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.
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
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
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.
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