Carrier Safety & Operation Manual

GEFC FAILING SPEEDSTAR KING OIL TOOLS 185K Carrier Safety & Operation Manual Keep this manual with vehicle at all times. Performance Through Exper ence Truck Number T00408 & Later Revision B November 15, 2012 Part Number 990001-002

CALIFORNIA PROPOSITION 65 Battery posts, terminals and related accessories contain lead and lead compounds, chemical known to the State of California to cause cancer and reproductive harm. WASH HANDS AFTER HANDLING! CALIFORNIA PROPOSITION 65 Diesel Engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

Revision Log REVISION LOG Revision Log 1 August, 2008 - A - Original Issue of Manual 15 November, 2012 - B - Revised Section 9.1 Coolant Type to include SCA 990001-002 a

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. Please read it thoroughly; pay 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 the 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. Modifications Any modification to this vehicle must be approved by Kimble Custom Chassis. 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 appropriate environmental rules and regulations when disposing of materials. b 990001-002

Product Safety & Reliability Read This First 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 Applications and Safety Questions Regarding Product Modifications Contact: Product Safety and Reliability Department Kimble Custom Chassis 1951 Reiser Ave SE New Philadelphia, OH 44663 Phone: 1-330-308-6766 Email: 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. 990001-002 c

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 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. 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 need good mechanical training, 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. WARNING EQUIPMENT DAMAGE/PERSONAL INJURY. Do NOT attempt repair work without sufficient training, parts and service manuals and the proper tools. Do only those tasks qualified to do. Failure to comply could cause equipment damage or result in death or serious injury. Other Publications Available Illustrated Parts Manual... 990001-005 d 990001-002

Table of Contents Table of Contents TABLE OF CONTENTS Revision Log Read This First Operator Qualifications...b Modifications...b Event Data Recorder...b Environmental Concerns and Recommendations...b 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 Operator Seat...3-4 Adjustments...3-4 Seat Belt...3-5 990001-002 i

Table of Contents 3.4 Cab Door & Windows... 3-6 Cab Door... 3-6 Right Slider Window... 3-6 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 Console... 4-6 Heating/Cooling Panel... 4-7 4.3 Steering Column Adjuster... 4-8 4.4 Ignition Switch... 4-9 4.5 Transmission Shifter... 4-10 Travel Direction... 4-10 Gear Selection... 4-10 Shifting Suggestions Under Normal Operation... 4-11 4.6 Park Brake... 4-12 4.7 Power Outlet... 4-13 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 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 ii 990001-002

Table of Contents 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 Inter-Axle Lock...8-6 8.7 Pusher Axle...8-7 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 990001-002 iii

Table of Contents iv 990001-002

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. WARNING OA0190 WARNING 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 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. 990001-002 1-1

Section 1 - General Safety Practices 1.3 OPERATION SAFETY Electrical Hazards OA0380 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 OA0350 Be sure that the ground conditions are able to support the vehicle. 1-2 990001-002

Section 1 - General Safety Practices OA0351 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. 990001-002 1-3

Section 1 - General Safety Practices Travel Hazard OA0460 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 OA0390 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. 1-4 990001-002

Riding Personnel Hazard Section 1 - General Safety Practices OA0410 DO NOT drive vehicle when personnel are in platform. No riders permitted in vehicle. Operator only in cab while driving. 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. Driving Hazards on Slopes OA0420 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. 990001-002 1-5

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. OA0401 Keep others away while operating. 1-6 990001-002

Fall Hazard Section 1 - General Safety Practices OA0340 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. OA0320 DO NOT carry riders. Riders could fall off vehicle causing death or serious injury. 990001-002 1-7

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 Custom Chassis 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. 1-8 990001-002

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 OA0150 3. Operation and Safety Manual - Review manual located in operators 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. 990001-002 2-1

Section 2 - Pre-Operation and Inspection 2.2 SAFETY PRECAUTIONS 4 1 3 13 15 16 2 9 7 11 5 10 14 6 12 8 OA0360 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. 2-2 990001-002

Section 2 - Pre-Operation and Inspection WARNING 2. No riders permitted on vehicle. Operator only in cab while driving. Riders could fall off vehicle causing serious injury or death. 3. Stay clear of any pinch point area anytime engine is running. Being in a pinch point area could cause serious injury or death. 4. The protection offered by this cab will be impaired if it has been subjected to any modification, structural damage or has been involved in an accident. 5. Keep away from exhaust system when hot. Hot exhaust components can cause severe burns. 6. Stay clear of moving parts while engine is running. Moving parts can cause serious injury. 7. Diesel fuel is flammable. Extinguish all open flame and smoking material when refueling injury or death could result from fire. 8. Do NOT engage park brake while vehicle is in motion. Abrupt stop could cause serious injury and damage to the vehicle. 9. Always replace guards, covers, secure panels and access doors upon completion of inspection, service or maintenance tasks. Failure to comply could result in death or serious injury. 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. Do NOT drive until air springs are fully inflated to ride height or damage to suspension will occur. 14. Disconnect positive and negative sides of battery before welding on unit. Failure to do so could permanently damage electronic controls on engine. 15. Do NOT push or tow another vehicle or object other than approved trailers. This use could result in damage to the vehicles or persons nearby. 16. Do NOT push or pull vehicle sideways. The vehicle is not designed for side loading or opposing pressures and could result in damage to the vehicle. 990001-002 2-3

Section 2 - Pre-Operation and Inspection 2.3 WALK-AROUND INSPECTION 13 12 14 11 10 15 9 16 8 17 7 18 6 19 20 5 21 4 1 OA0020 3 2 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. 1. Mirrors - Clean and undamaged, adjust for maximum visibility. 2. Wiper blade - Check condition and replace as required. 3. Headlights & Turn Signals - Clean, undamaged and work properly. 4. Air Cleaner - Air cleaner restriction indicator, check for clogged condition. Replace element as required. 2-4 990001-002

5. Coolant System - See inspection note. 6. Engine - Section 2 - Pre-Operation and Inspection Drive belts, check condition and replace as required. Hoses, inspect for leaks and replace as required. See inspection note. 7. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug nuts. Inspect for worn tread, cuts, tears or other discrepancies. 8. Transmission - See inspection note. 9. Steps & Handles - Clean and unobstructed. 10. Fuel Tank - Inspect for leaks, structural damage, excessive corrosion or other damage. Ensure fill cap is secured. 11. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug nuts. Inspect for worn tread, cuts, tears or other discrepancies. 12. Platform - Clean and walkways clear of objects. 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, excessive corrosion or other damage. Ensure fill cap is secured. 16. Steps & Handles - Clean and unobstructed. 17. PTO - See inspection note. 18. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug nuts. Inspect for worn tread, cuts, tears or other discrepancies. 19. Battery - Cables tight, no visible damage or corrosion. Cover properly secured. 20. Power Steering Reservoir - See inspection note. 21. 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. 990001-002 2-5

Section 2 - Pre-Operation and Inspection 2.4 CAB AND PLATFORM ACCESS OA0510 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. WARNING 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. 2-6 990001-002

Section 2 - Pre-Operation and Inspection 2.5 WARM-UP AND OPERATIONAL CHECKS Warm-Up Check During warm-up period, check: 1. Heater, defroster and windshield wiper. 2. Check 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. 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 7. 990001-002 2-7

Section 2 - Pre-Operation and Inspection This Page Intentionally Left Blank 2-8 990001-002

3.1 OPERATORS CAB Section 3 - Operators Cab SECTION 3 - OPERATORS CAB OA0580 The vehicle is equipped with a standard operator cab. 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 damaged, the CAB CANNOT BE REPAIRED. It must be REPLACED. Failure to comply could result in death or serious injury. Note: Each Kimble Chassis is custom made, cab layout may not look exactly like illustrations. 990001-002 3-1

R R Eaton Fuller 18 SPEED RANGE Transmissions SPLITTER SELECTOR SELECTOR MAY BE SHIFTED HI IN ALL GEAR SHIFT HI H R 5 H H LEVER POSITIONS L 7 L L LO LO 1 H H L 3 L Neutral LO H 6 H H L 8 L L 2 H H L 4 L PUT TRANSMISSION IN NEUTRAL BEFORE STARTING ENGINE EATON WARNING O N L O H I O N L O H I 21628 Section 3 - Operators Cab 3.2 CAB LAYOUT 7 8 9 10 6 11 12 5 4 3 PRE-SELECT ALL RANGE AND SPLITTER SHIFTS (MOVE RANGE AND SPLITTER SELECTOR BEFORE MOVING SHIFT LEVER) UPSHIFTING START WITH RANGE SELECTOR DOWN SHIFT LO-1-2-3-4 RAISE RANGE SELECTOR SHIFT 5-6-7-8 DOWNSHIFTING SHIFT 8-7-6-5 MOVE RANGE SELECTOR DOWN SHIFT 4-3-2-1-LO DO NOT CHANGE WHILE MOVING IN REVERSE 13 14 15 16 2 COLD HOT HEATER DEFROST TEMPERATURE 17 FRESH AIR RECIRC. AIR 18 1 OA0030 1. Fire Extinguisher: Portable container used for extinguishing minor fires. 2. Grab Handle: Handle to assist in entry/exit of operators cab. 3. Clutch Pedal: Depress pedal to allow shifter to move easily from gear to gear. 4. Steering Wheel: Turning the steering wheel to the left or right steers the vehicle in the corresponding direction. 5. Cab Door: See page 3-6 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. Press switch left to illuminate both, right to illuminate map light. 3-2 990001-002

10. Air Horn Lanyard: Pull lanyard to sound air horn. 11. Instrument Panel: See page 4-2 for details. 12. Horn Button: Depress button to sound horn. 13. Front Panel: See page 4-6 for details. Section 3 - Operators Cab 14. Brake Pedal: Operates the service brakes. The further the pedal is depressed, the greater the braking. 15. Accelerator Pedal: Pressing down on the pedal increases engine speed. 16. Right Slider Window: See page 3-6 for details. 17. Right Console: See page 4-6 for details. 18. Operator Seat: See page 3-4 for details. 990001-002 3-3

Section 3 - Operators Cab 3.3 OPERATOR SEAT Adjustments 4 3 5 2 1 Prior to starting engine adjust seat for position and comfort as follows: 6 Press the switch (1) on the side of seat to adjust the air suspension height. Slide handle (2) to move seat fore and aft. Press lever (3) to adjust backrest angle. Pull handle (4) to adjust height of shoulder strap. A two inch seat belt (5) is standard equipment. See page 3-5 for details. Tether belts (6) are installed on suspension seat. The belts secure the seat to 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 OA0081 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. 3-4 990001-002

Section 3 - Operators Cab Seat Belt Shoulder Belt 9 Lap Belt (if equipped) 7 10 8 11 7 8 11 9 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) WARNING 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. 990001-002 3-5

Section 3 - Operators Cab 3.4 CAB DOOR & WINDOWS Note: Keep all windows and mirrors clean and unobstructed. Cab Door 1 3 2 OA0470 Pull handle (1) to close door after entry. Pull door lever (2) to open door for exit. Turn window crank handle (3) clockwise to raise, counterclockwise to lower. Right Slider Window 4 5 OA0270 To open front window press handle (4) then slide window. To open rear window press handle (5) then slide window. WARNING Keep limbs in vehicle at all times. Failure to comply could result in death or serious injury. 3-6 990001-002

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. See supplemental 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 continued use. 990001-002 4-1

H T 3 2 1 ENGINE BRAKE SELECT ENGINE BRAKE O O W PULL TO APPLY PUSH TO RELEASE BENDIX Section 4 - Controls & Indicators 4.2 INSTRUMENT PANEL Note: Each Kimble Chassis is custom made. Instrument panel may not look exactly like the one illustrated. 1 2 3 4 5 6 7 8 20 40 60 80 150 200 PTO ATC ABS 50 100 9 21 20 0 100 PSI 1 2 E F 100 250 12 15 9 18 15 10 20 RPM x 100 5 25 0 30 30 40 50 60 20 60 80 40 100 10 70 20 120 0 0 80 MPH km/h 0 150 FRONT PSI 50 100 0 150 REAR PSI PARKING BRAKE O F F B R I G F F F F I P 19 P A R K O N D I M O N L O H I E R O F F W A S H 18 14 13 12 11 10 17 16 PUSH FOR TELE PULL FOR TILT 15 HAZARD OA0010 1. Oil Pressure Gauge: Indicates engine oil pressure. See specific manufacturer s manual for normal operating range. 2. Engine Temperature Gauge: Indicates the engine coolant temperature. See specific manufacturer s manual for normal operating ranges. 3. Driver Information Center: See page 4-4 for details. 4. Tachometer: Indicates the engine speed in revolutions per minute (rpm). 5. Speedometer: Indicates vehicle speed in miles per hour (mph) and kilometers per hour (kph). 6. Front Brake Air Pressure Gauge: Indicates air pressure in the front brake system. Normal operating pressure is 120 psi. 7. Rear Brake Air Pressure Gauge: Indicates air pressure in the rear brake system. Normal operating pressure is 120 psi. 8. Power Outlet: See page 4-13 for details. 9. Parking Brake Switch: See page 4-12 for details. 10. Air Vent: Adjustable air vent. 11. Intermittent Windshield Wiper/Washer Fluid Switch: Press slider upward to activate 3 stage intermittent wipers. Press slider further to activate windshield wash function. 4-2 990001-002

Section 4 - Controls & Indicators 12. Windshield Wiper Switch: Press switch to second position to activate low speed wipers. Press switch to third position to activate high speed wipers. Return switch to first position to turn off wipers. 13. Engine Brake Switch: On/Off switch. See Engine Exhaust Brake on page 8-4 for additional infromation. 14. Engine Brake Select Switch: Press switch to third position to activate 1st stage engine brake. Press switch to second position to activate 2nd engine brake. Press switch to first position to activate 3rd stage. 15. Hazard Warning Switch: On/Off switch for hazard flashers. 16. Steering Column Tilt/Tele Lever: See page 4-8 for details. 17. Turn Signal/High Beam lever: Press lever downward to activate left turn signal. Press lever upward to activate right turn signal. Pull lever to activate/deactivate high beam lights. 18. Instrument Panel Dimmer Switch: Slide switch to adjust instrument panel brightness. 19. Headlight Switch: Press switch to second position to activate parking lights. Press switch to third position to activate headlights. Return switch to first position to turn off lights. 20. Fuel Level Gauge: Level gauge for diesel fuel tank. 21. Voltmeter Gauge: Displays the battery voltage. The proper operating range should show 12 to 14V (volts). 990001-002 4-3

Section 4 - Controls & Indicators Driver Information Center 1 2 3 4 5 19 6 7 8 9 PTO ATC ABS 10 11 12 13 14 21 20 15 16 17 18 OA0220 The Driver Information Center displays messages and notifies driver of vehicle status. The center also uses notifying telltales that illuminate when a fault message has been received. See specific manufacturer s manual for additional information. 1. Left Turn Signal: Illuminates and flashes when left hand turn signal is activated. 2. Stop Engine: Illuminates when there is a fault in the engine system. Audible alarm will sound. Determine cause and correct before continued use. 3. Check Engine: Illuminates when there is a fault in the engine system. Audible alarm will sound. Determine cause and correct before continued use. 4. Park Brake: Illuminates when park brake is activated. Park brake must be applied to start engine. 5. High Beams: Illuminates when high beam headlights are activated. 6. Low Oil Pressure: Illuminates when oil pressure is below safe operating level. Audible alarm will sound. Determine cause and correct before continued use. 7. Coolant Temperature: Illuminates when coolant temperature exceeds manufacturer s recommendations. Determine cause and correct before continued use. 8. Transmission Temperature: Illuminates when transmission temperature exceeds manufacturer s recommendations. Determine cause and correct before continued use. 9. Right Turn Signal: Illuminates and flashes when right hand turn signal is activated. 10. Front Axle Lock (if equipped): Illuminates when Front Axle Lock is activated. 11. Differential Lock: Illuminates when Inter Axle or Main Differential Lock is activated. 12. Low Coolant: Illuminates when coolant level is below safe operating level. Determine cause and correct before continued use. 4-4 990001-002

Section 4 - Controls & Indicators 13. Power Take-Off: Illuminates when Power Take-Off is activated. 14. Neutral: Illuminates when park brake is set and transmission is in neutral. 15. Automatic Traction Control (if equipped): Illuminates when Automatic Traction Control is activated. 16. Anti Lock Brakes: Illuminates when there is a fault in the ABS system. Determine cause and correct before continued use. See Anti-lock Braking System on page 8-3 for additional infromation. 17. Check Transmission: Illuminates when there is a fault in the transmission system. Determine cause and correct before continued use. 18. Exhaust Regeneration (if equipped): Illuminates when diesel particulate filter regeneration is in process. 19. Scroll Right: Scroll right through menu on the information screen. 20. Scroll Down: Scroll down through menu on the information screen. 21. Information Screen: Review and receive messages regarding vehicle status. WARNING Do NOT scroll Information Screen while driving vehicle. Removing concentration and vision from road could cause an accident. Failure to comply could result in death or serious injury. 990001-002 4-5

50 30 AIR 130 150 10 0 PSI VDO HI LO H L H 7 L H 3 L HI H 8 L H 4 L 21628 O N L O H I O N L O H I Section 4 - Controls & Indicators Front Panel REMOTE THROTTLE REMOTE POWER TRANSFER CASE ROAD OFF IGN START DRILL IGNITION 1 2 3 4 OA0120 1. Remote Throttle Switch: On/Off switch. 2. Remote Power Switch: On/Off switch. 3. Transfer Case Control: Move control upward to activate ROAD operation, move control downward to activate DRILL operation. 4. Ignition Switch: See page 4-9 for details. Right Console INTER AXLE DISENGAGE ENGAGE AXLE PRESSURE 70 90 110 18 SPEED RANGE SPLITTER SELECTOR SELECTOR MAY BE SHIFTED IN ALL GEAR SHIFT LEVER POSITIONS PRE-SELECT ALL RANGE AND SPLITTER SHIFTS (MOVE RANGE AND SPLITTER SELECTOR BEFORE MOVING SHIFT LEVER) UPSHIFTING START WITH RANGE SELECTOR DOWN SHIFT LO-1-2-3-4 RAISE RANGE SELECTOR SHIFT 5-6-7-8 DOWNSHIFTING SHIFT 8-7-6-5 MOVE RANGE SELECTOR DOWN SHIFT 4-3-2-1-LO DO NOT CHANGE WHILE MOVING IN REVERSE PUT TRANSMISSION IN NEUTRAL BEFORE STARTING ENGINE WARNING Eaton Fuller Transmissions HEATER DEFROST TEMPERATURE COLD HOT FRESH AIR RECIRC. AIR 5 6 7 R R Eaton Fuller Transmissions R 5 H L LO 1 H L Neutral LO H 6 H L L 2 H L EATON 8 9 5. Inter Axle Lock: Move control right to engage inter axle operation, move control left to disengage inter axle operation. See Inter-Axle Lock on page 8-6 for additional infromation. 6. Pusher Axle Pressure Regulator (if equipped): (if equipped) Adjustment to increase and decrease axle pressure. Increase pressure to increase load on pusher axle. See Pusher Axle on page 8-7 for additional infromation. 7. Pusher Axle Pressure Gauge (if equipped): Indicates air pressure for the axle. 8. Transmission Decal: See page 4-10 for details. 9. Transmission Shifter: See page 4-10 for details. 10. Heating/Cooling: See page 4-7 for details. 10 OA0500 4-6 990001-002

Heating/Cooling Panel Section 4 - Controls & Indicators HEATER DEFROST TEMPERATURE FRESH AIR O F F O F F L O L O H I H I COLD HOT RECIRC. AIR 11 12 13 14 OA0520 11. Heater Switch: Press switch to second position to activate low speed fan. Press switch to third position to activate high speed fan. Return switch to first position to turn off heater. 12. Defrost Switch: Press switch to second position to activate low speed defrost. Press switch to third position to activate high speed defrost. Return switch to first position to turn off defrost. 13. Temperature Control: Turn the adjustable rotary control to the desired temperature. 14. Air Selection Control: Rotary control for selecting fresh air or recirculated air. Heating/Cooling Turn the temperature control to the desired temperature and set the fan speed. Adjust the air flow through the air louvers. Defrosting Once engine reaches operating temperature turn the control to HOT and select the defrost switch to HIGH. 990001-002 4-7

Section 4 - Controls & Indicators 4.3 STEERING COLUMN ADJUSTER 3 2 1 OA0140 Before adjusting steering column follow Shut-Down Procedure on page 5-4. Push adjuster lever (1) to telescope (2) the column. Place the steering column in the desired position. Pull adjuster lever to tilt (3) the column. Place the steering column in the desired position. WARNING Do NOT adjust steering column while driving vehicle. A sudden change in direction of travel could cause an accident. Failure to comply could result in death or serious injury. 4-8 990001-002

Section 4 - Controls & Indicators 4.4 IGNITION SWITCH 4 OFF IGN START 5 IGNITION OA0590 In the OFF position (4) the key can be inserted and removed, only in this position. Some electrical functions can be operated in the OFF position. Full clockwise rotation to START (5) engages starter motor. Counter-Clockwise rotation to OFF stops engine and removes voltage from certain electrical functions. See Starting the Engine on page 5-1 for details. Note: In IGN or START position, the vehicle power is available for all electrical functions. 990001-002 4-9

Section 4 - Controls & Indicators 4.5 TRANSMISSION SHIFTER Travel Direction The 18-speed transmission has eighteen speeds for forward travel and four speeds for reverse travel. Gear Selection HI R LO LO H L 5 H L 1 H L Neutral 6 H L 2 H L 7 3 8 H L H L H L H L H L 1 4 OA0490 2 HI LO Note: Pre-select all range and splitter shifts (move range and splitter selector BEFORE moving shift lever). 1. Range Selector (1) shifts between HIGH and LOW. 2. Splitter selector (2) may be shifted in ALL gear shift lever positions. UPSHIFTING Start with range selector down Shift LO-1-2-3-4, raise range selector Shift 5-6-7-8 DOWNSHIFTING Shift 8-7-6-5, press range selector down Shift 4-3-2-1-LO Do NOT change while moving in reverse 4-10 990001-002

Shifting Suggestions Under Normal Operation Section 4 - Controls & Indicators Always select an initial starting gear that provides sufficient reduction for the load and terrain. Always use normal double-clutching procedures when making transmission shifts. Never slam or jerk the transmission shifter to complete gear engagements. Never coast with the transmission shifter in the neutral position. Never move the transmission shifter to the LO speed gear position while operating in HI range. Never move the range lever or the splitter button with the transmission shifter in neutral while the vehicle is moving. Never make a range shift while traveling in REVERSE. Never downshift at too high of a road speed. Do NOT skip shift across the range, up or down. See Operating the Transmission on page 8-5 for additional infromation. CAUTION EQUIPMENT DAMAGE. Never move the splitter button or the range lever with the shift lever in neutral while the vehicle is moving. Failure to comply could result in equipment damage. 990001-002 4-11

Section 4 - Controls & Indicators 4.6 PARK BRAKE 1 PULL TO APPLY PARKING BRAKE PUSH TO RELEASE BENDIX OA0620 The parking brake valve (1) controls the activation and deactivation of the parking brake. Pull the valve out to apply the parking brake and press the valve to release the parking brake. This applies and releases air pressure in brake chambers which engages and disengages rear axle spring brake mechanism. WARNING Do NOT leave the cab without applying the parking brake. Failure to comply could cause the 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 guage and a audible alarm will sound. Safely bring vehicle to a stop and perform shut down procedure. If pressure continues to drop, at 40 psi parking brake will set and stop the vehicle abruptly, which could cause an accident resulting in death or serious injury. 4-12 990001-002

Section 4 - Controls & Indicators 4.7 POWER OUTLET 3 2 OA0480 Note: The power outlet will operate with the ignition switch in either the OFF, IGN (ignition) or START position. To operate, push in the knob end of the lighter (2). 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. The outlet (3) may be used to operate 12 volt, 15 ampere devices, such as a spotlight or mobile phone charger. 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 instructions in the operator s manual of the device being used. 990001-002 4-13

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SECTION 5 - OPERATION Section 5 - Operation 5.1 ENGINE Starting the Engine This vehicle can be operated under normal conditions in temperatures of 0 F to 120 F (-17 C to 48 C). Consult Kimble Custom Chassis for operation outside this range or under abnormal conditions. 1. Make sure shifter is in Neutral and all electrical components (lights, heater, defroster, etc.) are turned off. Ensure parking brake is set. 2. Disengage (depress) clutch, manual transmission only. 3. Turn ignition switch to START to engage starting motor. Release key immediately when engine starts. If engine fails to start within 15 seconds, release key and allow starting motor to cool for a few minutes before trying again. 4. After engine starts, observe engine oil pressure gauge. If gauge remains on zero for more than ten seconds, stop engine and determine cause before restarting engine. Reference engine manual for minimum pressure at operating temperature. 5. Allow engine to idle, increasing air pressure within the air brake system reservoir. Note: Engine will not start unless transmission shifter is in Neutral, clutch pedal depressed and park brake applied. CAUTION EQUIPMENT DAMAGE Failure to allow starter to cool could result in serious damage or premature failure of the starter motor. Do NOT engage the starting motor when flywheel is turning. WARNING UNEXPECTED MOVEMENT HAZARD. Always ensure that transmission shifter is in neutral and the service brake is applied before releasing park brake. Releasing park brake in either forward or reverse could cause the vehicle to move abruptly, causing an accident resulting in death or serious injury. 990001-002 5-1

Section 5 - Operation Cold Weather Operation Use these cold weather starting guidelines when the air temperature falls. Check Engine Operation manual for further details on when cold weather starting aids are needed. Engine manufacturer and Kimble Custom 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 Engine Operation manual) Use the recommended engine lubricating oil 5-2 990001-002

Battery Boosted Starting Section 5 - Operation OA0370 If battery-boost starting (jump-start) is necessary, proceed as follows: Never allow vehicles to touch. Connect the positive (+) jumper cable to positive (+) post of discharged battery. Connect the opposite end of positive (+) jumper cable to positive (+) post of booster battery. Connect the negative (-) jumper 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 battery. Lead acid batteries generate explosive gases when charging. Wear safety glasses. Failure to comply could result in death or serious injury. 990001-002 5-3

Section 5 - Operation Normal Engine Operation Observe gauges frequently to be sure all engine systems are functioning properly. Be alert for unusual noises or vibration. When an unusual condition is noticed, park vehicle in a safe position and perform shut-down procedure. Report condition to your supervisor or maintenance personnel. Avoid prolonged idling. If the engine is not being used, turn it off. Shut-Down Procedure Individual applications may have different shutoff procedures. Ensure the shutoff procedures 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 heat. DO NOT over rev engine. Refer to Engine Manufacturers Operation Manual for additional information. 5. Shut off engine and remove ignition key. 6. Exit vehicle properly. Refer to page 2-6 for details. 7. Block wheels (if necessary). Note: If vehicle will be shut down for extended period, disconnect battery. See page 5-5 for details. 5-4 990001-002

Section 5 - Operation 5.2 BATTERY DISCONNECT 2 3 OFF MASTER DISCONNECT ON 1 OA0130 The battery disconnect switch (1) is located on the side of the battery box. The disconnect switch removes all battery power to the vehicle when turned to the OFF position (2). The disconnect should also be used whenever 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 two weeks, or the vehicle may not start and permanent battery damage could occur. 990001-002 5-5

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Section 6 - Vehicle Recovery SECTION 6 - VEHICLE RECOVERY 6.1 FREEING THE VEHICLE Always look ahead for wet, muddy or icy patches in path, stop vehicle and engage Inter-Axle Lock ahead of time. If the vehicle gets stuck in sand, mud, snow or ice: Engage Inter-Axle Lock, see page 4-6 for details Move the shift lever to First or Reverse Apply light pressure on the accelerator pedal while the transmission is in gear Remove foot from the accelerator while shifting Do NOT race the engine For best traction and safety, avoid spinning the wheels WARNING Do NOT spin wheels, spinning wheels can be dangerous - tires can explode from spinning too fast. Under some conditions, a tire may be spinning at a speed twice that shown on the speedometer. Any resulting tire explosion could cause severe injury or death to a bystander or passenger, as well as extensive vehicle damage including: tire, transmission and/or rear axle malfunction. WARNING Do NOT engage the Inter-Axle Lock while the wheels are spinning freely (slipping), failure to comply could cause loss of vehicle control or axle damage. 990001-002 6-1