Ransomes diabline Operation & Service Manual
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Ransomes diabline Operation & Service Manual

Ransomes diabline Operation & Service Manual

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24882G-GB (rev.0)
Safety, Operation & Service Manual
DIABLINE
WARNING: If incorrectly used this machine can
cause severe injury. Those who use and maintain
this machine should be trained in its proper use,
warned of its dangers and should read the entire
manual before attempting to set up, operate, adjust
or service the machine.
RJL 100 June 2009

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Summary of Contents for Ransomes diabline

  • Page 1 24882G-GB (rev.0) Safety, Operation & Service Manual DIABLINE WARNING: If incorrectly used this machine can cause severe injury. Those who use and maintain this machine should be trained in its proper use, warned of its dangers and should read the entire manual before attempting to set up, operate, adjust or service the machine.
  • Page 2 REGULATIONS OF YOUR EMPLOYER, INSTRUCTIONS IN THIS MANUAL AND THE CURRENT REGULATIONS FOR THIS TYPE OF MACHINE. A NON-QUALIFIED OPERATOR IS EXPOSED TO AND EXPOSES OTHERS TO THE RISK OF SERIOUS INJURY. © 2009, Ransomes Jacobsen Limited. All Rights Reserved...

  • Page 3: Table Of Contents

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL TABLE OF CONTENTS INTRODUCTION ................9 GENERAL DESCRIPTION A.2.1 DESCRIPTION OF THE VEHICLE ..........11 A.2.2 DIMENSIONS AND TECHNICAL CHARACTERISTICS ....12 SAFETY ADVICE A.3.1 GENERAL ..................14 A.3.1.1 INFORMATION FOR THE DRIVER ..........14 A.3.1.2...
  • Page 4 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL TYRES .................... 32 GENERAL MAINTENANCE B.1.1 GENERAL ..................34 B.1.2 CLEANLINESS ................34 B.1.3 REMOVAL AND REFITTING ............35 B.1.4 PROCEDURE ................. 35 B.1.5 BATTERIES..................35 B.1.6 BATTERIES CENTRAL FILLING ............ 36 B.1.7 SIMPLE STEPS FOR LONGER BATTERY LIFE ......37 B.1.8...
  • Page 5 NOTES To obtain a copy of the terms and conditions of the application of the warranty, call or write to Ransomes Jacobsen Limited. The use of parts not originating from Ransomes Jacobsen Limited can result in the cancellation of this warranty.
  • Page 6 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL FOREWORD This manual has been prepared in order to allow you to correctly use and service your electric vehicle. Before putting the vehicle into service, take the time to carefully read and familiarise yourself with the contents of this manual.
  • Page 7 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL The defi nitions DANGER, ATTENTION, and NOTE in this manual are the following: DANGER - Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury. WARNING - Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.
  • Page 8 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL Section A SAFETY AND USE GB-8...

  • Page 9: Introduction

    SAFETY AND OPERATORS MANUAL A.1 INTRODUCTION This manual contains all-important information relative to the functions and maintenance of the Ransomes Diabline model electric vehicles. This vehicle is an automotive type with a chassis in steel and aluminium. Power is by electric motor situated on the rear axle.
  • Page 10 Lighting and indicators If you fi nd a problem… Immediately draw up a list and send it to: Ransomes Jacobsen Limited West Road, Ransomes Europark, Ipswich IP3 9TT, England WARNING DO NOT REPAIR, MODIFY OR ADJUST A PART OF THE...

  • Page 11: General Description

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A.2 GENERAL DESCRIPTION A.2.1 Description of the vehicle Driving Position Passanger Cabin Motor / Reducer Drive Wheels Steering Wheels Batteries GB-11...

  • Page 12: Dimensions And Technical Characteristics

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A.2.2 Dimensions and technical characteristics Diabline side (mm) Wheelbase 2345 Length 3790 Front overhang Rear overhang Front track 1270 Front width 1440 Rear track 1310 Rear width 1520 Drivers Cabin height 1800 Passenger Cabin Height...
  • Page 13 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL Motor Electric Volt Wheels Number of driving wheels 2 AR Rear deck length x width 2320 x 1450 Deck height height empty Dimensions length 3790 width 1520 seat height height with cabin 1800 Turning circle...

  • Page 14: Safety Advice

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A.3 SAFETY ADVICE A.3.1 General It is impossible to establish a complete list of safety advice covering all situations. In the meantime, a certain number of basic rules MUST be followed in the course of the daily use of the vehicle. Safety is your FIRST RESPONSIBILITY, because the vehicle can only be PERFECTLY MASTERED by the user.

  • Page 15: Qualifications Of The Driver

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A.3.1.2 Qualifi cations OF THE DRIVER WARNING DO NOT USE THIS VEHICLE UNLESS YOU HAVE BEEN TRAINED IN ITS USE AND SAFETY. TRAINING CONSISTS OF KNOWLEDGE OF THE WORK REGULATIONS OF YOUR EMPLOYER, INSTRUCTIONS IN...

  • Page 16: Basic Rules

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A.3.2 Basic rules Never put your safety at risk and that of others in trying to use a machine for something for which you have not been trained. It is VITAL that the operator has received adequate training and knows perfectly the regulations for the use of the vehicle: •...

  • Page 17: Servicing

    «General maintenance and servicing». For all questions concerning procedures and specifi cations, speak to your Ransomes distributor. Except with the written authorisation and agreement of Ransomes Jacobsen Limited, no modifi cation affecting the original design may be made to the vehicle.

  • Page 18: Lubrication

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A.3.3.1 Lubrication The vehicle must be lubricated and greased according to the constructor’s recommendation concerning the lubrication points, periods and types of products to be used. If your vehicle is not correctly greased, there is a risk of overheating of the mechanical parts, which can result in their deterioration.

  • Page 19: Vehicle Controls Driving Position

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A.4 VEHICLE CONTROLS A.4.1 Driving position This section describes the function and position of each control. It is vital that the driver familiarises himself with the use of the controls before using the vehicle (details follow):...

  • Page 20: Starter Key

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL Handbrake Emergency stop Forward/ back control for seat A.4.2 Starter key The Neiman anti theft/starter key is situated on the right hand side of the dashboard and activates the electrical functions of the vehicle.

  • Page 21: Accelerator Pedal

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A.4.6 Accelerator pedal The accelerator pedal is situated to the right of the brake pedal. It must be operated only with the right foot. This pedal controls the speed of the vehicle using a potentiometer. The more you push on the pedal, the more you accelerate the vehicle.

  • Page 22: Audible Alarm (Horn)

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A.4.9 Audible alarm (Horn) It is situated at the end of the left control lever, on the left side of the steering column. Push on the button to warn then release. An audible safety-warning signal sounds when the vehicle moves in reverse. When reverse is engaged, the buzzer sounds to warn personnel that the vehicle is reversing.

  • Page 23: A.4.15 M.d.i. Indicator

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A.4.15 M.D.I. indicator This is an indicator, in the form of luminous warning lights and a liquid crystal display, situated on the dashboard. The MDI indicator provides information on: CODES DESIGNATION SIGNIFICANCE AL02 Problem with the dialogue between the speed control and the MDI...
  • Page 24 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL NOTE T IS POSSIBLE THAT AN UNKNOWN CODE IS DISPLAYED. IN THIS CASE, NOTE THE CODE BEFORE CALLING AFTER SALES SERVICE THAT WILL BE ABLE TO DIAGNOSE THE PROBLEM. • Battery charging The warning lights indicate the state of battery charge...

  • Page 25: Indicator

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A.4.16 Fuses To check and/or change one or more fuses, open the lid situated under the passenger/driver seats: Indicators/ Hazard/ Head lights main Horn/ Convertor Dipped lights/ Trailer connection Emergency stop Side/Main lights Heater...

  • Page 26: Hydraulic Dump Truck Control (D24)

    OF THE HYDRAULIC SYSTEM, ENSURE THAT THE SYSTEM IS SECURED AND THAT NO ONE RISKS BEING INJURED. A.4.18 Special operations For all questions relating to vehicles fi tted with special equipment , please consult the technical service department of Ransomes Jacobsen Limited. GB-26...

  • Page 27: Procedures For Use

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A.5 PROCEDURES FOR USE A.5.1 Checks before use Carry out a complete systematic inspection of the vehicle before use: Look for possible non-operational equipment, leaks or other defects, which necessitate immediate action to make the vehicle safe to use. The non-exhaustive list of checks that follows has been provided in order that the user can carry out all the checks before taking the vehicle into use.

  • Page 28: Emergency Stop

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A.5.2.5 EMERGENCY STOP Pull the emergency stop switch to establish electrical supply to the vehicle WARNING BEFORE RESTARTING IT IS NECESSARY TO ELIMINATE THE PROBLEM THAT CAUSED THE EMERGENCY STOP. GB-28...
  • Page 29 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A.5.2.6 TOWING WARNING WARNING IF THE VEHICLE BECOMES COMPLETELY UNLOAD THE STUCK, USE AN APPROPRIATE VEHICLE BEFORE BEING TOWED. TRACTOR TO RETRIEVE IT. DO NOT TRY TO MOVE IT UNDER IT'S OWN POWER AS THIS WILL WARNING DAMAGE THE DRIVE SHAFT.

  • Page 30: Charge Of Batteries

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A.5.2.7 CHARGE OF BATTERIES During the charge: • Open the cover of the electronic box (under the front seats) during the charge for ventilation to gives the charger optimal performance. • Let open the panel above the batteries to avoid risks of explosion.

  • Page 31: Instructions For Transporting

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A.6 INSTRUCTIONS FOR TRANSPORTING To tie down the vehicle: • Pull on the hand brake • It is essential to block the vehicle wheels ensuring that the chocks are correctly fi xed to the bed of the transport vehicle •...

  • Page 32: Tyres

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A.7 TYRES • Check that the tyres are correctly infl ated (sticker on the left of the driver). • Check for cuts or embedded foreign bodies in the treads. • Ensure that the wheel nuts are properly tightened IN CASE OF A FLAT TYRE: Use the aerosol provided for this eventuality.
  • Page 33 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL Section B GENERAL MAINTENANCE AND SERVICING GB-33...

  • Page 34: General Maintenance General

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B.1 GENERAL MAINTENANCE B.1.1 General This section comprises information relative to the maintenance and general procedures. Qualifi ed personnel must carry out maintenance operations and/or repairs carried out on your vehicle. To fi nd the frequency of maintenance, study the table of scheduled maintenance.

  • Page 35: Removal And Refitting

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B.1.3 Removal and refi tting While servicing your vehicle, do not try to manually lever heavy parts when a method of mechanical leverage can be used. Do not place and never leave heavy parts in an unstable position. When lifting a part of the vehicle or the whole vehicle, ensure that it is well wedged and that it’s weight is supported by wedges rather...

  • Page 36: Batteries Central Filling

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B.1.6 Batteries central fi lling Thanks to this system, you can easily make the batteries water level : • Connect the removable tank to the mouth located on the right of the batteries compartment and keep it higher than it.

  • Page 37: Simple Steps For Longer Battery Life

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B.1.7 Simple Steps For Longer Battery Life Proper Torque Values for Connection Hardware Copyright Trojan Inc. used with permission Flooded Equipment: Automotive: 50-70 in-lbs Trojan recommends the following equipment for Side: 70-90 in-lbs Wingnut: 95-105 in-lbs...
  • Page 38 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL If any specifi c gravity reading still registers lower Watering than the factory specifi cation, one or more of these (Flooded batteries only) conditions may exist: Water should only be added after fully charging the The battery is old and nearing end of life.
  • Page 39 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL section.) Add water until the electrolyte level is 1/8" Electrolyte Freezing Point at Various below the bottom of the fi ll well. Clean, replace and tighten all vent caps SPECIFIC %STATE OF FREEZING WARNING: Never add acid to a battery.
  • Page 40 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL Equalizing (Flooded batteries only) WARNING: Do not equalize Gel or AGM batteries. Equalizing is an overcharge performed on fl ooded lead-acid batteries after they have been fully charged. It helps eliminate stratifi cation and sulfation, two conditions that can reduce the overall performance of a battery.

  • Page 41: Electric Wires And Cables

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B.1.8 Electric wires and cables The batteries must always be disconnected before working on the electrical system. Before removing or disconnecting a bundle of wires or cables, mark each one of them to ensure that you can correctly reconnect them.

  • Page 42: Bearings

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B.1.10 Bearings Once a bearing is removed, cover it to keep out dirt and abrasive matter. Clean the bearings in a solvent and leave them to dry. The bearings can be dried with compressed air but avoid turning them too fast.

  • Page 43: Servicing

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL SERVICING B.2.1 Washing the vehicle Whatever is the version of the vehicle, if you wash it by water jet don’t aim at the batteries area (see below) because there is risk of acid splashes.

  • Page 44: Lubrication Points

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B.2.2 Lubrication points REP. DESCRIPTION TYPE OF LUBRICANT Filling of axle/reduction gear SAE 90 Axle/reduction Oil level SAE 90 Oil change axle/reduction Level Plug Filler Plug Drain Plug Breather The axle oil be checked ever 6 months and replaced annually using SAE90 gear oil.
  • Page 45 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL Lubricate the PTO U joint, using the 30 degree. grease nipple. GB-45...

  • Page 46: Suspension Pressure

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B.2.3 Suspension pressure The standard pressures are: • Front: 13 bars • Rear: 12 bars To service suspension system use the following process: Remove the suspension arm from the vehicle Release compressed air from the ram...

  • Page 47: Steering

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B.2.4 Steering If any play is felt in the steering wheel, contact your dealer. B.2.5 Brake fl uid Max. The brake fl uid level must be checked every two weeks. To do this open the lid situated under the passenger and driver seats.

  • Page 48: Charger

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B.2.6 Charger Note: If the battery pack goes below 20% charge B.2.6.1 Charger - NG1 then the charger fi tted to the machine cannot detect the pack and will not switch on. If this occurs a...

  • Page 49: Maintenance Schedule

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B.2.7 Maintenance schedule The following table gives a resume of the maintenance periods in normal conditions of use. HALF 4 MONTH 6 MONTHS DAIL Y . MONTHL Y MONTHL Y ANNUALL Y TASKS TO BE CARRIED OUT...

  • Page 50: Breakdown Guide

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B.3 CIRCUIT ELECTRIQUE B.2.8 Breakdown guide B.3.1 Circuit standard SYMPTOM PROBABLE CAUSE Steering « pulls » to right or left Unequal tyre pressure Misalignment of front axle in relation to rear Problem with stub axle (shock or bar badly refi tted) Diffi...

  • Page 51: Electrical Diagram

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL ELECTRICAL DIAGRAM B.3.1 Electrical diagram standard GB-51...

  • Page 52: Electrical Diagram With Gas Generator

    RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B.3.2 Electrical diagram with gas generator GB-52...
  • Page 54 Ransomes Jacobsen Limited Jacobsen, A Textron Company West Road, Ransomes Europark, Ipswich, IP3 9TT 11108 Quality Drive, Charlotte, English Company Registration No. 1070731 NC 28273, USA www.ransomesjacobsen.com www.Jacobsen.com...

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