department of Transportation and/or any other state or federal laws are followed.

WARNINGVEHICLE SLIDE HAZARD. Before loading vehicle for transport, make suredeck, ramps and vehicle wheels are free of mud, snow and ice. Failure to do socould cause vehicle to slide, resulting in an accident causing serious injury ordeath.

6-3990001-016



6-4 990001-016

Section 7 - Lubrication and Maintenance

SECTION 7 - LUBRICATION AND MAINTENANCE

7.1 INTRODUCTIONService the vehicle in accordance with the maintenance schedule on the followingpages. Provides general service instructions that must be followed to keep thisvehicle in good operating condition. In addition, follow Service Manuals of eachmajor component which contain more detailed service information with specificinstructions.

Use of your product may vary significantly and you must adjust service frequency foryour usage to obtain maximum service life.

Clothing and Safety Gear

• Wear all the protective clothing and personal safety devices issued to you orcalled for by job conditions.

• DO NOT wear loose clothing or jewelry that can get caught on controls or movingparts.

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7-1990001-016


7.2 GENERAL MAINTENANCE INSTRUCTIONSPrior to performing any service or maintenance on the vehicle, follow theshut-down procedure on page 5-4 unless otherwise instructed. Ensure vehicleis level, for proper fluid readings.

• Clean lubrication fittings before lubricating.

• After greasing vehicle, cycle all functions several times to distribute lubricants.

• Apply a light coating of engine oil to all linkage pivot points.

• Intervals shown are for normal usage and conditions. Adjust intervals forabnormal usage and conditions.

• Drain engine and gear cases after operating, when oil is warm.

• Check lubricant levels when lubricant is cool, unless otherwise instructed.

Note: Only perform repair & maintenance work qualified to do.

WARNINGCUT/CRUSH/BURN HAZARD. Do not perform service or maintenance on thevehicle with the engine running, except when directed differently. Failure tocomply could cause death or serious injury.

7-2 990001-016


7.3 SERVICE AND MAINTENANCE SCHEDULES

10, 50 & 250 Hour Maintenance Schedule

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500, 2000 & 3000 Hour Maintenance Schedule
Note: Never mix oils or fluids. When switching between types of lubricants, all areas of each affected component must be thoroughly drained.

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7.4 LUBRICATION SCHEDULES

50 Hour Lubrication Schedule

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7.5 OPERATOR MAINTENANCE INSTRUCTIONS

Fuel System

A. Fuel Level Check

1. Check fuel gauge (1) located on instrument panel in cab.

2. If fuel is low, proceed to fuel source and perform “Shut-Down Procedure” on page 5-4.

3. Locate fuel tank (2), remove fuel tank cap (3) from filler neck. Add diesel fuel to both tanks as needed.

4. Secure fuel tank cap.

Note: Replenish diesel fuel at end of each work shift to minimize condensation.

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B. Drain Fuel/Water Separator

1. Perform “Shut-Down Procedure” on page 5-4.

2. Loosen drain cock (4) on underside of fuel filter (5).

3. Allow all water to drain into a glass until clear fuel is visible.

4. Dispose of drained fuel/water mixture properly.

5. Tighten drain cock.

Note: When fuel reaches the change filter line located at the top of the filter assembly it is time to replace filter.

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7-9990001-016

Air Intake System
A. Air Filter Restriction Indicator Check


2. Locate air cleaner (1) and check restriction indicator (2). If red band is visible (3), filter must be cleaned or replaced.

3. Squeeze evacuator valve (4) to remove dirt from air cleaner body.

4. Remove any obstructions, leaves, dirt etc. from rain cap intake (5).

5. Clean primary filter (6) as restriction indicator indicates by loosening wing nut (7) and pulling filter assembly out. Replace filter after five cleanings or 2000 hours, whichever comes first.

6. Clean primary filter by washing or compressed air to clean dirt from filter. Compressed air is recommended when the element must be reused immediately because a washed element must be completely dried before use. Reset restriction indicator. Do NOT replace filter when wet.

Note: Only remove air cleaner cover to service the filter element as restriction indicator indicates. Excessive access to check filter element can lead to premature failure.

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B. Primary Element Change (as Restriction Indicator indicates)
1. Squeeze evacuator valve to remove dirt from air cleaner body.

2. Loosen primary element nut (7).

3. Remove primary element (6) and discard.

4. Thoroughly clean the interior of the air cleaner canister.

5. Slide the new primary element into the air cleaner making sure the sealing edge is flush with the base of the air cleaner.

6. Position air cleaner cover in place, secure into position.

7. Depress button on restriction indicator to reset.

C. Safety Element Change (as Safety Signal Service Indicator indicates)

1. After the removal of the primary element, check the safety signal service indicator (8).

2. Safety filter will need replaced when green disappears from window (9).

3. Loosen safety signal nut and remove safety element (10) and discard.

4. Slide the new safety element into the air cleaner making sure the sealing edge is flush with the base of the air cleaner. Replace safety signal service indicator.

5. Slide the new primary element into the air cleaner making sure the sealing edge is flush with the base of the air cleaner.

6. Position air cleaner cover in place, secure into position.

7. Depress button on restriction indicator to reset.

Note: Do NOT attempt to clean the safety element, it is not intended to be cleaned. For maximum engine protection, replace the safety element with a new safety element every third primary element change/cleaning or as indicated by the Donaldson Safety Signal Service Indicator.

CAUTIONEQUIPMENT DAMAGE. Do NOT use air filters with damaged pleats, gaskets orseals. Do NOT run engine without filter element or with a damaged elementallowing dirt to pass through. Failure to comply could result in engine damage.

7-11990001-016

Engine Oil
A. Engine Oil Level Check


2. Twist and pull to remove dipstick (1) and check oil mark. The oil should be between the full (2) and add (3) marks within the crosshatched area of the dipstick. Replace dipstick.

3. If oil is low, remove oil fill cap (4) and add engine oil to bring oil up to the full mark in the crosshatch area.

4. Replace oil fill cap.

Note: The standard service interval for engine oil and filter is 250 hours maximum. If an extended service interval is desired, see the engine manual for specific guidelines for optimizing oil change intervals.

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7-12 990001-016

Power Steering Fluid
A. Power Steering Fluid Level Check


2. Remove power steering fluid fill cap/dipstick (5) to check fluid mark.

3. The fluid when “HOT” should be between the full (6) and add (7) marks on the dipstick.

4. The fluid when “COLD” should be between the full (8) and add (9) marks on the dipstick.

5. If fluid is low, fluid to bring level up to the full mark on the dipstick.

6. Replace power steering fluid fill cap/dipstick.

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Tires
A. Tire Air Pressure Check


2. Remove valve stem cap.

3. Check tire pressure using a good quality gauge.

4. Add air if required.445/65R22.5.............................................................................120 psi (8,27 bar)12R22.5....................................................................................120 psi (8,27 bar)

5. Replace valve stem cap.

B. Tire Damage

For pneumatic tires, Kimble Custom Chassis recommends that when any cut, rip ortear is discovered that exposes sidewall or tread area cords in the tire, measures betaken for replacement of the tire or tire assembly.

C. Tire and Wheel Replacement

Kimble Custom Chassis recommends a replacement tire to be the same size, plyand brand as originally installed. Refer to the appropriate parts manual for orderinginformation. If not using a Kimble approved replacement tire, Kimble recommendsthat replacement tires have the following characteristics:

• Equal or greater ply/load rating and size of original.

• Tire tread contact width equal or greater than original.

• Wheel diameter, width and offset dimensions equal to the original.

• Approved for the application by the tire manufacturer (including inflation pressureand maximum tire load).

Note: If vehicle is equipped with directional tire assemblies, the wheel and tire assemblies must be installed with the directional tread pattern “arrows” facing in the direction of forward travel.

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7-14 990001-016

E. Wheel Installation
Torque lug nuts before first use and after each wheel removal.

Note: Lug nuts must be re-torqued after first 500 miles of operation.

1. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts.

2. Tighten lug nuts in an alternating pattern as indicated in figure. Torque to 450-500 lb-ft (610-678 Nm).

WARNINGTIP OVER HAZARD. Lug nuts must be installed and maintained at the propertorque to prevent loose wheels, broken studs and possible separation of wheelfrom the axle. Failure to comply could result in death or serious injury.

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Engine Cooling System
A. Engine Coolant Level Check


2. Check level of engine coolant fluid in the sight tube (1) on the recovery tank (2). The coolant level should be visible.

3. If coolant is low in recovery tank, open the tank cover (3) and add coolant(50/50 mixture of ethylene glycol and water) as required.

4. If recovery tank is empty, allow engine to cool, remove radiator cap (4). Check coolant level in radiator. Add fluid to bring level up in the radiator.

5. Add coolant to recovery tank to COLD FILL arrow (5) and run engine to circulate fluid.

6. Check for leaks and add additional coolant if needed.

CAUTIONEQUIPMENT DAMAGE. Never mix brands of antifreeze or anti-corrosionadditives, could cause the coolant to perform poorly. If a different coolant additivehas been used, be sure to thoroughly flush the cooling system before addingengine specific coolant.

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Battery
A. Battery Check


2. Open the battery cover (6).

3. Ensure hinge (7) is fully in the locked position and hinge hardware is secure before inspecting batteries

4. Wearing eye protection, visually inspect the battery (8) and jump-start provisions (9). Check terminals for corrosion. Replace battery if it has a cracked, melted or damaged case.

5. Secure the battery cover.

WARNINGCRUSH HAZARD. Use extreme caution when opening battery box cover. Ensurehinge is fully in the locked position and hinge hardware is secure beforeinspecting batteries. Failure to comply could result in death or serious injury.

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7-18 990001-016

Section 8 - Additional Information

SECTION 8 - ADDITIONAL INFORMATION

8.1 AIR BRAKE SYSTEM

The operation of the vehicle’s braking system depends upon the storage andapplication of high-pressure air.

The air brake system has a circuit for the front wheels and a separate circuit for therear wheels. The system is supplied by an engine driven compressor. The vehicle’scompressor takes outside air and compresses it. The compressor air then goes tothe reservoirs to be stored until needed.

When operating air brakes, the stored compressed air flows in the chambers whereit is used to apply truck brakes. When depressing the brake pedal, an air valve isopened to allow air flow into the brake chambers.

A water ejector valve and air dryer remove water and contaminants from the airsystem before entering the brake system. Provides clean, dry air to the componentsof the brake system, which increases the life of the system and reducesmaintenance costs.

WARNINGThe brake system is a critical vehicle safety system. Have the vehicle submittedfor periodic preventative maintenance checks as well as having any suspectedproblems immediately checked by a qualified mechanic. Failure to properlymaintain brake system could result in death or serious injury.

8-1990001-016


8.2 AIR DRYER

The function of the air dryer is to collect and remove air system contaminants insolid, liquid and vapor form before they enter the brake system. It provides clean,dry air to the components of the brake system, which increases the life of the systemand reduces maintenance costs. Nearly eliminating manual draining of thereservoirs.

It is recommended to manually check for moisture in the air brake system byopening drain cocks.

Note: No two vehicles operate under same conditions, maintenance and intervals will vary.

A tablespoon of water found in the tank could point to the need for a desiccantcartridge change. However, certain conditions can also cause water accumulationand should be considered:

• Air usage required from vehicle is above normal. Due to accessory air demandsor some unusual air requirement that does not allow the compressor to load andunload.

• Vehicle usage is in a area with more than a 30° F (17° C) temperature range inone day. Could cause small amounts of water to accumulate in air brake system.

• An outside air source has been used to charge the air system which allowed theair to bypass the air dryer.

Maintenance intervals for typical operation would be 1 year, 100,000 miles or 3,000operating hours, intervals will vary for each vehicle application

CAUTIONEQUIPMENT DAMAGE. Air Dryer is intended to remove moisture and othercontaminants normally found in the air brake system. Do NOT inject alcohol, anti-freeze or other de-icing substances into or upstream of air dryer. Failure tocomply could result in damage to the air dryer.

WARNINGIf the supply and service tanks are not drained at the recommended frequency,water could enter the air lines and valves. This could cause corrosion orblockage, which could compromise the brake system safety and potentiallycause an injury accident. When draining the air reservoir, do not look into the airjets or direct them toward anyone. Dirt or rust may be in the airstream and couldcause injury.

8-2 990001-016


8.3 ANTI-LOCK BRAKING SYSTEM

The chassis is equipped with a anti-lock braking system (ABS). The ABS reducesthe possibility of wheel lock-up during hard braking. If a wheel is about to lock duringbraking, ABS will automatically adjust air pressure to the brake chambers on theappropriate wheel(s) to prevent wheel lock-up. The ABS is automatically turned onwhen the ignition switch is turned on.

Important Safety Reminders

• ABS does not reduce the time or distance it takes to stop the vehicle, it onlyhelps with steering control during braking. Always maintain a safe followingdistance from other vehicles.

• ABS will not prevent a skid that results from changing direction abruptly, such astrying to take a corner too fast. Always drive at a safe speed for the road andweather condition.

• ABS cannot prevent a loss of stability. Always steer moderately when brakinghard. Severe or sharp steering wheel movement can still cause vehicle to veeroff the road.

WARNINGDo NOT rely on an anti-lock brake system that is functioning improperly. Loss ofvehicle control could result in death or serious injury. If ABS lamp illuminateswhile driving or remains illuminated after power-on test, anti-lock system may notbe working. The ABS may not function in an emergency. The vehicle will operatewith conventional brakes, but not anti-lock brakes, have the ABS systeminspected immediately.

8-3990001-016


8.4 ENGINE EXHAUST BRAKE

An engine exhaust brake is designed to restrict the flow of the vehicle’s exhaustgases and build up back pressure within the engine. This causes the engine toabsorb horsepower which results in control of the vehicle’s speed.

Placing the engine brake switch in the “ON” position will activate the exhaust brake.The exhaust brake will engage when the operator releases the accelerator pedal.When the operator returns to depressing the accelerator pedal the exhaust brakewill disengage.

The engine brake select switch has 3 positions, “LOW”, “MED” and “HIGH” whichenables operator to adjust level of retardation.

Operating Characteristics

• Slight change in the sound of the engine may be noticed when the exhaust brakeis applied.

• Engine temperature should remain in the normal operating range.

• The exhaust brake retards the vehicle with a smooth braking effect. Do notexpect a retarding effect similar to sudden hard application of service brakes.

• Exhaust emission should appear normal.

• Road speed usually decreases when the exhaust brake is applied duringdescent.

• Tachometer usually shows a drop in rpm during a descent.

Before shutting down the engine be sure the exhaust brake is turned to the “OFF”position.

CAUTIONEQUIPMENT DAMAGE. Do NOT turn the exhaust brake on until the engine hasreached normal operating temperature.

WARNINGEQUIPMENT DAMAGE. An engine exhaust brake is a vehicle slowing device,not a vehicle stopping device. It is not a substitute for the service braking system.The vehicle’s service brake must be used to bring the vehicle to a complete stop.

8-4 990001-016


8.5 OPERATING THE TRANSMISSION

The transmission shifter control for the vehicle is located on the right console.Understand the transmission and the transmission shifting pattern before operatingthe vehicle.

Upon start up make sure the vehicle’s systems are in proper working condition then:

1. Use Reverse (R) to back the vehicle. Completely stop the vehicle before shifting from a forward gear to reverse or from reverse to a forward gear.

2. Evaluate the road surface conditions and terrain your vehicle is on.

3. Select Drive (D) for all normal driving conditions. The vehicle will start out in First (1) gear, and as speed increases, the transmission will upshift through each gear automatically. As the vehicle slows down, the transmission will downshift to the correct gear automatically.

The pressure of your foot on the accelerator pedal influences the automatic shifting. When the pedal is fully depressed, the transmission will automatically upshift near the governed speed of the engine. A partially depressed position of the pedal will cause the upshifts to occur at a lower engine speed.

4. Occasionally the road, load or traffic conditions make it desirable to restrict the automatic shifting to a lower range. The lower the gear range, the greater the engine braking power. Use the up or down arrow buttons on the shift selector to reach the desired gear.

5. Use Neutral (N) and apply the parking brake when the vehicle is parked with the engine running.

Note: See specific manufacturer’s manual for additional information.

WARNINGTo avoid unexpected vehicle movement always have the service brake set,accelerator throttle released and the engine at idle before making a directionalshift. Failure to comply could result in vehicle damage or serious injury.

8-5990001-016


8.6 INTER-AXLE DIFFERENTIAL LOCK

The Inter-Axle Lock provides differential action between the axles of a tandem driveunit. Allows the wheels of either axle to revolve faster or slower than the wheels ofthe other axle to compensate for cornering, uneven road surfaces and slightlydifferent tire size.

When extra traction is needed under adverse road conditions, the inter-axledifferential can be locked out. With the lockout engaged (“Engage” position), theinter-axle differential acts as a solid shaft and inputs to each axle will rotate equally.

Inter-Axle lock must only be used under adverse road conditions where greatertraction is needed. Under normal traction conditions, do not use the Inter-Axle lock.

To engage Inter-Axle lock allow vehicle to come to a stop, shift control to “Engage”.The Inter-Axle telltale illuminates on the driver information center when Inter-Axlelock is engaged.

To disengage Inter-Axle Lock after leaving adverse road conditions, slow vehicle orcome to a stop, shift control to “Disengage”. The Inter-Axle telltale on the driverinformation center will turn off.

Note: See specific manufacturer’s driver instructions manual on Inter-Axle Differential (IAD) for more information.

CAUTIONEQUIPMENT DAMAGE. Inter-Axle lock should only be engaged/disengagedwhen the vehicle is stopped and transmission in “Neutral”. Failure to complycould result in vehicle damage.

WARNINGEQUIPMENT DAMAGE. Locking the axle when the vehicle is traveling downsteep grades or when the wheels are slipping could damage the differential and/or loss of vehicle control. Failure to comply could result in vehicle damage orserious injury.

8-6 990001-016


8.7 MAIN DIFFERENTIAL LOCK

The Main Differential Lock is a driver controlled traction device operated from thevehicle cab. The switch allows the driver to lock or unlock the differential to providemaximum traction under adverse road conditions.

When extra traction is needed the main differential can be locked. With thedifferential locked (“Engage” position), the clutch collar completely locks thedifferential case, gearing and axle shafts together.

Main differential lock must only be used under adverse road conditions wheregreater traction is needed. Under normal traction conditions, do not use the maindifferential lock.

To engage main differential lock allow vehicle to come to a stop, shift control to“Engage”. The Inter-Axle telltale illuminates on the driver information center whenInter-Axle lock is engaged. When the main differential is fully locked, the turningradius will increase, due to vehicle understeer. Be sure to allow for a larger turningradius and greater steering effort.

To disengage main differential after leaving adverse road conditions, slow vehicle orcome to a stop, shift control to “Disengage”. The main differential telltale on thedriver information center will turn off.

Note: See specific manufacturer’s driver instructions manual on Wheel Differential for more information.

CAUTIONEQUIPMENT DAMAGE. Main differential lock should only be engaged when thevehicle is stopped (recommended) or moving less than 25 MPH. Do NOT use themain differential lock at speeds over 25 MPH. Failure to comply could result invehicle damage.

WARNINGEQUIPMENT DAMAGE. Locking the main differential when the vehicle istraveling down steep grades or when the wheels are slipping could damage thedifferential and/or loss of vehicle control. Failure to comply could result in vehicledamage or serious injury.

8-7990001-016


8.8 PUSHER/TAG AXLE

The Pusher/Tag Axles increases the load capacity of the vehicle within federal, stateor local weight laws by distributing the total load carried between more axles.

The suspension for the pusher/tag axles uses air pressure from the chassis airsystem to control the axle, ride and weight loading. Air enters the air springs whichexpand, increasing the load on the pusher axle. Pressure in the air springsincreases to provide shock absorption to smooth the ride of the vehicle and toprovide support for the weight carried by the pusher axle.

The operator controls the pressure to the air springs by using the regulator and thesuspension pressure is indicated on the gauge. Pressure is increased by turningregulator knob clockwise. Pressure is reduced by turning regulator knobcounterclockwise.

Due to varying conditions and weights, the recommended pressure settings for axleweights are unknown. For accurate axle loading it is recommended that actual scaleweights be used, then adjust pressure settings as required. During operation ofvehicle, occasionally check pressures.

Decreasing the air pressure from the air springs reduces the weight carried by thepusher axle. Also increases the weight on the drive axles for better traction andsteering control when traveling under adverse road conditions.

WARNINGEQUIPMENT DAMAGE. Never exceed assigned gross axle weight ratings(GAWR) of each axle. Exceeding the specified weight rating of any axle couldresult in equipment damage or serious injury.

8-8 990001-016

Section 9 - Specifications

SECTION 9 - SPECIFICATIONS

9.1 VEHICLE SPECIFICATIONS

Fluid and Lubrication Capacities

Engine Crankcase Oil

Capacity with Filter ChangeHigh ....................................................................................11 gallons (41,6 liters)

Type of Oil .................................................................... Cummins approved - 15W40

Transmission Fluid

Transmission CapacityInitial Capacity........................................................................18 gallons (68 liters)Refill Capacity ........................................................................13 gallons (49 liters)

Type of Fluid.............................................................Allison approved - TranSynd RD

Fuel Tank

Capacity (per tank) ...................................................... 119 usable gallons (450 liters)

Type of Fuel.......................................................................................... #2 Diesel Fuel

Cooling System

System Capacity ........................................................................ 20 gallons (76 liters)

Type of Coolant ............................................... 50/50 ethylene glycol & water w/ SCA

Power Steering

System Capacity ..................................10 quarts (9,5 liters) Fill to Dipstick FULL line

Type of Fluid............................................... Automatic Transmission Fluid Dextron III

Axles

Front Axles ......................................................................................... Fill to FULL line

Rear Axles.........................................................................................Fill to FULL plug

Type of Fluid...................................................................................................85W140

9-1990001-016

Section 9 - Specifications
Tires
Pressure

Front445/65R22.5 Pneumatic.............................................................120 psi (8,27 bar)

Rear12R22.5 Pneumatic....................................................................120 psi (8,27 bar)

Wheel Lug Nut

Torque ............................................................................. 450-500 lb-ft (610-678 Nm)

Dimensions

Gross Vehicle WeightSpecified on the vehicle’s door verification label.

Front Axle WeightSpecified on the vehicle’s door verification label.

Rear Axle WeightSpecified on the vehicle’s door verification label.

Overall Height.................................................................................129 in (3.277 mm)

Overall Width ...................................................................................102 in (2.591mm)

Overall Length ..............................................................................531 in (13.487 mm)

Track WidthFront............................................................................................74 in (1.880 mm)Rear ............................................................................................85 in (2.159 mm)

Wheelbase......................................................................................304 in (7.722 mm)

9-2 990001-016

Section 10 - Troubleshooting

SECTION 10 - TROUBLESHOOTING

10.1 POWER PANEL LAYOUT

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10.2 ABS DIAGNOSTIC

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10.3 AIR SCHEMATIC

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10.4 POWER STEERING SCHEMATIC

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Troubleshooting Guide
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10.5 FUEL SYSTEM SCHEMATIC

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10-6 990001-016


10.6 TAG/PUSHER AXLE INSTRUCTIONS

1. U-bolts and fasteners have been torqued according to the chart and should be retorqued according to the schedule.

2. U-bolts must be tightened and torqued using a cross pattern sequence.

3. Tighten #1 & #4 to partial torque then partial torque #2 & #3.

4. Using the same sequence fully torque U-Bolt nuts.

Trouble Shooting

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10-7990001-016


10.7 MAJOR COMPONENTSIf experiencing problems with a major component such as engine, transmission, axleetc. it may be necessary to use the manufacturers manual for troubleshootingguides. If the problem persists or is beyond the capabilities of companies expertise itmay be necessary go to a local distributor or service center for that component.

Kimble Chassis, Chassis,1951 Reiser Ave SE New Philadelphia, Ohio 44663

• 1-877-KIMBLES

• www.kimblechassis.com

Cummins, Engine, P.O. Box 3005 Columbus, Indiana 47202

• 1-800-DIESELS

• www.cummins.com

Allison, Transmission, P.O. Box 894 Indianapolis, Indiana 46206

• 1-800-252-5283

• www.allisontransmission.com

Dana-Roadranger, Axles, P.O. Box 4097, Kalamazoo, Michigan 49003

• 1-800-826-HELP

• www.roadranger.com

Watson & Chalin, Lift Axles, 725 East University Drive, McKinney Texas 75069

• 1-800-445-0736

• www.WatsonSuspensions.com

10-8 990001-016

IndexIndex

AABS Diagnostic .............................. 10-2Additional Information....................... 8-1Air Brake System.............................. 8-1Air Dryer ........................................... 8-2Air Schematic ................................. 10-3Allison............................................. 10-8Anti-Lock Braking System ................ 8-3Axles................................................. 9-1

BBattery ............................................ 7-17Battery Boosted Starting .................. 5-3Battery Disconnect .................... 5-5, 5-6

CCab and Platform Access................. 2-6Cab Door & Window......................... 3-6Cab Layout ....................................... 3-2Capacities......................................... 9-1Chemical Hazards ............................ 1-8Clothing & Safety Gear..................... 7-1Cold Weather Operation................... 5-2Controls & Indicators ........................ 4-1Coolant Level ................................. 7-16Cooling System ................................ 9-1Cummins ........................................ 10-8

DDana-Roadranger........................... 10-8Danger, Warning, Caution................ 2-2Dimensions....................................... 9-2Driver Information Center ................. 4-4Driving Hazards on Slopes............... 1-5

EElectrical Hazards ............................ 1-2Engine .............................................. 5-1

Normal Operation........................ 5-4Starting........................................ 5-1

Engine Crankcase Oil .......................9-1Engine Exhaust Brake ......................8-4Engine Oil Level..............................7-12Entry and Exit....................................2-6

FFall Hazard........................................1-7Freeing the Vehicle ...........................6-1Front Panel .......................................4-6Fuel Level .........................................7-8Fuel System Schematic ..................10-6Fuel Tank ..........................................9-1Fuel/Water Separator........................7-9

GGeneral Maintenance........................7-2

HHazard Classification System ...........1-1Heating/Cooling Panel ......................4-7

IIgnition Switch...................................4-9Instrument Panel...............................4-2Inter-Axle Lock ..................................8-6

KKimble Chassis ...............................10-8

LLubrication and Maintenance............7-1Lubrication Schedule ........................7-6

50 Hour........................................7-6

MMain Differential Lock .......................8-7Major Components..........................10-8

OOperating the Transmission..............8-5Operation ..........................................5-1Operational Check ............................2-7

1

Index
Operator Maintenance Instructions .. 7-8Operator Seat ................................... 3-4
Adjustments ................................ 3-4Operators Cab.................................. 3-1

PPark Brake...................................... 4-14Pinch Points and Crush Hazards...... 1-6Power Outlet................................... 4-13Power Panel Layout ....................... 10-1Power Steering ................................. 9-1Power Steering Fluid Level............. 7-13Power Steering Schematic ............. 10-4

Troubleshooting Guide.............. 10-5Pre-Operation Check and Inspection 2-1Push-button Gear Selection ........... 4-10Pusher/Tag Axle Regulators........... 4-15

RRestriction Indicator........................ 7-10Riding Personnel Hazard.................. 1-5Right Console................................... 4-6Rocking Out...................................... 6-1

SSafety ............................................... 2-2Safety Practices................................ 1-1Safety Precautions ........................... 2-2Safety Signal Words......................... 1-1Seat Belt ........................................... 3-5Service and Maintenance Schedule . 7-3

10 Hour ....................................... 7-32000 Hour ................................... 7-4250 Hour ..................................... 7-33000 Hour ................................... 7-450 Hour ....................................... 7-3500 Hour ..................................... 7-4

Shifting Suggestions....................... 4-11Shut-Down Procedure ...................... 5-4Specifications ................................... 9-1Steering Column Adjuster................. 4-8

TTag/Pusher Axle Instructions ..........10-7

Trouble Shooting .......................10-7Tip Over Hazard................................1-2Tires ........................................ 7-14, 9-2

Air Pressure ...............................7-14Damage .....................................7-14Replacement..............................7-14

Towing...............................................6-2Moving Longer Distances ............6-2Moving Short Distances...............6-2

Transfer Gear Shifter ......................4-16Transmission Filter Indicator ...........4-12Transmission Fluid ............................9-1Transmission Shifter .......................4-10Travel Direction ...............................4-10Travel Hazard....................................1-4Troubleshooting ..............................10-1

VVehicle Loading Hazard ....................1-4Vehicle Recovery ..............................6-1

WWalk-Around Inspection ....................2-4Warm-Up Check................................2-7Watson & Chalin .............................10-8Wheel Installation............................7-15Wheel Lug Nut ..................................9-2Wheel Replacement........................7-14

2

Inspection, Maintenance and Repair LogInspection, Maintenance and Repair Log

VIN Number ________________________________

Date Comments

Inspection, Maintenance and Repair Log

Date Comments

Kimble Custom Chassis

TRANSFER OF OWNERSHIPTo: Kimble vehicle owner:

If you now own or were not the original purchaser of the product covered by this manual, we would like to know who you are. For the purpose of receiving safety-related bulletins, it is very important to keep Kimble Custom Chassis updated with the current ownership of all Kimble products. Kimble Manufacturing maintains owner information for each Kimble product and uses this information in cases where owner notification is necessary.

Please copy this form to provide Kimble with updated information in regard to the current ownership of Kimble products. Please return completed form to the Product Safety & Reliability Department via electronic mail (PS&[email protected]) or mail to address as specified below. Thank You,

Product Safety & Reliability DepartmentKimble Custom Chassis1951 Reiser Ave SENew Philadelphia, OH 44663Telephone: (330) 308-6766

Mfg. Model: _______________________________________________________________

VIN Number: ______________________________________________________________

Previous Owner: ___________________________________________________________

Address: _________________________________________________________________

_________________________________________________________________________

Country: _________________________ Telephone: (_______) ____________________

Date of Transfer: _________________________________

Current Owner: ____________________________________________________________

Address: _________________________________________________________________

_________________________________________________________________________

Country: _________________________ Telephone: (_______) ____________________

Who in your organization should we notify?

Name: ___________________________________________________________________

Title: _____________________________________________________________________

Hand Signals

Hand Signals - Should be used by the signalman to indicate their intentions to the driver, allowing for continued operation from cab.

Special Signals - When signals for attached equipment functions or conditions not covered are required, they shall be agreed upon in advance by the operator and sig-nalman.

EMERGENCY STOP - With both arms extended laterally, hands open downward, move arms back and forth.

STOP - With either arm extended laterally, hand open downward, move arm back and forth.

STOP ENGINE - Draw thumb or forefinger across throat.

MOVE SLOWLY - Place one hand motionless in front of hand giving motion signal. (Move left slowly shown)

THIS FAR TO GO - With hands raised and open inward, move hands laterally, indicating dis-tance to go.

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Kimble Manufacturing Company1951 Reiser Ave SE

New Philadelphia, OH 44663

Customer Support Toll Free: 1-877-KIMBLESFax: 330-339-4892

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