Front Discharge Mixer Operation & Safety Manual

Transcription

1 KF3100 Series Front Discharge Mixer Operation & Safety Manual Keep this manual with vehicle at all times. KIMBLE MIXER COMPANY Original August 18, 2011 Part Number

2 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.

3 Revision Log REVISION LOG 18 August, A - Original Issue of Manual Revision Log 22September, B - Vehicle Specifications updated, DPF Instructions revised. Power Panel updated a

4 Read This First 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 Mixer 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 Mixer 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. b

5 Modifications Read This First Any modification to this vehicle must be approved by Kimble Mixer. 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 Mixer 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 Mixer 1951 Reiser Ave SE New Philadelphia, OH Phone: tharding@kimblemixer.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 Mixer. 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 or write to: U.S. Department of Transportation, NHTSA, Office of Defects Investigation (NVS-210), 1200 New Jersey Avenue, S.E., Washington, D.C Other information about auto safety can be received from the Hotline c

6 Read This First Canada Canadian customers who wish to report a safety-related defect to Transport Canada, Defect Investigation and Recalls, may telephone the toll-free hotline , 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: 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. 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. Other Publications Available Illustrated Parts Manual d

7 Table of Contents Table of Contents 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 Safety Alert System and Safety Signal Words General Precautions Safety Decal Locations Exterior Decals Interior Decals Safety Decal Illustrations Operation Safety Electrical Hazards Tip Over Hazard Travel Hazard Vehicle Loading Hazard Riding Personnel Hazard Driving Hazards on Slopes Pinch Points and Crush Hazards Fall Hazard Chemical Hazards Section 2 - Pre-Operation and Inspection 2.1 Pre-Operation Check and Inspection Vehicle Descriptions Safety Precautions Walk-Around Inspection Cab and Platform Access Warm-Up and Operational Checks Warm-Up Check Operational Check Section 3 - Operators Cab i

8 Table of Contents 3.1 Operators Cab Cab Layout Cab Seats Adjustments Seat Belt Safety Belt System Cab Doors & Windows Cab Doors Section 4 - Controls & Indicators 4.1 General Instrument Panels Overhead Switch Panel Front Right-hand Panel Front Left-hand Panel Heating/Cooling Panel Right-hand Console Panel Axle Control Panel Driver Information Center Settings and Diagnostic Screens Steering Column Adjuster Ignition Switch Park Brake Rear Vision System Chute Joystick Remote Station Control Axle Control Box Transmission Shifter Travel Direction Shift Selector Shifting Suggestions Under Normal Operation Exhaust Aftertreatment System Aftertreatment Information Cruise Control Power Outlets Audio System Section 5 - Operation 5.1 Engine Starting the Engine Cold Weather Operation Battery Boosted Starting Normal Engine Operation Shut-Down Procedure Storage Preparation ii

9 Table of Contents 5.3 Drum Lockout Procedure Battery Disconnect Drum Operation Chute Storage Water Tank Operation Section 6 - Vehicle Recovery 6.1 Freeing the Vehicle Towing a Disabled Product Moving Short Distances Moving Longer Distances Loading and Securing for Transport Section 7 - Lubrication and Maintenance 7.1 Introduction Clothing and Safety Gear General Maintenance Instructions Service and Maintenance Schedules , 50 & 250 Hour Maintenance Schedule , 2000 & 3000 Hour Maintenance Schedule Lubrication Schedules Hour Lubrication Schedule Operator Maintenance Instructions Fuel System Air Intake System Engine Oil Transmission Fluid Power Steering Fluid Tires Engine Cooling System Battery Section 8 - Additional Information 8.1 Air Brake System Air Dryer Anti-lock Braking System Engine Exhaust Brake Operating the Transmission Cruise Control Operation Inter-Axle Differential Lock Main Differential Lock Front Axle High/Low Range Automatic Traction Control Daytime Running Lights iii

10 Table of Contents 8.13 Parked DPF Regeneration Section 9 - Specifications 9.1 Vehicle Specifications (2007 Reg Engines) Fluid and Lubrication Capacities Tires Dimensions Section 10 - Troubleshooting 10.1 Power Panel Layout ABS Diagnostic Battery Cable Schematic Major Components Index Inspection, Maintenance and Repair Log iv

11 Section 1 - General Safety Practices SECTION 1 - GENERAL SAFETY PRACTICES 1.1 HAZARD CLASSIFICATION SYSTEM Safety Alert System and Safety Signal Words DANGER OA0180 DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. OA0190 indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION OA0200 CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. 1.2 GENERAL PRECAUTIONS All safety decals must be in place before the equipment is used. Placement of these safety decals are extremely important to protect the users, the equipment and persons working around the vehicle. Do NOT paint over any safety decal. Do NOT use solvents to clean decals, use soap and water only. 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

12 Section 1 - General Safety Practices 1.3 SAFETY DECAL LOCATIONS Exterior Decals OI

13 Section 1 - General Safety Practices Table 1: Exterior Decal Parts List Item Part Number Description QTY /092 Burn Hazard Decal, Horizontal/Vertical Pinch Point Decal Acid Corrosion Decal Battery Burn Hazard Decal Chute Extension Damage Decal Do Not Drink Water Decal Do Not Drill or Weld Decal Platform Fall Hazard Decal Rotating Parts Decal Enter Drum Instructions Decal Contents Under Pressure Decal Booster Axle Decal, (if equipped) Not a Step Decal Fresh Concrete Decal Fluid Under Pressure Decal Secure Chutes in Rack Decal Tighten All Mounting Bolts Decal Ladder Fall Hazard Decal Chute Pinch Point Decal Check Chute For Damages Decal Hot Surface Decal Axle Settings Decal Height Decal

14 Section 1 - General Safety Practices Interior Decals 5 OVERHEAD CONSOLE 6 2 INSIDE CAB 7 INSIDE DOOR OI0140 Table 2: Interior Decal Parts List Item Part Number Description QTY Read Operation Manual Decal Chute Extension Damage Decal Do Not Drill or Weld Decal No Passengers Decal Rotate Drum In Transit Decal Over Loading GVWR Or GAWR Decal Booster Axle Safety Instructions Decal, (if equipped) Chute Pinch Point Decal Check Chute for Damages Decal Water Tank Air On/Off Decal

15 1.4 SAFETY DECAL ILLUSTRATIONS Section 1 - General Safety Practices OPERATOR INSTRUCTIONS Do NOT expose chrome rod area to acid. Corrosion will occur and is NOT covered by warranty OPERATOR INSTRUCTIONS Always rotate drum when in transit. Drum must rotate at approximately 2-3 rpm. Failure to comply could result in equipment damage ACID CORROSION ROTATE DRUM IN TRANSIT SAFETY INSTRUCTIONS Adjust booster axle pressure to weight of payload to be carried. ALWAYS raise booster axle before backing. Do NOT coast rearward with booster axle down. When driving a loaded mixer with the booster axle raised, the recommended MAX Speed is 3 mph. Failure to comply could result in equipment damage or injury. - SAFETY INSTRUCTIONS LB/FT (Nm) BOOSTER AXLE INSTR. Tighten all mounting bolts monthly per manufacturer s specifications. Failure to comply could result in equipment damage TIGHTEN MOUNTING BOLTS CAUTION BURN HAZARD Wear safety shield and gloves when near batteries. Do NOT have sparks or open flames near battery. Failure to comply could result in injury BATTERY BURN HAZARD SAFETY INSTRUCTIONS FRESH CONCRETE KEEP CHILDREN AWAY FROM FRESH CONCRETE Fresh concrete can cause burns and eye injuries. Wear protective clothing and avoid skin contact. Wash exposed skin with water. If concrete gets into eyes, rinse immediately with water, obtain prompt medical attention. NOT A STEP NOT A STEP ON WATER TANK AIR OFF WATER TANK AIR ON/OFF CAUTION EQUIPMENT DAMAGE 3 STOP FRESH CONCRETE CAUTION FALL HAZARD Use care when climbing on ladder or platform, areas may be slippery. Keep clear of grease and dirt. Failure to comply could result in injury. 5 4 Do NOT exceed 4 extension chutes from main chute Failure to comply could result in equipment damage or injury. OI LADDER FALL HAZARD CHUTE EXTENSION DAMAGE 1-5

16 Section 1 - General Safety Practices EQUIPMENT DAMAGE Do NOT drill or weld on heat treated frame rails or flange. Failure to comply could result in equipment damage DO NOT DRILL OR WELD Do NOT drink water from vehicle s holding tank. Water may contain harmful/deadly contaminates that could cause serious illness. Failure to comply could result in death or serious injury DO NOT DRINK WATER CRUSH HAZARD Clear area of people before raising or lowering booster axle. Axle can crush person close to operation. Failure to comply could result in death or serious injury BOOSTER AXLE Before unfolding chute be sure area is clear of people/objects. Keep hands away when folding or unfolding chute. Moving parts can crush or cut. Failure to comply could result in serious injury CHUTE PINCH POINT Do NOT fill vehicle with material that will cause the GVWR or GAWR, stated by manufacturer, to be exceeded. Exceeding limits can cause equipment damage or vehicle roll over. Failure to comply can result in death or serious injury OVERLOADING GVWR OR GAWR Do NOT pull chute over yourself or others. Do NOT stand under chute. Check chutes, hoses and hardware before operating. Replace damaged parts. Failure to comply could result in serious injury CHECK CHUTE FOR DAMAGES EQUIPMENT DAMAGE Properly secure chute extensions in the storage rack. Failure to comply could result in equipment damage SECURE CHUTES IN RACK Burn Hazard PINCH POINT Moving parts can crush or cut. Keep all limbs clear during operation. Failure to comply could result in serious injury PINCH POINT Burn Hazard. Hot Surfaces. Do NOT Touch Exhaust System EXHAUST BURN HAZARD Burn Hazard. Hot Surfaces. Do NOT Touch Exhaust System EXHAUST BURN HAZARD Hot Surfaces Do NOT touch Do not start, operate or service vehicle until you read and understand operator s manual BURN HAZARD Failure to comply could result in death or serious injury OI READ OPERATION MANUAL

17 Section 1 - General Safety Practices HT HEIGHT PRESSURIZED SYSTEM System is under enough pressure that it can penetrate the skin. Do NOT attempt to repair or tighten any hoses or fittings while the engine is running or when system is under pressure. Do NOT use hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to protect hands from spraying fluid. Failure to comply could result in death or serious injury FLUID UNDER PRESSURE DANGER ROTATING PARTS Stay clear and keep others away while in operation. Contact with rotating parts can catch you or your clothes. Failure to comply could result in death or serious injury ROTATING PARTS DANGER FALL HAZARD NEVER lean or climb on platform railing. Do NOT climb on ladder or stand on platform while truck is in motion. Failure to comply could result in death or serious injury PLATFORM FALL HAZARD DANGER EXPLOSION HAZARD Contents under pressure. Do NOT tamper with regulator or relief valve. Maximum 120 PSI. Failure to comply could result in death or serious injury PASSENGER DANGER No passenger is allowed in the cab unless a Kimble approved passenger seat and seat belt are provided. Sudden stop or vehicle accident could eject passenger. Failure to comply could result in death or serious injury CONTENTS UNDER PRESSURE NO PASSENGERS DANGER Read and follow all Safety Instructions before entering drum. Failure to comply with safety instructions could result in death or serious injury. SAFETY INSTRUCTIONS 1. Read and follow OSHA Regulation Confined Space procedure. 2. Disable vehicle by disconnecting battery cables. 3. Use proper Lockout/Tagout procedure. 4. Properly chock drum rollers. 5. Place Danger Person In Drum sign in both side cab windows. 6. When finished remove chocks from rollers, connect battery cable, unlock lockouts and remove sign from windows ENTER DRUM INSTRUCTIONS OI

18 Section 1 - General Safety Practices 1.5 OPERATION SAFETY Electrical Hazards OI0410 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 OI0420 Be sure that the ground conditions are able to support the vehicle

19 Section 1 - General Safety Practices OI0430 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. OA0161 PROPERLY INFLATED OVER- INFLATED UNDER- INFLATED 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. OA0170 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

20 Section 1 - General Safety Practices Travel Hazard OI0440 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 OI0460 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. 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

21 Riding Personnel Hazard Section 1 - General Safety Practices OI0470 DO NOT drive vehicle when personnel are on platform. Only operator permitted in cab while driving. 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. Driving Hazards on Slopes OI0450 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

22 Section 1 - General Safety Practices Pinch Points and Crush Hazards Stay clear of pinch points and rotating parts on the vehicle. OA0210 Stay clear of moving parts while engine is running. Keep all guards and covers secured in place. OA0630 OW0220 Keep clear of steering tires and frame or other objects. OI0490 Keep others away while operating

23 Fall Hazard Section 1 - General Safety Practices OI0500 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 2-8 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. OI0510 DO NOT carry riders on the outside of the vehicle. Riders could fall off vehicle causing death or serious injury

24 Section 1 - General Safety Practices 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 Mixer Company and site owner. Sparks from the electrical system and the engine exhaust can cause an explosion. Flammable Fuel OA0230 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) OA0250 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

25 Section 2 - Pre-Operation and Inspection 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. PARENT METAL CRACK WELD CRACK OA 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 2-6 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 2-9) 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. 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

26 Section 2 - Pre-Operation and Inspection 2.2 VEHICLE DESCRIPTIONS Be familiar with all parts of the vehicle OI

27 Section 2 - Pre-Operation and Inspection 1. Hopper 2. Charge Hopper 3. Hopper Lift Cylinder 4. Wash Down Hose 5. Drum Track 6. Drum Roller 7. Pressure Controls and Gauges, (if equipped) 8. Water Tank 9. Water Tank Fill 10. Water Tank Control 11. Ladder 12. Work Platform 13. Cab 14. Tow Plate 15. Chute 16. Chute Hoist Cylinder 17. Folding Chute 18. Folding Chute Cylinder 19. Air Tanks 20. Remote Chute Controls 21. Drum Drive Motor 22. Tag Axle, (if equipped) 23. Engine Enclosure 24. Battery Box 25. Fuel Tank 26. Drum Man Hole 27. Chute Rack 28. Hydraulic Tank

28 Section 2 - Pre-Operation and Inspection 2.3 SAFETY PRECAUTIONS OI0530 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

29 Section 2 - Pre-Operation and Inspection 2. No riders permitted on vehicle. Only operator 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. 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 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. 12. Vehicle must be in neutral and park brake set to start. 13. Disconnect positive and negative sides of battery if it is necessary to weld on unit. Failure to do so could permanently damage electronic controls on engine. 14. 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. 15. 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

30 Section 2 - Pre-Operation and Inspection 2.4 WALK-AROUND INSPECTION OI0550 It is the driver s responsibility to perform an inspection and ensure the complete road-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 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

31 Section 2 - Pre-Operation and Inspection 1. Mirrors - Clean and undamaged, adjust for maximum visibility. 2. Headlights & Turn Signals - Clean, undamaged and work properly. 3. Wiper blade - Check condition and replace as required. 4. Hydraulic Cylinders - See inspection note. 5. Chute Assembly - See inspection note. 6. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug nuts. Inspect for worn tread, cuts, tears or other discrepancies. 7. Fuel Tank - Inspect for leaks, structural damage, excessive corrosion or other damage. Ensure fill cap is secured. 8. Coolant System - See inspection note. 9. Trailer Axle (if equipped) - See inspection note. 10. Hydraulic Pump - See inspection note. 11. Tail Lights & Turn Signals - Clean, undamaged and work properly. 12. Battery - Cables tight, no visible damage or corrosion. Cover properly secured. 13. Engine - Drive belts, check condition and replace as required. Hoses, inspect for leaks and replace as required. See inspection note. 14. Air Cleaner - Air cleaner restriction indicator, check for clogged condition. Replace element as required. 15. Transmission - See inspection note. 16. Drum Roller - Inspect for proper wear and alignment. Replace as required. 17. Ladder & Platform - Clean and unobstructed. 18. 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, damaged buckles or loose mounting hardware

32 Section 2 - Pre-Operation and Inspection 2.5 CAB AND PLATFORM ACCESS OI0230 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. FALL HAZARD. Keep all stations, handrails, floors, steps, etc. wiped free of foreign substances. Metal surfaces become extremely slippery when oily, greasy, muddy, etc. Failure to comply could result in death or serious injury

33 Section 2 - Pre-Operation and Inspection 2.6 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. All gauges working properly. 4. Engage and disengage PTO (if equipped). 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 and correctly. 8. Perform any additional checks described in Section

34 Section 2 - Pre-Operation and Inspection This Page Intentionally Left Blank

35 3.1 OPERATORS CAB Section 3 - Operators Cab SECTION 3 - OPERATORS CAB OI0270 The vehicle is equipped with a standard operator cab. The actual cab of your mixer may not include all the options shown in this manual. Find control illustrations that match your mixer. Never operate vehicle unless the cab structure is in good condition. Any modification to this vehicle must be approved by Kimble Mixer 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

36 Section 3 - Operators Cab 3.2 CAB LAYOUT OI Steering Wheel: Turning the steering wheel to the left or right steers the vehicle in the corresponding direction. 2. Clean-Out Plate: Remove when washing interior to allow water, dirt and debris to exit cab. 3. Accelerator Pedal: Pressing down on the pedal increases engine speed. 4. Brake Pedal: Operates the service brakes. The further the pedal is depressed, the greater the braking. 5. Horn Button: Depress button to sound horn. 6. Heating/Cooling Panel: See page 4-6 for details. 7. Grab Handle: Handle to assist in entry/exit of operators cab

37 Section 3 - Operators Cab 8. Defroster Vent: Defroster and defogging louver directing air to windshield. 9. Air Horn Lanyard: Pull lanyard to sound air horn. 10. Audio System: Radio can be used when ignition switch is in the IGN position or the START position. See page 4-22 for details. 11. Overhead Instrument Panel: See page 4-2 for details. 12. Righthand Axle Control Panel: See page 4-2 for details. 13. Drink Holder: Courtesy beverage caddy. 14. Joystick: See Chute Joystick on page Righthand Window Crank: Turn window crank handle clockwise to raise, counterclockwise to lower. 16. Overhead Switch Panel: See Overhead Switch Panel on page Courtesy Light & Map Light: Illuminates when door opens. 18. Antenna: Fixed position receiver for audio system. 19. Righthand Console: See page 4-2 for details. 20. Fuse & Relay Access: Remove cover to access vehicle s power distribution panel. Electrical schematic located on back of cover. 21. Water Valve: The water valve controls the charge of water into the drum. Turn handle to turn water supply ON and OFF. 22. Air Pressure Switch: The air switch conrols the air supply to the water tank. Flip the switch to turn air supply ON and OFF. 23. Road Reflector Triangle & Flare Kit: Erect triangle on roadway to warn approaching traffic of the presence of a stopped vehicle. Ignite flares and place a distance away from vehicle to warn approaching traffic of the presence of a stopped vehicle when necessary. 24. Fire Extinguisher: Portable container used for extinguishing minor fires

38 Section 3 - Operators Cab 3.3 CAB SEATS Adjustments OI 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. Turn knob (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 the floor to restrain it in case of a sudden stop or an accident. Before driving the vehicle, ensure that there is adequate head clearance at maximum upward travel of seat. Serious head or neck injury can occur. Do NOT remove, modify or replace the tether belt system with a different tether system. A failed or missing tether belt could allow the seat base to fully extend in the event of an accident leading to greater injuries or death

39 Section 3 - Operators Cab Seat Belt Shoulder Belt 9 Lap Belt (if equipped) OA0040 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. OA0050 Correct (over arm) Incorrect (under arm) Incorrect (twisted) & (lap belt too high on hips) Adding too much slack to the seat belt will reduce the seat belt s effectiveness during a crash. Failure to comply could result in injury or death

40 Section 3 - Operators Cab Safety Belt System Safety belt systems are designed to limit occupant motion by restraining occupants' bodies within the vehicle and prevent, or reduce the severity of injuries during most types of collisions. When safety belts are used properly, they are effective in reducing the risk of injury. The safety belts must be worn by the driver and passenger properly anytime the vehicle is in motion. Get in the habit of connecting the safety belt anytime you enter the cab. Do NOT start the machine outside the cab or attempt to fasten the belt when the vehicle is in motion, this leads to inattentive driving and bad safety habits. The safety belt assemblies meet FMVSS 209, Type 1 and Type 2 requirements. This system does not meet the requirements of passengers less then 50 lbs. (25 kg). If a passenger is less than this weight, other considerations must be put in place. Operating the Safety Belt To fasten, pull the belt out of the retractor with the latch and insert into the buckle. Make sure the latch is locked. Adjust the slack so the lower portion of the belt is snug across the hip and with a maximum of 1 in. (25 mm) between the belt and chest. More slack reduces the efficiency of the safety belt. The release button on the buckle unfastens the belt. Hold the buckle and belt after it is released and allow the retractor to draw in the belt completely. Do NOT allow the belt and buckle to slap back into the retractor or damage to the system can result. Inspect the safety belt system regularly. The hardware, mounts, retractor and belt should work freely. The belt and/or components must not show signs of deterioration. If you suspect any part of the system is in need of repair, have the system repaired or replaced immediately and use only parts designed for the safety system. Do NOT alter or temper with any safety belt system components. The system should be replaced at least every five years. Do NOT use harsh cleaners, bleach or any products which could cause the belt material to deteriorate

41 Section 3 - Operators Cab 3.4 CAB DOORS & WINDOWS Note: Keep all windows and mirrors clean and unobstructed. Cab Doors OI0290 Pull handle (1) to close door after entry. Pull door lever (2) to open door for exit. Move door lock lever (3) to lock and unlock door. Turn window crank handle (4) clockwise to raise, counterclockwise to lower. Keep limbs in vehicle at all times. Failure to comply could result in death or serious injury. 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 result in death or serious injury

42 Section 3 - Operators Cab This Page Intentionally Left Blank

43 Section 4 - Controls & Indicators SECTION 4 - CONTROLS & INDICATORS 4.1 GENERAL This section provides the necessary information needed to understand control functions and indicator lights. Not all the controls and indicators shown in this section are equipped on every vehicle. Controls and indicators covering various models and options are illustrated and labeled with an if equipped. To ensure proper operating procedures and to avoid hazardous operating conditions, refer to this section to become familiar with controls and indicators on this vehicle. This section will refer to Section 8 - Additional Information to provide more detailed information on operating this vehicle. Read and understand this section before placing vehicle in service. See supplemental manufacturer s material for further information. Note: Kimble Mixer Company 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 continued use

44 FRONT AIR RPM x100 PSI REAR AIR STOP MODE TRIP WATER TEMP TRANS TEMP Section 4 - Controls & Indicators 4.2 INSTRUMENT PANELS Note: Each Kimble Mixer is custom made. Instrument panel may not look exactly like the one illustrated MPH km/h F 1/2 FUEL 100 OIL 50 PRESS E PSI 0 0 F 30 R P ABS ATC N! F 100 F OI Tachometer: Indicates the engine speed in revolutions per minute (rpm). The tachometer operates from a signal from the engine ECU. Always monitor the tachometer and DO NOT allow the engine to over-speed, operating above the engine s limits can cause serious engine damage. 2. Front Brake Air Pressure Gauge: Indicates air pressure in the front brake system. Normal operating pressure is 120 psi. 3. Rear Brake Air Pressure Gauge: Indicates air pressure in the rear brake system. Normal operating pressure is 120 psi. 4. Driver Information Center: See page 4-9 for details. 5. Speedometer: Indicates vehicle speed in miles per hour (mph) and kilometers per hour (kph). 6. LCD Screen/Odometer: The LCD screen in the speedometer is a multi-function display. It can be used as an odometer, trip odometer, voltmeter, engine hour meter, to test instrument panel, priority messages and on-board diagnostics. The odometer is a LCD screen in the speedometer. The odometer will register up to 9,999,999.9 miles or kilometers. 7. Mode Function Button: The LCD screen in the speedometer is a multi-function display. It can be used as a trip odometer, voltmeter, engine hour meter, to test instrument panel, priority messages and for on-board diagnostics. Use button to navigate through the functions. See page 4-9 for details. 8. Trip Button: Press button to toggle between functions. Clear trip odometer

45 9. Fuel Level Gauge: Level gauge for diesel fuel tank. Section 4 - Controls & Indicators 10. Fuel Level Telltale: Illuminates when fuel level drops below 1/8 of a tank. Fill fuel tank to turn off telltale. Audible alarm will sound once with no repeat. 11. Oil Pressure Gauge: Indicates engine oil pressure. See specific manufacturer s manual for normal operating range. 12. Oil Pressure Telltale: Illuminates when oil pressure falls below 12 PSI. Determine cause and correct before continued use. Audible alarm will sound once with no repeat. 13. Engine Water Temperature Gauge: Indicates engine oil pressure. See specific manufacturer s manual for normal operating range. 14. Engine Water Temperature Telltale: Illuminates when engine water temperature becomes greater than 212 F. Determine cause and correct before continued use. Audible alarm will sound once with no repeat. 15. Transmission Fluid Temperature Gauge: Indicates the transmission temperature. See specific manufacturer s manual for normal operating ranges. 16. Transmission Fluid Temperature Telltale: Illuminates when transmission fluid temperature becomes greater than 255 F. Determine cause and correct before continued use. Audible alarm will sound once with no repeat. 17. Slump Meter: Indicates the hydraulic pressure required to turn the mixing drum. 18. Drum Rotation Counter: Counts the number of rotations of the drum in RPM s (Revolutions Per Minute). 19. Reset Button: Press to reset drum rotation counter after each payload is discharged

46 UP DOWN ON STROBE LIGHTS OFF UP PUSHER AXLE DOWN UP PUSHER AXLE DOWN UP PUSHER AXLE DOWN ON OFF Section 4 - Controls & Indicators Overhead Switch Panel DOME LIGHTS CHARGE HOPPER RUN EMPTY OI Dome Light Switch - Turn ON/OFF the interior dome lights for low light conditions 2. Charge Hopper Switch - Raise and lower the charge hopper UP/DOWN. Charge hopper used for loading the drum with payload. 3. Strobe Light Lamp - Indicator lamp will illuminate when the strobe light is engaged. 4. Strobe Light Switch - Turn ON/OFF the strobe light. 5. Pusher Axle Switch - Raise and lower air supported pusher axles UP/DOWN for properly distributing weight when carrying a payload. Pressure regulators on retractable axles must be adjusted according to Gross Vehicle Weight accompanying federal, state, and local weight requirements per axle. 6. Trailer Axle Switch - Raise and lower hydraulic supported trailer axle UP/DOWN for properly distributing weight when carrying a payload. Pressure regulators on retractable axles must be adjusted according to Gross Vehicle Weight accompanying federal, state, and local weight requirements per axle. 7. Run Empty Switch - Engage hydraulic supported trailer axle ON/OFF for improved stability without a drum payload. Only to be engaged when the drum is completely empty

47 Front Right-hand Panel Section 4 - Controls & Indicators ENGAGE ENGAGE ENGAGE ENGAGE FRONT AXLE LOW RANGE INTER AXLE DIFF. LOCK MAIN DIFF. LOCK DISENGAGE DISENGAGE DISENGAGE DISENGAGE 1. Front Axle Switch (if equipped): Engage/Disengage switch. Engage during offroad operation. See page 8-10 for details. 2. Low/High Range Switch (if equipped): Engage/Disengage switch. Use High Range in normal operation, use Low Range for maximum pulling power and reduced vehicle speed. See page 8-11 for details. 3. Inter-Axle Diff. Lock Switch (if equipped): Engage/Disengage switch. Engage to provide additional traction when operating in adverse road conditions. See page 8-8 for details. 4. Main Diff. Lock Switch (if equipped): Engage/Disengage switch. Use to eliminate one wheel spin in slippery surfaces and improve traction. See page 8-9 for details. 5. Engage Light: Illuminates when corresponding switch is in engage position. Front Left-hand Panel OI Parking Brake Switch: See page 4-14 for details. OI Ignition Switch: See page 4-13 for details. 8. Heating/Cooling Control Panel: See page 4-6 for details

48 Section 4 - Controls & Indicators Heating/Cooling Panel FRESH OFF LO HI RECIRC. DEF VENT A/C FLOOR COOL HOT MODE TEMP OI Fan Speed Control: Rotary control. Turn knob to adjust fan speed between low and high. Return switch to first position to turn off fan. 2. Mode Control: Rotary control. Turn the knob to select desired operation: defrost, vent, A/C or floor. 3. Temperature Control: Rotary control. Turn the adjustable rotary control to the desired temperature. 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. Use extreme caution while adjusting HVAC controls when driving vehicle. Removing concentration and vision from road could cause an accident. Failure to comply could result in death or serious injury