Ransomes diabline Installation and operating instructions

Safety, Operation & Service Manual
RJL 100 June 2009
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.
24882G-GB (rev.0)
DIABLINE

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
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.
WARNING
© 2009, Ransomes Jacobsen Limited. All Rights Reserved

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TABLE OF CONTENTS
A.1 INTRODUCTION..............................................................................9
A.2 GENERAL DESCRIPTION
A.2.1 DESCRIPTION OF THE VEHICLE.................................................11
A.2.2 DIMENSIONS AND TECHNICAL CHARACTERISTICS.................12
A.3 SAFETY ADVICE
A.3.1 GENERAL.......................................................................................14
A.3.1.1 INFORMATION FOR THE DRIVER................................................14
A.3.1.2 QUALIFICATIONS OF THE DRIVER.............................................15
A.3.2 BASIC RULES ................................................................................16
A.3.3 SERVICING.....................................................................................17
A.3.3.1 LUBRICATION ................................................................................18
A.3.3.2 BATTERIES.....................................................................................18
A.4 VEHICLE CONTROLS
A.4.1 DRIVING POSITION.......................................................................19
A.4.2 STARTER KEY................................................................................20
A.4.3 FORWARD-REVERSE CONTROL.................................................20
A.4.4 STEERING WHEEL........................................................................20
A.4.5 BRAKE PEDAL...............................................................................20
A.4.6 ACCELERATOR PEDAL.................................................................21
A.4.7 PARKING BRAKE...........................................................................21
A.4.8 EMERGENCY STOP ......................................................................21
A.4.9 AUDIBLE ALARM (HORN)..............................................................22
A.4.10 LIGHTING.......................................................................................22
A.4.11 INDICATORS ..................................................................................22
A.4.12 WINDSCREEN WIPER...................................................................22
A.4.13 WINDSCREEN WASHER...............................................................22
A.4.14 WINDSCREEN DE-ICER / HEATER...............................................22
A.4.15 M.D.I. INDICATOR.........................................................................23
A.4.16 FUSES............................................................................................25
A.4.17 HYDRAULIC DUMP TRUCK CONTROL (D24)..............................26
A.4.18 SPECIAL OPERATIONS.................................................................26
A.5 PROCEDURES FOR USE
A.5.1 CHECKS BEFORE USE.................................................................27
A.5.1.1 CONTROLS....................................................................................27
A.5.1.2 SAFETY EQUIPMENT....................................................................27
A.5.1.3 LIGHTING AND SIGNALLING ........................................................27
A.5.2 ADVICE ON USE............................................................................27
A.5.2.1 DRIVING.........................................................................................27
A.5.2.2 LOADING AND UNLOADING .........................................................27
A.5.2.3 STARTING PROCEDURE .............................................................27
A.5.2.4 STOP PROCEDURE.......................................................................27
A.5.2.5 EMERGENCY STOP .....................................................................28
A.5.2.7 CHARGE OF BATTERIES..............................................................30
A.6 INSTRUCTIONS FOR TRANSPORTING.......................................31

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A.7 TYRES............................................................................................32
B.1 GENERAL MAINTENANCE
B.1.1 GENERAL.......................................................................................34
B.1.2 CLEANLINESS ...............................................................................34
B.1.3 REMOVALAND 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 ELECTRIC WIRES AND CABLES..................................................41
B.1.9 ELECTRIC MOTOR........................................................................41
B.1.10 BEARINGS.....................................................................................42
B.1.11 NUTS AND BOLTS..........................................................................42
B.1.12 WATERPROOFING ........................................................................42
B.2 SERVICING
B.2.1 WASHING THE VEHICLE...............................................................43
B.2.2 LUBRICATION POINTS.................................................................44
B.2.3 SUSPENSION PRESSURE............................................................46
B.2.4 STEERING......................................................................................47
B.2.5 BRAKE FLUID.................................................................................47
B.2.6 CHARGER......................................................................................48
B.2.7 MAINTENANCE SCHEDULE .........................................................49
B.2.8 BREAKDOWN GUIDE....................................................................50
B.3 ELECTRICAL DIAGRAM
B.3.1 ELECTRICAL DIAGRAM STANDARD............................................51
B.3.2 ELECTRICAL DIAGRAM WITH GAS GENERATOR......................52

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NEW PRODUCT WARRANTY
The seller guarantees each new product against all material or manufacturing fault, without obligation, his
responsibility being limited under this guarantee to the repair or replacement of each part recognised as being
defective in use or normal maintenance, and the reasonable cost of repair and or replacement of the said
parts during the twelve months from the initial date of purchase, hire purchase or rental, on the understanding
that the taking into service of the equipment has been registered with the seller. In the case that the
equipment has not been registered with the seller, the initial date of sale, of hire purchase or of rental will be
the date of despatch from the factory. This warranty replaces all other guarantees explicit or implicit and the
responsibility of the seller under this guarantee excludes the cost of transport or others or all responsibility for
damage, direct or indirect or consecutive such as all delays due to possible faults. The warranty will be null
and void in the case of use over capacity or in conditions not foreseen by the seller or in the case of use of
parts not recognised by the said seller.
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.
The charging of the batteries by a means other than the fitted charger will result in the cancellation of the
warranty.
FOR THE ATTENTION OF
THE CLIENT / USER
If this vehicle is involved in an accident, please contact your distributor immediately and provide him with all
the details of the accident in order that he may notify the firm.
If the distributor is unknown or cannot be notified, please contact:
Ransomes Jacobsen Limited
West Road, Ransomes Europark,
Ipswich IP3 9TT, England
Tel: [phone]
Fax: [phone]
www.ransomesjacobsen.com

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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. After having read and understood all the sections, keep the manual in its place.
This vehicle has been designed to offer maximum performance with minimum servicing. The proper
employment of the servicing operations ensures years of use without problems.
With our policy of continuous improvement of our products, we reserve the right to make changes without
warning to the specifications and equipment.
The servicing procedures and routines are given in this manual with each machine and must be consulted for
detailed information.
Information in this manual in no case replaces internal regulations, advice or insurance policy clauses.
This manual consists of the following main parts:
Section A: SAFETYAND USE
This part covers the safety of personnel in relation to:
• conditions of use of the vehicle
• the functioning of the vehicle
• the vehicle itself
Section B: GENERAL MAINTENANCE AND UPKEEP
This part aims to assist you to keep to the basic rules of , to maintain your vehicle and to detect possible
breakdowns.

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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.
CAUTION - Indicates a potentially hazardous
situation which, if not avoided, MAY result in minor
or moderate injury and property damage. It may
also be used to alert against unsafe practices.
The definitions DANGER, ATTENTION, and NOTE in this manual are the following:

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Section A
SAFETY AND USE

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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. Batteries provide electric power. The driving position is on the front left of the vehicle.
The nominal capacity of the machine is indicated on the plate displaying the permissible loads situated on left
of the driver seat. This stipulated load must not be exceeded.
ON DELIVERY…
You must immediately check your vehicle on delivery in order to ensure that nothing has been forgotten or
appears to have deteriorated.
Checking of the vehicle
Examine the vehicle such as the accessories delivered separately. Ensure that all that you have ordered has
been delivered. Nothing must appear damaged or deteriorated.

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Check the function of controls
Carry out each of the following checks :
• Accelerator pedal
• Brake pedal
• Forward/reverse switch
• Brakes
• Steering
• Audible alarm
• Lighting and indicators
If you find a problem…
Immediately draw up a list and send it to:
Ransomes Jacobsen Limited
West Road, Ransomes Europark,
Ipswich IP3 9TT, England
DO NOT REPAIR, MODIFY
OR ADJUST A PART OF THE
VEHICLE WITHOUT THE WRITTEN
AGREEMENT OF RANSOMES
JACOBSEN LIMITED, THIS WILL
RESULT IN THE CANCELLATION
OF THE WARRANTY. FURTHER
AN INCORRECT REPAIR CAN
CAUSE SERIOUS INJURY.
WARNING