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Kimble Custom Chassis C6000, Safety Manual

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Kimble Custom Chassis C6000 Safety Manual Download Page 9

Table of Contents

iii

990001-014

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

Summary of Contents for C6000

Page 1: ...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 ...

Page 2: ...ccessories 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 ...

Page 3: ...Revision Log a 990001 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 ...

Page 4: ...d 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 ca...

Page 5: ...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 cau...

Page 6: ...irs 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 ...

Page 7: ...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 Insp...

Page 8: ...se 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 Disa...

Page 9: ...ction 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 Sect...

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Page 11: ...NG 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 prop...

Page 12: ...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 ...

Page 13: ...o 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 INFLA...

Page 14: ...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...

Page 15: ...ivetrain 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 rema...

Page 16: ...ards 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 ...

Page 17: ... 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 ...

Page 18: ...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 ca...

Page 19: ...anual 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...

Page 20: ...Y 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 ...

Page 21: ...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 CAUTION 10 Cooling system is pressurized Allow unit to cool before servicing Remove cap slowly hot fluid can cause burns 11 Turbocharger damage can result from qui...

Page 22: ...e when viewed from top checking each item in sequence INSPECTION NOTE On all components make sure there are no loose or missing parts that they are securely fastened and no visible leaks or excessive wear exists in 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 Wip...

Page 23: ... is secured 12 Wheel Tire Assembly Properly inflated and secured no loose or missing lug nuts Inspect for worn tread cuts tears or other discrepancies 13 Tail Lights Turn Signals Clean undamaged and work properly 14 Wheel Tire Assembly Properly inflated and secured no loose or missing lug nuts Inspect for worn tread cuts tears or other discrepancies 15 Fuel Tank Inspect for leaks structural damage...

Page 24: ...fore 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 WARNING FALL HAZARD Keep all stations handrails floors steps etc wiped free of foreign substances Metal surfaces become extremely ...

Page 25: ... adjust mirrors for maximum visibility Operational Check When engine warms check 1 Service brake and parking brake operation 2 Forward and reverse travel 3 All gauges working properly 4 Engage and disengage PTO 5 Steering in both directions with engine at low idle 6 Horn and back up alarm Must be audible from inside operators cab with engine running 7 All other vehicle functions operate smoothly a...

Page 26: ...Section 2 Pre Operation and Inspection 2 8 990001 014 This Page Intentionally Left Blank ...

Page 27: ... may not look exactly like illustrations WARNING Never operate vehicle unless the cab structure is in good condition Any modification to this vehicle must be approved by Kimble Custom Chassis to assure compliance with this carrier configuration If cab structure is damaged the CAB CANNOT BE REPAIRED It must be REPLACED Failure to comply could result in death or serious injury OD0730 ...

Page 28: ... for details 6 Mirror Adjust properly to view side of vehicle and rear view 7 Defroster Vent Defroster and defogging louver directing air to windshield 8 Sun Visor Screens sunlight from operator change angle as needed 9 Courtesy Light Map Light Illuminates when door opens 10 Air Horn Lanyard Pull lanyard to sound air horn 11 Instrument Panel See page 4 2 for details 12 Horn Button Depress button t...

Page 29: ...perator Passenger Seat See page 3 4 for details 19 Heating Cooling Panel See page 4 7 for details 20 Power Outlets See page 4 11 for details 21 Glove Box Use to keep loose items off of cab floor 22 Audio System Radio can be used when ignition switch is in the IGN position or the START position See page 4 19 for details 23 Antenna Fixed position receiver for audio system 24 Road Reflector Triangle ...

Page 30: ...equipment See page 3 5 for details Tether belts 6 are installed on suspension seat The belts secure the seat to the floor to restrain it in case of a sudden stop or an accident WARNING Before driving the vehicle ensure that there is adequate head clearance at maximum upward travel of seat Serious head or neck injury can occur WARNING Do NOT remove modify or replace the tether belt system with a di...

Page 31: ...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 WARNING Adding too much slack to the seat belt will reduce the seat belt s effectiveness during...

Page 32: ... unlock door Power window switches 4 see page 3 7 for details CAUTION Before opening either door check for vehicles and pedestrians approaching from behind Failure to comply could result in vehicle damage or serious injury WARNING Do NOT open cab doors while vehicle is in motion Shift transmission into the parked P position and set parking brake before exiting vehicle Failure to comply could resul...

Page 33: ...oor window operation switch 5 Passenger side door window operation switch 6 To open the window press switch in the UP position 7 To close the window press switch in the DOWN position 8 CAUTION Do NOT keep any window open in rainy weather or spill liquid on any of the window switches Water on the window switches can cause a vehicle damage WARNING Keep limbs in vehicle at all times Failure to comply...

Page 34: ...Section 3 Operators Cab 3 8 990001 014 This Page Intentionally Left Blank ...

Page 35: ...manufacturer s material for further information 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 CAUTION EQUIPMENT DAMAGE When a stop engine telltale or a gauge red light illuminates safely bring vehicle to a stop and preform shut down procedure Determine cause and correct before...

Page 36: ...psi 7 Rear Brake Air Pressure Gauge Indicates air pressure in the rear brake system Normal operating pressure is 120 psi 8 Hourmeter Records actual operation time in hours with contrasting tenth of an hour 9 Transmission Temperature Gauge Indicates the transmission temperature See specific manufacturer s manual for normal operating ranges 10 DPF Regeneration Switch See page 4 16 for details PTO AT...

Page 37: ...t turn signal Pull lever to activate deactivate high beam lights 17 Cruise Control Select Multiple function switch See page 4 14 for details 18 Cruise Control Switch On Off switch Press switch to ON position to activate cruise control select switch 19 Headlight Switch Press switch to first position to activate parking lights Press switch to third position to activate headlights and parking lights ...

Page 38: ...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 I...

Page 39: ...itional 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 Infor...

Page 40: ...ont axle drive operation move control left to disengage front axle drive operation See Front Axle on page 8 10 for additional infromation 8 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 9 for additional infromation 9 Inter Axle Differential Lock Move control right to en...

Page 41: ...rol to the desired temperature 13 Air Selection Switch On Off switch Select between fresh outside air or recirculated cab air Defrosting Once engine reaches operating temperature turn the control to desired temperature and select the defroster switch to ON and the blower switch to HIGH WARNING Use extreme caution while adjusting HVAC controls when driving vehicle Removing concentration and vision ...

Page 42: ...n Place the steering column in the desired position Pull adjuster lever to tilt 3 the column Place the steering column in the desired position WARNING Do NOT adjust steering column while driving vehicle A sudden change in direction of travel could cause an accident Adjust to comfortable position prior to vehicle start up Failure to comply could result in death or serious injury OD0240 1 2 3 ...

Page 43: ... power is available for all electrical functions CAUTION EQUIPMENT DAMAGE Do NOT turn key to start position while vehicle is running This engages the starter into a moving flywheel and can cause starter and flywheel damage Failure to comply could result in product damage SHORTDELAY LOWSPEED HIGHSPEED PUSHFORWASHER WIPER WASHER PTO ATC ABS LONGDELAY OFF 10 5 0 15 20 25 30 RPM x 100 0 0 10 20 30 40 ...

Page 44: ...e vehicle to roll resulting in death or serious injury WARNING Do NOT manually apply parking brake while the vehicle is moving Stopping with the parking brake can cause a sudden wheel lock up or loss of control Failure to comply could result in death or serious injury WARNING If the air pressure falls below 60 psi red light illuminates in gauge and a audible alarm will sound Safely bring vehicle t...

Page 45: ...one charger Cigar lighter if equipped To operate push in the knob end of the lighter 3 The lighter will automatically pop out glowing hot and ready to use After use insert the lighter back into the outlet without pushing all the way in WARNING Do NOT exceed the voltage amperage capacity of the power outlet Failure to comply could result in a fire or personal injury Follow all warnings and instruct...

Page 46: ...e 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 Diagnostic Mode Push both arrow buttons simultaneously to enter diagnostic mode and fluid level check 5 Hold Override Button The lever shift selector has three locked positio...

Page 47: ...d and traffic conditions The automatic transmission does it for the operator Knowledge of the shift selector positions available ranges and when to select them will make vehicle control easier To reduce wear on the service brakes select lower ranges when descending long grades with or without retarder Refer to transmission s operators manual for additional knowledge There is no speed limitation on...

Page 48: ...or additional infromation CAUTION Do NOT shift transmission to Neutral N when using cruise control which could cause engine over speeding Failure to comply could result in product damage WARNING Do NOT use the cruise control system when driving conditions do not permit maintaining a constant speed such as heavy traffic winding ice snow or slippery roads Failure to comply could result in death or s...

Page 49: ...Section 4 Controls Indicators 4 15 990001 014 This Page Intentionally Left Blank ...

Page 50: ...ition engine power may be reduced automatically Note Engine derate does not apply to emergency vehicle applications A Parked regeneration may be performed using the Regeneration Initiation Switch Warning or Check Engine Lamp A flashing DPF Lamp combined with an illuminated Warning or Check Engine Lamp indicates that the Aftertreatment Diesel Particulate Filter needs regeneration immediately Engine...

Page 51: ...EXHAUST AFTERTREATMENT SYSTEM INFORMATION INDICATOR LAMP S Indicator Lamp Message s Diesel Particulate Filter Condition Required Action Filter Regeneration Recommended Filter is reaching capacity Bring vehicle to highway speeds to allow for an auto Regeneration or perform a parked regeneration Filter Regeneration Necessary Filter is now reaching maximum capacity Parked Regeneration Required Engine...

Page 52: ...ht mirror position 5 to adjust right mirror 6 Once mirror is selected press directional control knob 7 in the desired direction Note To provide good visibility adjust mirrors so the side of the vehicle appears in the inboard part of the mirror WARNING Adjust all mirrors before driving Removing concentration and vision from road could cause an accident Failure to comply could result in death or ser...

Page 53: ...rom plater 6 Volume knob Audio button Turn knob to adjust desired volume level Press button to select desired audio function 7 Scan button Press to scan through stations 8 Track Tuning buttons Press to skip through tracks and stations 9 Display face Displays stations mode time and other functions WARNING Do NOT adjust audio system while driving vehicle Removing concentration and vision from road c...

Page 54: ...Section 4 Controls Indicators 4 20 990001 014 This Page Intentionally Left Blank ...

Page 55: ... 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 CAUTION EQUIPMENT ...

Page 56: ...om Chassis must approve additional starting aids Using special cold starting equipment will help the engine start easier In cold weather fast engine starting helps relieve the loads on the electrical system and cranking motor Follow these simple guidelines to extend the service life of vehicle s engine Keep the electrical system in top condition Use best quality and recommended grade of fuel see E...

Page 57: ...cable to negative post on booster battery Connect opposite end of negative jumper cable to ground point on vehicle away from discharged battery Follow standard starting procedures Remove cables in reverse order after vehicle has started WARNING BATTERY EXPLOSION HAZARD Never jump start or charge a frozen battery as it could explode Keep sparks flames and lighted smoking materials away from the bat...

Page 58: ...dures are understood Use the following general guideline in order to stop the engine When parking the vehicle park in a safe location away from other equipment and or traffic 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 hea...

Page 59: ... the vehicle is placed out of service 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 CAUTION EQUIPMENT DAMAGE The batteries must be disconnected if the vehicle is not to be used for a period exceeding ...

Page 60: ...Section 5 Operation 5 6 990001 014 This Page Intentionally Left Blank ...

Page 61: ...e 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...

Page 62: ...onger Distances If the vehicle must be moved longer distances it must be loaded onto a trailer of sufficient capacity See Loading and Securing for Transport on page 6 3 If towing DO NOT attempt to tow a vehicle long distances without disconnecting the drive line Note All federal state and local regulations applicable to a vehicle in tow must be followed WARNING Only qualified personnel should atte...

Page 63: ...l 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 transport...

Page 64: ...Section 6 Vehicle Recovery 6 4 990001 014 This Page Intentionally Left Blank ...

Page 65: ...condition In addition follow Service Manuals of each major component which contain more detailed service information with specific instructions Use of your product may vary significantly and you must adjust service frequency for your usage to obtain maximum service life Clothing and Safety Gear Wear all the protective clothing and personal safety devices issued to you or called for by job conditio...

Page 66: ...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 for abnormal 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 WARNING CUT CRU...

Page 67: ...evel Check Tire Pressure Check Air Filter Restriction Indicator Check Engine Oil Level 50 H O 2 D Check Engine Coolant Level Drain Fuel Water Separator EVERY 250 Change Engine Oil and Filter EVERY Inspect Fan Belt Check Battery D Change Fuel Filter Check Axle Oil Level Check Power Steering Fluid Lubrication Schedule OD0410 Manual Drain Air Reservoirs ...

Page 68: ...ts all areas of each affected component must be thoroughly drained 500 Check Wheel Lug Nut Torque EVERY Inspect Air Intake System LB FT Nm Check Transmission Fluid Level 2000 Change Axle Oil EVERY Change Wheel End Oil Change Trans Fluid and Filter Change Air Filter 3000 Change Engine Coolant Filter EVERY Change Air Dryer Filter OD0420 Change Power Steering Fluid ...

Page 69: ...Section 7 Lubrication and Maintenance 7 5 990001 014 NOTES OA0430 ...

Page 70: ...Section 7 Lubrication and Maintenance 7 6 990001 014 7 4 LUBRICATION SCHEDULES 50 Hour Lubrication Schedule 50 EVERY OD0860 GREASE ALL LUBRICATION POINTS ...

Page 71: ...Section 7 Lubrication and Maintenance 7 7 990001 014 50 EVERY OD0460 ALL DRIVESHAFTS ALL STEERING SHAFTS GREASE ALL LUBRICATION POINTS ...

Page 72: ...3 from filler neck Add ultra low sulfur diesel fuel to tank as needed 4 Secure fuel tank cap Note Replenish diesel fuel at end of each work shift to minimize condensation 10 PTO ATC ABS 10 5 0 15 20 25 30 RPM x 100 0 0 10 20 30 40 50 60 70 80 20 40 60 80 100 120 MPH km h 0 50 100 150 REAR PSI 50 100 0 150 FRONT PSI E F 1 2 9 12 15 18 100 250 150 200 0 20 40 60 80 100 PSI HOURS 000 0 0 0 VDO 100 25...

Page 73: ...el 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 50 OD0810 5 4 ...

Page 74: ... 3 Locate air cleaner 1 and check restriction indicator 2 If red band is visible filter must be replaced 4 Remove any obstructions leaves dirt etc from air intake 3 Damaged intake tube should be replaced 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 10 OD0880 5 2 3 4 ...

Page 75: ...ment 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 air filter Filter is treated with a chemical for carbon resistance and is not cleanable CAUTION EQUIPMENT DAMAGE Do NOT use air filters with damaged pleats gaskets ...

Page 76: ...rosshatched 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 10 OD08...

Page 77: ...l 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 50 OD0840 5 A D D F U L L H O T 6 7 A D D F U L L C O L D 8 9 ...

Page 78: ...sis recommends a replacement tire to be the same size ply and brand as originally installed Refer to the appropriate parts manual for ordering information If not using a Kimble approved replacement tire Kimble recommends that 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 diame...

Page 79: ... 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 WARNING TIP OVER HAZARD Lug nuts must be installed and maintained at the proper torque to prevent loose wheels broken studs and possible separation of wheel from the axle Failure to comply could result in death or serious injur...

Page 80: ... and water as required 4 Secure surge tank cap and run engine to circulate fluid 5 Check for leaks and add additional coolant if needed Note Never mix brands of antifreeze or anti corrosion additives could cause the coolant to perform poorly If a different coolant additive has been used be sure to thoroughly flush the cooling system before adding engine specific coolant WARNING BURN HAZARD Turning...

Page 81: ...ocedure on page 5 4 2 Turn latches 4 to unlock position and remove the battery cover 5 3 Wearing eye protection visually inspect the batteries 6 on both sides of vehicle Check terminals for corrosion Replace battery if it has a cracked melted or damaged case 4 Secure the battery cover 50 OD0780 5 4 6 ...

Page 82: ...Section 7 Lubrication and Maintenance 7 18 990001 014 This Page Intentionally Left Blank ...

Page 83: ...stored compressed air flows in the chambers where it is used to apply truck brakes When depressing the brake pedal an air valve is opened to allow air flow into the brake chambers A water ejector valve and air dryer remove water and contaminants from the air system before entering the brake system Provides clean dry air to the components of the brake system which increases the life of the system a...

Page 84: ...load and unload Vehicle usage is in a area with more than a 30 F 17 C temperature range in one 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 the air to bypass the air dryer Maintenance intervals for typical operation would be 1 year 100 000 miles or 3 000 operating hours intervals will vary for ea...

Page 85: ...safe following distance from other vehicles ABS will not prevent a skid that results from changing direction abruptly such as trying to take a corner too fast Always drive at a safe speed for the road and weather condition ABS cannot prevent a loss of stability Always steer moderately when braking hard Severe or sharp steering wheel movement can still cause vehicle to veer off the road WARNING Do ...

Page 86: ...ge in the sound of the engine may be noticed when the exhaust brake is applied Engine temperature should remain in the normal operating range The exhaust brake retards the vehicle with a smooth braking effect Do not expect 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 duri...

Page 87: ...o 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 desira...

Page 88: ...rong wind Bring the vehicle up to speed with the accelerator pedal and then let the cruise control take over To set cruise at a particular speed 1 Press the cruise control switch into the ON position 2 Hold accelerator pedal down until the vehicle reaches the desired speed The speed must be above 35 mph 56 km h 3 Press and release the set coast switch located on the dash This will hold the speed s...

Page 89: ...hold the Resume Accel switch Reducing Speed with Cruise Control Press and hold the Set Coast switch until the vehicle reaches the desired speed then release switch To decrease the vehicle s speed by very small amounts briely hold the Set Coast switch Passing with Cruise Control Depress the accelerator pedal to increase vehicle speed to overtake slower vehicle After accelerator pedal is released th...

Page 90: ...ter traction 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 Axle lock is engaged To disengage Inter Axle Lock after leaving adverse road conditions slow vehicle or come to a stop shift control to Disengage The I...

Page 91: ... allow vehicle to come to a stop shift control to Engage The Inter Axle telltale illuminates on the driver information center when Inter Axle lock is engaged When the main differential is fully locked the turning radius will increase due to vehicle understeer To disengage main differential after leaving adverse road conditions slow vehicle or come to a stop shift control to Disengage The main diff...

Page 92: ...teering wheel motion and loss of control Driving with front drive axle engaged cannot prevent loss of control if driving or cornering too fast It is still the drivers responsibility to drive at reasonable speeds for weather road surfaces traffic conditions and to leave a margin of safety CAUTION EQUIPMENT DAMAGE Front Axle should only be engaged disengaged when the vehicle is stopped and transmiss...

Page 93: ... lost traction and by diverting torque to the opposite drive wheel For safety reasons the traction control function is automatically disengaged at speeds over 25 miles per hour If the vehicle becomes immobile due to being stuck on a slippery surface such as snow or ice traction control can limit a drivers ability to control the vehicle It may be necessary to disengage traction control by manually ...

Page 94: ...mps will be illuminated The taillights side markers instrument panel and other lamps will not be illuminated Turn headlights ON one half hour before sunset and one half hour after sunrise Headlights should always be used when operating in fog snow rain or any adverse condition that limits visibility CAUTION Do NOT operate vehicle with only one working headlight or with lights that are not aimed pr...

Page 95: ...the first position for 3 5 seconds Engine speed will increase when DPF regeneration is active 6 Observe the vehicle and immediate surroundings during regeneration procedure 7 Regeneration may take time regeneration process ends when regeneration telltale is no longer illuminated 8 If regeneration causes hazardous situation immediately interrupt regeneration process by pressing the DPF control swit...

Page 96: ...Section 8 Additional Information 8 14 990001 014 This Page Intentionally Left Blank ...

Page 97: ...mission Capacity Initial Fill 48 quarts 45 liters Refill 39 quarts 37 liters Type of Fluid Allison Approved TES 295 Fuel Tank Capacity per tank 100 gallons 379 liters Type of Fuel Ultra Low Sulfur Diesel Fuel Cooling System System Capacity 20 2 gallons 76 5 liters Type of Coolant 50 50 ethylene glycol water w SCA Power Steering System Capacity 11 25 quarts 10 7 liters Type of Fluid 15W40 Axles Fro...

Page 98: ...Specified on the vehicle s door verification label Front Axle Weight Specified on the vehicle s door verification label Rear Axle Weight Specified on the vehicle s door verification label Overall Height 126 in 3 251 mm Overall Width 102 in 2 591 mm Overall Length 457 8 in 11 628 mm Track Width Front Track 83 in 2 108 mm Rear Track 84 in 2 134 mm Wheelbase 288 in 7 315 mm ...

Page 99: ...trol 8 7 Reducing Speed 8 7 Resuming Set Speed 8 7 D Danger Warning Caution 2 2 Daytime Running Lights 8 12 Dimensions 9 2 Driver Information Center 4 4 Driving Hazards on Slopes 1 5 E Electrical Hazards 1 2 Engine 5 1 Normal Operation 5 4 Starting 5 1 Engine Crankcase Oil 9 1 Engine Exhaust Brake 8 4 Engine Oil Level 7 12 Entry and Exit 2 6 Exhaust Aftertreatment System 4 16 F Fall Hazard 1 7 Fre...

Page 100: ...2 Safety Practices 1 1 Safety Precautions 2 2 Safety Signal Words 1 1 Seat Belt 3 5 Service and Maintenance Schedule 7 3 10 Hour 7 3 2000 Hour 7 4 250 Hour 7 3 3000 Hour 7 4 50 Hour 7 3 500 Hour 7 4 Shifting Suggestions 4 13 Shut Down Procedure 5 4 Specifications 9 1 Steering Column Adjuster 4 8 T Tip Over Hazard 1 2 Tires 7 14 9 2 Air Pressure 7 14 Damage 7 14 Replacement 7 14 Towing 6 2 Moving L...

Page 101: ...Inspection Maintenance and Repair Log VIN Number ________________________________ Date Comments Inspection Maintenance and Repair Log ...

Page 102: ...Inspection Maintenance and Repair Log Date Comments ...

Page 103: ...51 Reiser Ave SE New Philadelphia OH 44663 Telephone 330 308 6766 Mfg Model _______________________________________________________________ VIN Number ______________________________________________________________ Previous Owner ___________________________________________________________ Address _________________________________________________________________ _____________________________________...

Page 104: ......

Page 105: ...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 inw...

Page 106: ...Kimble Manufacturing Company 1951 Reiser Ave SE New Philadelphia OH 44663 Phone 330 308 6725 Customer Support Toll Free 1 877 KIMBLES Fax 330 339 4892 Performance Through Exper ence MADE IN THE USA ...

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