Kimble Custom Chassis C6000 Safety Manual

C6000 Carrier Operation

& Safety Manual

Keep this manual with vehicle at all times.

Performance

Through

Exper ence

NSC

NSC Series

Truck Number T00510 & After

Revised

November 15, 2012

Part Number

990001-014

Vehicle meets EPA 2007, CARB 2007 Emission Certification

CALIFORNIA PROPOSITION

65

Battery posts,

terminals and related

accessories contain

lead and lead compounds,

chemical known to the

State of California

to cause cancer and

reproductive harm.

WASH HANDS

AFTER 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

a990001-014

Revision Log REVISION LOG

26 June, 2009 - A - Original Issue of Manual

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

Read This First

b990001-014

Read This First

This 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 relevant

information concerning the safety and daily operation of this vehicle. It is the

operator’s responsibility to read this manual thoroughly; paying particular

attention to hazard labels that have been included to draw attention to

important issues of operator safety and overall performance.

The information, specifications and illustrations contained in this manual are based

on data that was current at the time of publication. Kimble Custom Chassis reserves

the right to make changes and/or improvements at any time without notification or

liability, or without applying those changes or improvements to vehicles previously

manufactured.

Operator Qualifications

Personnel must not operate the vehicle until this manual has been read, training is

accomplished and operation of the vehicle has been completed under the

supervision 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 normal

reflexes and reaction time, good vision and depth perception and normal hearing.

Operator must not be using medication which could impair abilities nor be under the

influence of alcohol or any other intoxicant during the work shift.

This manual is not a training manual, Kimble Custom Chassis cannot anticipate

everything the operator needs to know about operating a Kimble vehicle. A good

training program or a truck driving school can provide proper education. Receive

proper training before operating this vehicle. Only qualified drivers should drive this

vehicle.

The operator must also read, understand and comply with all applicable Employer,

Industry and Governmental rules, standards and regulations, which apply to the

operation of this vehicle.

Event Data Recorder

This vehicle is equipped with one or more devices that record specific data. The type

and amount of data recorded varies depending on how the vehicle is equipped (such

as the brand of engine).

Environmental Concerns and Recommendations

Any instructions in this manual to discard materials, a first attempt to reclaim and

recycle them should be made. To preserve the environment, follow environmental

rules and regulations when disposing of materials.

Read This First

c990001-014

Modifications

Any modification to this vehicle must be approved by Kimble Custom

Chassis.

Product Safety & Reliability

Every new Kimble vehicle is designed to conform to all Federal Motor Vehicle Safety

Standards applicable at the time of manufacture. However, even with these safety

features, continued safe and reliable operation depends greatly upon correct

operation and regular vehicle maintenance, See Section 7 - Lubrication and

Maintenance. The vehicle must be operated within the range of its mechanical

capabilities and the limits of its load ratings.

Kimble Custom Chassis must be notified immediately in all instances where Kimble

products have been involved in an accident involving bodily injury or death of

personnel or when damage has occurred to personal property or the Kimble

product.

For:

• Accident Reporting and Product Safety Publications

• Questions Regarding Product Modifications, Product Applications and Safety

Contact:

Product Safety & Reliability Department

Kimble Custom Chassis

1951 Reiser Ave SE

New Philadelphia, OH 44663

Phone: Email:

1-330-308-6766 PS&R@KimbleChassis.com

Reporting Safety Defects

United States

If you believe that your vehicle has a defect which could cause a crash or cause

injury or death, immediately inform the National Highway Traffic Safety

Administration (NHTSA) in addition to notifying Kimble Custom Chassis.

If NHTSA receives similar complaints, it may open an investigation, and if it finds

that a safety defect exists in a group of vehicles, it may order a recall and remedy

campaign.

To contact NHTSA, call the Auto Safety Hotline toll-free at 1-800-424-9393 or write

to: U.S. Department of Transportation, NHTSA, Office of Defects Investigation

(NVS-210), 1200 New Jersey Avenue, S.E., Washington, D.C. 20590. Other

information about auto safety can be received from the Hotline.

Read This First

d990001-014

Canada

Canadian customers who wish to report a safety-related defect to Transport

Canada, 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, small

shovel, 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 vehicle

specifications and proper tools. If you are not an experienced mechanic or do not

have the right equipment, allow the repairs to be done by a qualified mechanic. They

are equipped to do the job safely and correctly.

The Preventive Maintenance section in this manual contains general service

information for the operator. This is summary information only, used for general

maintenance of major components installed on the Kimble vehicle.

Additional information on major component suppliers to Kimble also supply

operation manuals specific to their products. Additional manuals and other pieces of

literature are included in the vehicle.

Other Publications Available

Illustrated Parts Manual.............................................990001-015

WARNING

EQUIPMENT DAMAGE/PERSONAL INJURY. Do NOT attempt repair work

without sufficient training, parts and service manuals and the proper tools. Failure

to comply could cause equipment damage or result in death or serious injury.

Table of Contents

i990001-014

TABLE OF CONTENTS

Revision Log

Read This First

Operator Qualifications ......................................................b

Event Data Recorder .........................................................b

Environmental Concerns and Recommendations..............b

Modifications......................................................................c

Product Safety & Reliability................................................c

Reporting Safety Defects...................................................c

Emergency Equipment.......................................................d

Vehicle Repair....................................................................d

Other Publications Available..............................................d

Table of Contents

Section 1 - General Safety Practices

1.1 Hazard Classification System..............................................1-1

Safety Alert System and Safety Signal Words................1-1

1.2 General Precautions............................................................1-1

1.3 Operation Safety..................................................................1-2

Electrical Hazards...........................................................1-2

Tip Over Hazard..............................................................1-2

Travel Hazard .................................................................1-4

Vehicle Loading Hazard..................................................1-4

Riding Personnel Hazard................................................1-5

Driving Hazards on Slopes .............................................1-5

Pinch Points and Crush Hazards....................................1-6

Fall Hazard......................................................................1-7

Chemical Hazards...........................................................1-8

Section 2 - Pre-Operation and Inspection

2.1 Pre-Operation Check and Inspection...................................2-1

2.2 Safety Precautions...............................................................2-2

2.3 Walk-Around Inspection.......................................................2-4

2.4 Cab and Platform Access ....................................................2-6

2.5 Warm-Up and Operational Checks......................................2-7

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

Operational Check ..........................................................2-7

Section 3 - Operators Cab

3.1 Operators Cab.....................................................................3-1

3.2 Cab Layout ..........................................................................3-2

3.3 Cab Seats............................................................................3-4

Adjustments....................................................................3-4

Seat Belt .........................................................................3-5

Table of Contents

ii 990001-014

3.4 Cab Doors & Windows........................................................ 3-6

Cab Doors ...................................................................... 3-6

Power Windows.............................................................. 3-7

Section 4 - Controls & Indicators

4.1 General................................................................................ 4-1

4.2 Instrument Panel................................................................. 4-2

Driver Information Center............................................... 4-4

Front Panel..................................................................... 4-6

Right Panel..................................................................... 4-6

Heating/Cooling Panel.................................................... 4-7

4.3 Steering Column Adjuster ................................................... 4-8

4.4 Ignition Switch..................................................................... 4-9

4.5 Park Brake......................................................................... 4-10

4.6 Power Outlets.................................................................... 4-11

4.7 Transmission Shifter..........................................................4-12

Travel Direction ............................................................4-12

Lever Shift Selector...................................................... 4-12

Shifting Suggestions Under Normal Operation.............4-13

4.8 Cruise Control ................................................................... 4-14

4.9 Exhaust Aftertreatment System......................................... 4-16

Aftertreatment Information............................................ 4-17

4.10 Power Mirrors.................................................................... 4-18

4.11 Audio System.................................................................... 4-19

Section 5 - Operation

5.1 Engine ................................................................................. 5-1

Starting the Engine......................................................... 5-1

Cold Weather Operation................................................. 5-2

Battery Boosted Starting................................................. 5-3

Normal Engine Operation...............................................5-4

Shut-Down Procedure.................................................... 5-4

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

Section 6 - Vehicle Recovery

6.1 Freeing the Vehicle ............................................................. 6-1

6.2 Towing a Disabled Product ................................................. 6-2

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

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

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

Section 7 - Lubrication and Maintenance

7.1 Introduction.......................................................................... 7-1

Clothing and Safety Gear............................................... 7-1

7.2 General Maintenance Instructions....................................... 7-2

7.3 Service and Maintenance Schedules.................................. 7-3

Table of Contents

iii990001-014

10, 50 & 250 Hour Maintenance Schedule .....................7-3

500, 2000 & 3000 Hour Maintenance Schedule .............7-4

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

50 Hour Lubrication Schedule.........................................7-6

7.5 Operator Maintenance Instructions......................................7-8

Fuel System....................................................................7-8

Air Intake System..........................................................7-10

Engine Oil .....................................................................7-12

Power Steering Fluid.....................................................7-13

Tires..............................................................................7-14

Engine Cooling System.................................................7-16

Battery...........................................................................7-17

Section 8 - Additional Information

8.1 Air Brake System.................................................................8-1

8.2 Air Dryer...............................................................................8-2

8.3 Anti-lock Braking System.....................................................8-3

8.4 Engine Exhaust Brake .........................................................8-4

8.5 Operating the Transmission.................................................8-5

8.6 Cruise Control Operation.....................................................8-6

8.7 Inter-Axle Differential Lock...................................................8-8

8.8 Main Differential Lock ..........................................................8-9

8.9 Front Axle ..........................................................................8-10

8.10 Automatic Traction Control ................................................8-11

8.11 Daytime Running Lights.....................................................8-12

8.12 Parked DPF Regeneration.................................................8-13

Section 9 - Specifications

9.1 Vehicle Specifications..........................................................9-1

Fluid and Lubrication Capacities.....................................9-1

Tires................................................................................9-2

Dimensions.....................................................................9-2

Index

Inspection, Maintenance and Repair Log

Table of Contents

iv 990001-014

Section 1 - General Safety Practices

1-1990001-014

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, will

result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could

result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may

result in minor or moderate injury.

1.2 GENERAL PRECAUTIONS

WARNING

Before operation, read & understand this manual. Failure to comply with the

safety precautions listed in this manual could result in vehicle damage, property

damage, personal injury or death.

DANGER

OA0180

WARNING OA0190

CAUTION

OA0200

Section 1 - General Safety Practices

1-2 990001-014

1.3 OPERATION SAFETY

Electrical Hazards

• This vehicle is not insulated and does not provide protection from contact or

being near electrical current.

•NEVER operate the vehicle in an area where overhead power lines, overhead or

underground cables, or other power sources may exist without ensuring the

appropriate 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.

OD0510

OD0530

Section 1 - General Safety Practices

1-3990001-014

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 not

maintained, 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 all

times.

OD0540

OA0161

PROPERLY

INFLATED

OVER-

INFLATED

UNDER-

INFLATED

OA0170

Section 1 - General Safety Practices

1-4 990001-014

Travel Hazard

• Look out for and avoid other personnel, machinery and vehicles in the area. Use

a 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. The

components of the vehicle are designed to operate within the gross vehicle weight

rating (GVWR), and the maximum front and rear gross axle weight rating (GAWR).

• GVWR: the MAXIMUM WEIGHT the vehicle is allowed to carry, including the

weight of the empty vehicle, platform, occupant, fuel and any load. NEVER

exceed the GVWR of the vehicle.

• GAWR: the total weight that one axle or axle set is designed to transmit to the

ground. A load too heavy over one axle can affect the braking and handling of

the vehicle. Even if the load is under the legal limits, be sure it is distributed

evenly.

WARNING

Do NOT exceed the load rating specified on the vehicle’s door verification label.

Overloading can cause component failure or affect vehicle handling resulting in

loss of vehicle control and personal injury. Exceeding load ratings can also

shorten the service life of the vehicle.

OD0550

OD0560

Section 1 - General Safety Practices

1-5990001-014

Riding Personnel Hazard

•DO NOT drive vehicle when personnel are on platform.

• Operator and one passenger permitted 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 a

slow speed. DO NOT shift into neutral and coast downhill.

• Avoid excessively steep slopes or unstable surfaces. To avoid tip over DO NOT

drive across excessively steep slopes under any circumstances.

• Avoid sharp turning on a slope.

•DO NOT park on a slope.

WARNING

Do NOT allow personnel to remain on work platform while driving. Unrestrained

riders can be thrown from the vehicle resulting in personal injury or death.

OD0570

OD0580

Section 1 - General Safety Practices

1-6 990001-014

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.

OA0210

OW0220

OA0630

OD0590

Section 1 - General Safety Practices

1-7990001-014

Fall Hazard

• Enter using the proper hand holds and steps provided. Always maintain 3-point

contact when entering or exiting the vehicle. Never grab control levers or

steering 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 been

performed.

•DO NOT jump from vehicle when exiting.

•DO NOT carry riders other than safely fastened passenger. Riders could fall off

vehicle causing death or serious injury.

OD0600

OD0610

Section 1 - General Safety Practices

1-8 990001-014

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 for

that purpose by Kimble Custom Chassis and site owner. Sparks from the

electrical 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, sparks or

smoking materials. Engine fuel is flammable and can cause a fire and/or

explosion.

Pressurized Systems (Air & Fluid)

•DO NOT attempt to repair or tighten any hoses or fittings while the engine is

running or when the system is under pressure.

• Stop engine and relieve trapped pressure. The system is under enough pressure

that it can penetrate the skin.

•DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to

search for leaks. Wear gloves to protect hands from spraying fluid.

OA0230

OA0250

Section 2 - Pre-Operation and Inspection

2-1990001-014

SECTION 2 - PRE-OPERATION AND INSPECTION

2.1 PRE-OPERATION CHECK AND INSPECTION

Note: Complete all required maintenance before operating vehicle.

The pre-operation check & inspection, performed at beginning of each work shift or

at 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.

WARNING

FALL HAZARD. Use extreme caution when checking items beyond your normal

reach. Use an approved ladder. Failure to comply could result in death or serious

injury.

OA0150

PARENT METAL CRACK WELD CRACK

Section 2 - Pre-Operation and Inspection

2-2 990001-014

2.2 SAFETY PRECAUTIONS

Read and understand all safety precautions that could cause possible product

damage and/or harmful situations.

DANGER

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

serious injury.

OD0490

7

13

6

9

11

10 12

8

2

14

15

5

1

4

3

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Kimble Custom Chassis C6000 Safety Manual

Kimble Custom Chassis C6000 Safety Manual

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