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

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A.2 GENERAL DESCRIPTION
A.2.1 Description of the vehicle
Motor / Reducer Drive Wheels
Batteries Steering Wheels
Driving Position Passanger Cabin

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A.2.2 Dimensions and technical characteristics
Diabline side (mm)
A Wheelbase 2345
B Length 3790
C Front overhang 880
D Rear overhang 635
E Front track 1270
F Front width 1440
G Rear track 1310
H Rear width 1520
I Drivers Cabin height 1800
Passenger Cabin Height 2200
J Load deck sill height 290
K Modular Main deck height 750
L Lower deck length 1070

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Motor Electric Volt 48
Wheels Number of driving wheels 2 AR
Rear deck length x width mm 2320 x 1450
Deck height height empty mm 750
Dimensions length mm 3790
width mm 1520
seat height mm 760
height with cabin mm 1800
Turning circle minimum between walls m 4,25
Road width for a turn of 90° mm 2700
Tow hook height centre in relation to ground mm 350
Weight empty without batteries kg 545
Tyres dimensions front 145/70/R13
dimensions rear 145/70/R13
Wheelbase mm 2345
Track from centre of tyre Front/rear mm 1270 / 1310
Height in relation to ground without load at the lowest point mm 150
without load at centre of wheelbase mm 165
Brakes Front + Rear hydraulic discs
Brake assistance Rear electric
Parking brake mechanical
Suspension 4 wheel independent oleo pneumati
Electric motor power kW 6
Electronic speed control Maximum power Amp 400
Batteries gel or lead/acid monobloc or cells
nominal voltage V 48
Tow bar patented system multi-arm
Batteries capacity (C/5) Amp 205 275
Batteries weight kg 250 380
Range in realistic usage when empty km 40-60 55-80
Consumption average when empty Wh/km 160 160
Charger 220V fitted power on charge Amp 20 50
Useable load in standard platform version kg 625 495
Transmission mechanical by differential reduction ratios 7 10 15 7 10 15
Effort to the hook continuous service : 60’ on flat ground kg - 100 150 - 100 150
Max : 5’ on flat ground kg - 190 280 - 190 280
Admissible slope empty / loaded % 15/7 17/9 18/10 15/7 17/9 18/10
maximum speed empty km/h 58 48 35 58 48 35

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FAILURE TO FOLLOW A SINGLE
PIECE OF SAFETY ADVICE
COULD RISK AN ACCIDENT
TO THE VEHICLE AND INJURY
TO THE PERSONNEL. YOU
ARE RESPONSIBLE FOR YOUR
SAFETY AND FOR THOSE
PERSONNEL AROUND YOU.
WARNING
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.
A.3.1.1 Information FOR THE DRIVER
You must READ and ASSIMILATE the MANUAL FOR THE SAFETY OPERATOR before using the vehicle.
This manual must be readily available at all times
Ensure that all persons in the vehicle perfectly understand the safety procedures and apply them.
You must know exactly the position of and the signs that appear on all the plates and stickers on the vehicle.
You must know the regulations and standards applying to industrial vehicles and their use. Works practices
can vary slightly according to national regulations, industry norms and employer regulations. It is for this
reason that all the different norms must be well understood.

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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
A.3.1.2 Qualifications OF THE DRIVER
Do not try to use the vehicle if you do not have the training and the knowledge necessary for all the functions
of the vehicle.
The controls, characteristics and procedures may vary from one vehicle to another, this is why it is VITAL that
the operator receives appropriate training and that it is given by competent and authorised personnel.
You must be in perfect physical and mental health to use the vehicle and must not be under the influence of
medicines, narcotics or alcohol. ALL types of drugs can reduce reactions and physical abilities, visual and
mental.
A qualified driver must be able to:
• Master each vehicle control
• Understand and abide by all the advice in this manual
• Know how to correctly load and unload material
• Know how to correctly park the vehicle
• Recognise a badly serviced vehicle
• Be able to control the vehicle in all situations

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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:
• Stay inside the vehicle during its movement. Do not leave an arm, a leg or the head outside the
vehicle
• Drive carefully
• Do not turn the steering wheel violently when moving at high speed
• Drive preferably on a flat surface or, if you have no other choice, on a surface with a slope that does
not exceed 15%
• Do not take the vehicle over holes or bumps or objects on the ground
• Observe all the driving regulations and speed restrictions (60 km/h max)
• Keep a safe distance between the vehicle and possible obstacles
• Always keep full control of the vehicle
• Warn personnel, by using the horn, when you approach a crossing or a corner of a wall behind
which people or another vehicle may be approaching
• Give priority to pedestrians, ambulances, firemen or all other emergency vehicles
• Always keep an eye on others; anticipate their manoeuvres or their movements

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A.3.3 Servicing
Always keep the vehicle clean. Eliminate all traces of mud, dirt or grease. Dirty equipment wears more and
makes servicing difficult. Use only appropriate and nonflammable cleaning products. Avoid spraying directly
on electrical components.
Routine servicing and inspection of this vehicle must be carried out by a qualified person and according
to the recommendations contained in the chapter «General maintenance and servicing». For all questions
concerning procedures and specifications, speak to your Ransomes distributor.
Except with the written authorisation and agreement of Ransomes Jacobsen Limited, no modification
affecting the original design may be made to the vehicle.
Such modifications render invalid the warranty and render the owner and/or user liable in the case of an
accident.
Before carrying out servicing or a repair on the vehicle:
1. The vehicle must be parked in a clean state and disengaged. The emergency stop button must be
pressed, the parking brake locked and the forward-reverse switch in the neutral position.
2. The batteries must be disconnected, also the charger plug and the starter key removed
After having carried out servicing or repair operations:
1. Replace all covers that have been removed
2. Reconnect the batteries
3. Remove all chocks and or supports
4. Carry out a functional test on all controls in order to ensure their proper functioning. If the brake
parts have been removed, test the brakes before refilling with hydraulic fluid. Purge the circuit if
necessary and check the level. Carry out the checks once more
IN THE ABSENCE OF PROPER
MAINTENANCE AND CHECKING
OF THIS VEHICLE, THERE IS A
RISK OF SERIOUS INJURY. THIS
VEHICLE MUST NOT BE USED IF
IT IS NOT IN PERFECT WORKING
ORDER.
WARNING

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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.
A.3.3.2 Batteries
The battery electrolyte must never be brought into contact with the skin or the eyes. In case of accidental
splashing, immediately and copiously wash the effected part with cold water and consult a doctor.
During inspection and maintenance of the battery, abide by the precautions and procedures below:
• Never check the state of charge of a battery by short-circuiting the connections. The sparks or
flames can produce an explosion of the battery
• Check the level of the electrolyte in the battery using the floats, generally green, in the centre of
each refill cap. If the batteries are not equipped with this type of device, check that the level of
water totally covers the plates.
• Wear safety glasses for all work on the batteries
• Never disconnect the positive cable of the battery first. On the contrary, disconnect the negative
cable first. This must be reconnected last when replacing the battery.

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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):
Accelerator
pedal
Driving lights
warning light
Lighting &
horn switch
Analog
speedometer
Brake
pedal
MDI
indicator
Ventilation
grills
Windscreen
wiper
switch
Change
Time/
Kilometre
Check
MDI
Keyswitch
Heating/
demisting
Optional
generator
starter
switch
Direction
warning
lights
Direction
control
button
Hazard
flasher
switch

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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.
Turn the key in a clockwise direction to switch on the vehicle (I), turn the key in an anticlockwise direction
to turn off the electricity (0).
A.4.3 Forward-Reverse control
This is a 3-position switch. It is situated to the right of the dashboard and establishes the direction of travel of
the vehicle.
A.4.4 Steering wheel
The steering wheel is attached to a column of the same type as a touring car. Turn the wheel to the right to
direct the wheels to the right and turn the wheel to the left to direct the wheels to the left.
A.4.5 Brake pedal
The brake pedal is situated to the right of the steering column. It must be operated only with the right foot.
This pedal works, by fluid, on pistons that push the brake pads onto a steel disc. The more you push on the
pedal, the more you brake the vehicle.
Handbrake
Forward/
back control
for seat
Emergency
stop
NOTE
WHEN THE PEDAL IS ACTIVATED SO ARE
THE BRAKE LIGHTS ON THE BACK OF THE
VEHICLE.
NOTE
THE STARTER KEY CAN ONLY BE
WITHDRAWN WHEN IT IS IN THE
0 POSITION.
NOTE
CERTAIN CONTROLS ARE OPTIONAL.
THE STARTER KEY MUST BE IN
THE 0 POSITION EACH TIME THE
DRIVER LEAVES THE VEHICLE
WARNING