KABI TruckTank TT250 User manual

KABI A/S
Kokkedalsvej 29
DK-2970 Hørsholm
Denmark
Phone: [phone]
Fax: [phone]
Mail: [e-mail]
Web: www.kabi.dk
Mobile Diesel Oil Tanks
TT250 / TT425 / TT600
Diesel Transporanke Mobila tankar för dieselolja Mobile dieseloljetanker Siirreävät dieselöljysäiliöt
Operang Manual
Brugsvejledning
Bruksanvisning
Bruksanvisning
Käyöohje

2.
TruckTank 425 L
TruckTank 250 L

3.
TruckTank 600 L
Operang Manual ................. 4
Brugsvejledning .................... 16
Bruksanvisning  28
Bruksanvisning  40
Käyöohje  52

4
KABI Mobile Diesel Oil Tanks
TABLE OF CONTENTS
I Applicaon  5
II Technical data and equipment  5
1 Technical specicaons .................................................................................... 5
2 Equipment  5
3 Oponal equipment  5
4 Marking consistent with ADR requirements  6
III Operaon  7
1 Transport – guidelines  7
2 Transport vehicle equipment  8
3 Required transport documents  8
IV Safety rules during operaon of TT250/425/600 tank  8
1 Informaon about dangerous substance  8
2 Hazards that may be posed by stored material (diesel) and ways of
minimizing them  8
3 Guidelines for persons authorized to operate the tank TT250/425/600  9
4 Operaons during refuelling  9
5 Emergencies  9
V TT250/425/600 tank maintenance  10
Table 1 List of standard maintenance acvies for TT250/425/600  10
VI Tests of ADR cered tanks  11
Table 2 Schedule of required tests and inspecons in accordance with
the guidelines of the ADR Agreement  11
VII Disposal  11
VIII Warranty  12
IX Reports of inspecon and audits performed by the owner/user  13
Audit report  13
Table 3 Approval test and periodic inspecons  13
Table 4 Report of damage and repairs of TT250/425/600  14
Table 5 Failure Nocaon Form  15
Service Manual is of auxiliary nature and does not constute a source of law.
Compliance with the Manual does not exempt from the obligaon to comply with local laws.

5
KABI Mobile Diesel Oil Tanks
I. APPLICATION
TT250/425/600 tank is designed to transport and distribute diesel oil (UN1202) for their own The tank is designed
as a self-supporng, single-shell structure made of UV-stabilized MDPE polyethylene The device can be used to
transport and refuelling the construcon equipment, farm-type tractors, combine harvesters, loaders, excavators,
etc, in place of their use
TruckTank’s have innovave body structure and special ns, which protect the fuel from excessive movement during
transport and protects against the pping of the tank while in transit KABI mobile fuel tanks meet the require-
ments of the European Union concerning the carriage of dangerous goods contained in the Internaonal ADR
Agreement
NOTE: On the basis of the exclusion under clause 113 of the ADR agreement, if once transported quanes are
not greater than 1,000 litres of diesel in TruckTank, it is not necessary to meet other requirements of ADR With
each fuel transport in the TruckTank device the measures must be taken to prevent any leakage of contents in
normal condions of carriage
II. TECHNICAL DATA AND EQUIPMENT
1. Technical specicaons
Tank Type Capacity (L) Dimensions
L (m) W (m) H (m)
TT250 250 1,20 0,80 0,57
TT425 425 1,20 0,80 0,77
TT600 600 1,20 0,80 0,97
Filling capacity of the tanks forms 95% of actual capacity
2. Equipment
The complete device with the distribuon system
includes:
A. The tank made of medium density polyethylene,
UV stabilized, with a lid and lock protecng the
distribuon system against unauthorized access
B. The distribuon system, includes:
• Flexible sucon hose with a non-return valve
and strainer
• KABI pump with nominal capacity of 40 l/min,
12 V DC
• KABI automac lling nozzle
• Flexible distribuon hose 3/4”, 5m long
• Cables with alligator clips to connect the baery
• 4 stainless steel shackles for liing
• Lid with telescopes
C. A 2 inch access hole for lling the tank comes with a cap ed with a venng-aeraon valve, which equalizes
pressure during refuelling
3. Oponal equipment
The distribuon system can be ed addionally with a digital ow meter The pump power supply opons are 24 V
DC or 230 V AC Equipment opons may dier depending on the version purchased
Fig.1. Scheme of tank equipment TT250/425/600
7
6
5
32
4
1
1 Electric cables with alligator clips
2 Sucon hose
3 Shut-o valve
4 Diesel oil pump 12V DC
5 Automac nozzle
6 Filling plug with 2” venng-aeraon valve
7 Distribuon hose 3/4”, 5m

6
KABI Mobile Diesel Oil Tanks
4. Marking consistent with ADR requirements
A permanent and legible label is mounted on the tank,
resistant to corrosion and operang ulity, axed in
an accessible and visible place, hereinaer referred to
as a “nameplate” The nameplate is placed on the lid
of the tank
The nameplate includes the following informaon:
• Tank Manufacturer’s name
• ADR Cercate No
• Serial number
• Tare weight (w/o fuel)
• Capacity at 20°C
• Material
• Test pressure
• Date of last leakproofness test
• Date of last inspecon
Fig.2. Nameplate of TT425 mobile tanks
Fig.3. KABI Art# nameplate
The tank is properly marked according to the type of
transported material:
UN 1202
Flammable liquid Diesel oil Product dangerous
Group III for the environment
The tank is marked with regard to transport
and storage:
Direcon arrows
The owner/operator is required to maintain the labelling in a legible condion
The method of marking the tank in compliance with ADR guidelines and
locaon of informaon and warning labels is shown below:
TruckTank 250 front TruckTank 425 front TruckTank 600 front

7
KABI Mobile Diesel Oil Tanks
III. OPERATION
The fuel tank with its unique robust design makes it strong, safe and not requiring any complicated maintenance
Upon receipt, check the tank, completeness of its equipment and ensure no damage occurred during transport The
tank is ed with a pumping and distribuon unit and is ready for operaon just aer lling the fuel
The user must comply with naonal legal requirements regarding the installaon and operaon of the product, as
well as the recommendaons of local re protecon and environmental protecon services The owner and users
of the facility should take adequate safety measures, according to the nature and extent of foreseeable dangers,
in order to prevent damage and injuries and, if necessary, in order to minimize their eects In the event of an im-
mediate threat to public safety, they should nofy the emergency services and provide them with the informaon
needed to take acon The obligaons in this scope are determined in relevant naonal regulaons
Due to the nature of the stored liquid and possible risks to the environment, it is necessary to observe the following
instrucons:
• The fuel tank should be lled only via a ller pipe 2” Do not overll the tank!
• To prevent contaminaon and damage to the pumping system, any contaminated fuel must not be stored in the
tank!
• Before starng, read and observe the service manual The service manual should be made available to every user
of the tank
• Filling and refuelling should be done under the supervision of an authorized worker
• During transportaon and storage of the fuel tank no damage to the tank may occur (see guidelines for trans-
port)
• Tank equipment should always be kept serviceable
• Do not operate the pump if the tank is empty Dry running will damage the pump
• In case of insucient delivery, clean the sucon hose lter and the pump strainer
• Calibrate the ow meter periodically according to the guidelines contained in the manual Replace the baeries
periodically
• The device must be protected against unauthorized access
• Any changes in the design, equipment and desnaon of the device are not permied without the consent of the
manufacturer
In case of damage to the fuel tank or part of its equipment it must not be used unl reced. If some leakage of
the tank is stated, the fuel must be pumped into another tank. Inform the supplier of the equipment.
1. Transport – guidelines
The tank and instrumentaon must be transported in a safe manner to exclude mechanical damage The tank
design allows you to approach with a forkli from any side
Do not stack the tanks on top of each other when full!
Before transporng carefully close the lid (do not use the ap as a carrying handle)
During transport the tank must be secured against displacement The transport space must be smooth and without
sharp edges, ed with aachment points for the transportaon straps
Filled fuel tanks should be transported with a forkli or with 4 shackles provided with the tank.
KABI is not responsible for any damage or accidents caused by usage of improper shackles.
Shackles must be secured in such a way so that they do not damage the tank
For liing and transporng the tank, do not use any other parts that are not intended for that purpose
It is forbidden to move or roll the fuel tank on the ground
Transportaon may take place only when the power supply is switched o, with the valves and stub pipes closed
and with a coiled hose, with the gun located in the handle and the lid closed
The vehicle operators must be familiar with the operaon of re exnguishers

8
KABI Mobile Diesel Oil Tanks
It is forbidden to enter the vehicle with the lighng equipment with an open ame Besides, the lighng equipment
cannot have metallic surfaces, which could produce sparks
When refuelling and handling with the load it is prohibited to smoke in vehicles, as well as in their environment
During loading and unloading the engine must be o, unless it is necessary to drive the pumps or other equipment
for loading and unloading, or if this is allowed by the naonal regulaons of the state where the vehicle is operated
The driver of the transport vehicle must be trained in the handling of hazardous materials in accordance with appli-
cable regulaons Diesel oil can be transported in quanes not exceeding 1000L on one vehicle Larger quanes
must be transported in compliance with all the provisions of ADR The driver can leave the vehicle transporng
hazardous material only when the parking brake is applied Protect the device against unauthorized access
2. Transport vehicle equipment
Each transport vehicle, which shall also meet the requirements resulng from other provisions, must be ed as
follows:
• Belts for fastening and securing the fuel tank during transport
• At least one portable powder re exnguisher min 2 kg with a seal, designaon of compliance with ocial stand-
ards and the expiraon date (month and year)
• The vehicle must be equipped with absorbent material in a minimal quanty of 2 kg (sand, sorbent, sawdust) in
addion to the lms or other forms of protecon against the ingress of substances into the soil, water, etc
3. Required transport documents
Apart from the documents, which are required under other regulaons the following documents shall be present in
the transport vehicle:
• Shipping list
• Printed service manual of the fuel tank
Printed service manuals must be kept in the driver’s cab in an easily accessible place, or in a dedicated pocket in
the lid of the tank A forwarding agent must ensure that the driver understands the service manual and proceeds
accordingly Transport vehicles that provide hazardous materials shall be labelled and ed with warning labels in
accordance with ADR provisions
For detailed informaon on the transport documentaon refer to the fuel seller, as a professional parcipant of
transport operaons
IV. SAFETY RULES DURING OPERATION OF TT250/425/600 TANK
1. Informaon about dangerous substance
Diesel oil is a commonly used fuel for diesel engines used in vehicles, staonary equipment, construcon machinery
and all kinds of agricultural machinery Diesel as a combusble liquid is classied to class III due to its ignion
temperature It is a liquid obtained by the disllaon of crude oil, consisng mainly of a mixture of hydrocarbons
having a carbon number from C9 to C20 Pour point depending on the grade from -4°C to -40°C Flash point from
56°C to 64°C Auto-ignion temperature from 270°C
Diesel oil vapours are about 6 mes heavier than air and accumulate at the ground surface and at the lower parts of
premises and land depressions Under specic condions, diesel oil vapours may form an explosive mixture with air
2. Hazards that may be posed by a stored material (diesel) and ways of minimizing them
During operaon of TT250/425/600 tank the users are required to:
• Use protecve gloves when refuelling
• Protect their skin from repeve or prolonged contact with diesel oil
• Immediately wash the body part with soap and water in case of contaminaon
• Not to eat or drink when operang TT250/425/600

9
KABI Mobile Diesel Oil Tanks
• In the area immediately adjacent to the device it is prohibited to use open ames, smoking, and use of any other
factors which may ignite the diesel oil
• Toxic oil fumes may cause irreversible changes in health; when handling diesel parcular cauon should be exer-
cised
• Protect your eyes, because there is a risk of exposure, wear protecve goggles
• Diesel is toxic for aquac and terrestrial organisms, may cause long-term adverse eects in the environment
• It increases re hazard; vapour form explosive mixtures with air, are heavier from the air, accumulate at the land
surface and at the lower parts of premises
3. Guidelines for persons authorized to operate the tank TT250/425/600
TT250/425/600 should be operated by a person who is 18 years old, that has read the service manual and is
acquainted with the rules of safe operaon Children and bystanders should be kept away from the operaon The
tank operators should follow the service manual of the tank, and in parcular:
• Check that the specied parameters are not exceed, and if they are exceeded, take acon as provided in the
service manual aimed at bringing the parameters to an acceptable level,
• Keep records of the operaon of the tank or installaon, in accordance with the service manual, as well as record
all inspecons, periodical tests and replacement of components and accessories
• The owner and users of TT250/425/600 should take appropriate safety measures, according to the nature and
extent of foreseeable dangers, in order to prevent damage and injuries and, if necessary, in order to minimize
their eects In the event of an immediate threat to public safety, they should nofy the emergency services and
provide them with the informaon needed to take acon Responsibilies are dened in relevant naonal rules
• When the tank is lled with diesel oil for the rst me the dues of driver/provider and owner of the device
include the vericaon whether the device is set rmly, the tank is clean inside and empty Refuelling should
be done in two phases between which you should check the condion of the tank - if there are no leaks Before
the rst lling of the tank the appropriate measures should be taken to prevent any possible threats in it or its
environment
• Pay special aenon to the patency of the tank venng (breathing) stub-pipe, it cannot be clogged, blinded or
fouled
4. Operaons during refuelling
During refuelling:
• Perform a visual inspecon of the device condion
• Make sure the distribuon nozzle and the hose are in good condion, with no apparent external damage
• Drive the vehicle in the vicinity of the device and turn o the engine
• It is forbidden to park the vehicle during refuelling in a way that can hamper any possible evacuaon from the re
danger zone
• In the event of fuel spills immediately remove contaminants using sorbents, dispersants, or other materials de-
signed to remove diesel oil from the environment before the machine is restarted
• The device can be used at a temperature from -20°C to +40°C Do not use the device in bad weather condions
such as heavy rain, strong wind, lightning etc
• Fuel distribuon pumps are not designed for connuous operaon The pumps are made for intermient opera-
on in cycles of 30 minutes operaon at maximum working pressure condions
5. Emergencies
In the event of TT250/425/600 failure (eg leakage of the tank):
• Disconnue any work in the aected area
• Disconnect the distributor power supply
• Help the vicms - aer making sure that it is safe to enter the danger zone
• Nofy the superior
• A person in a management posion responsible for the warehouse or the area in which the hazard occurred, or
the person designated, manages the rescue operaon, if necessary, calls the re brigade
• In the event of a leak from TT250/425/600 pump its contents to another device
• Call the manufacturer’s authorized service

10
KABI Mobile Diesel Oil Tanks
V. TT250/425/600 TANK MAINTENANCE
Table 1 below shows the scheme of the operaon procedure for TT250/425/600
Tab.1. The list of standard maintenance acvies for TT250/425/600
Acvity Minimum
frequency
Date Date Date Date
Check and clean the pump lter Every 6 months
Check and clean the ow meter lter (in the case
of heavy polluon of lters also check and clean
the measuring chamber)
Every 6 months
Check the ow meter baery condion Every 6 months
Calibrate the ow meter Every 2 months
or 40000 L
Check and clean the sucon strainer Every 6 months
Clean the tank and components of its equipment
(pump, ow meter, cables, housing, etc)
Every 6 months
Check the operaon of the pumping system
(ghtness, eciency, nozzle, etc)
Every 6 months
Check the condion of the tank and its equip-
ment for completeness and mechanical damage
Every 6 months
Check the electrical installaon of the pump
(correctness, connecon, protecon devices)
Every 6 months
Lubricate the ap lock Every 6 months
9 Correctly % Incorrectly
NOTE: Acvies included in the table above should be performed immediately if a malfuncon is noted on
TT250/425/600
Detailed informaon on the operaon and maintenance of the devices of the distribuon system (pump, ow
meter, etc) are included in the operang and maintenance manual of the manufacturer of these devices