TransTank DieselSergeant Service manual

Operator’s HandBook
DieselSergeant™
www.tti.com.au
Manufacturer of “The Safest Tanks in Motion”

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Product HandBook
DieselSergeant™
Contents
Safety 4
General Safety Instructions 5
General Information 6
Specifications 6
Description 7
Machine Limitations 8
Driving Stability 8
Operating Instructions 8
Before First Use 8
Filling the Tank 9
Operation 10
Risk Assessment 12
Maintenance 13
Periodic Checks 13
Maintenance Schedule 13
Trouble Shooting 15
Warranty 16
Warranty Policy 16
What this Warranty Does Not Cover? 16
How to Obtain Service Under this Warranty? 16
Warranty Limitations 16

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Disclaimer
All information, illustrations, and specifications contained in this manual are based on the latest product
information available at the time of this publication’s printing. TransTank International (TTi) reserves the right
to alter and substitute specifications and methods at any time, in line with our commitment to continuous
improvement.
No patent liability is assumed with respect to the use of information contained within this manual. While
every precaution has been taken in the preparation of this manual, TTi assumes no responsibility for errors or
omissions.
Thank you for purchasing a DieselSergeant™ Diesel Refueling Unit
(DieselSergeant), which will provide many years of reliable service when
operated and maintained in accordance with this manual.
TTi manufacture two DieselSergeant units, 220 and 400 litre tanks, supplied with an electric pump as
standardandmountingframeoptions. Thismanualdescribes theoperation,drivingstabilityandmaintenance
procedures applicable to all units, noting additional requirements to options where necessary.
All TTi DieselSergeant tanks are rotationally moulded from quality polyethylene, purpose designed
and manufactured to high standards, and complying with AS1940-2004 and AS2809.2-2008. The
DieselSergeant is designed as a trailer or tray-mounted tank diesel fuel dispensing system, to deliver and
refuel your equipment in the field.
The DieselSergeant unit is supplied complete, tested and ready to go. TTi recommends that only diesel be
used in the DieselSergeant unit. TTi warrants that the DieselSergeant has been designed and built for its
intended purpose for transporting and dispensing diesel fuel.
The owner is responsible to ensure that the equipment is operated in accordance with this manual, with
Australian WorkSafe requirements, applicable road rules and local council regulations. TTi is not liable for
any loss, injury or death resulting from the failure to observe all safe working regulations as required by law.
Included with your DieselSergeant unit is the following documents:
• Operator’s Handbook (this manual, which includes the Warranty Registration Card)
• Dieselflo electric pump manufacturer’s handbook
• Optional four-digit mechanical flow meter or 5-digit electronic flow meter manuals
• Tank Quality Check Form. This is your verification that the unit has been quality checked, and verifies the
serial number affixed to the unit.

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DieselSergeant™
Safety
This manual is intended for use by personnel experienced in the use of this and similar equipment. Read
and understand this manual before attempting to operate or perform routine maintenance on this equipment.
Your safety is of prime priority.
A WARNING highlights an essential operating or maintenance procedure,
practice, condition or statement, which, if not strictly observed, could
result in injury or death of personnel, or long-term health hazards.
A CAUTION highlights an essential operating or maintenance procedure,
practice, condition or statement, which, if not observed, could result in
damage or destruction of equipment.
A NOTE highlights or clarifies an essential systems description, operating or
maintenance procedure, condition or statement.

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DieselSergeant™
General Safety Instructions
1. This unit is designed and manufactured solely for the purpose of carrying and pumping diesel fuel for
refueling duties. Under no circumstances should it be used for any other purpose. It must never be used
for transporting petrol or chemicals.
2. Only authorised and trained personnel are to operate this equipment. Operators must have read and fully
understood this manual before operating the DieselSergeant unit.
3. Do not operate this equipment while under the influence of alcohol or any drugs that could impair your
capabilities in any way.
4. Personal Protection Equipment (PPE) must be worn when refuelling or operating the pump on the
DieselSergeant. Exposure to excessive noise over an extended period can cause impairment or loss of
hearing.
5. Avoid diesel contact with skin and eyes, and avoid breathing vapours or mists. Refer to the relevant Safety
Data Sheet (SDS).
6. Any spillage of fuel while refilling the tank should be immediately cleaned up and the materials used in the
clean-up disposed of safely and in accordance with relevant regulations applying to the safe use, storage
and disposal of fuel.
7. Ensure the capacity of the vehicle is suitable for the loaded mass of the DieselSergeant. Refer to the
vehicle’s operator manual for safe working loads and relevant safety instructions. Do not exceed the
carrying and braking capacity as specified by the vehicle manufacturer. As a guide, one litre of diesel
weighs approximately 0.85 kilograms (kg), therefore a full 400 litre DieselSergeant with optional steel
frame will weigh in excess of 500kg.
8. If equipped, the earth (static) lead must be unwound and attached to the vehicle’s metal tray or suitably
earthed object.
9. The DieselSergeant must never be left unattended while being filled with diesel.
10. Do not operate the pump when there is no diesel in the tank.
11. Do not disconnect any hoses or nozzles while the equipment is operating. Disconnecting any components
while under pressure may result in uncontrolled diesel discharge which may be hazardous.
12. Care should be taken at all times, particularly when operating on rough or steep terrain. Drivers should be
aware of fluid surge affecting the centre of gravity.
13. The DieselSergeant has safety labels affixed to various locations on the unit. These labels should be kept
clean and legible, and replaced if damaged.

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14. The tank is a confined space. Ensure compliance with AS 2865: 2001 Safe Working in a Confined Space
Guidelines and relevant state legislation.
15. Any unauthorised modifications to this equipment may affect its function and create a serious safety risk.
Any unauthorised modifications will void any warranty on the unit.
General Information
Specifications
Tank Heavy duty UV resistant diesel grade polyethylene tank (220 and 400 litre
capacities)
Standard features 250mm dia. lid and seal assembly
Lockable filler cap with inlet filter
Anti-static earth strap
¾ inch drain bung
Dieselflo 40L/min 12V electric pump (tank lid mounted)
4m 19mm diesel hose with auto shut-off dispensing nozzle
Options Fully welded and galvanised heavy duty steel frame
4-digit mechanical flow meter
5-digit electronic flow meter

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DieselSergeant™
Description
The TTi DieselSergeant is designed to carry and dispense diesel fuel using the self-contained pump and fuel
dispensing hose and auto shut-off nozzle. The DieselSergeant has the following features, refer to Figure 1:
Figure 1 – Component Identification – 1,000 L DieselMajor
Tank
All TTi tanks are constructed from UV resistant, virgin material polyethylene. Due to the rotational moulding
process, there may be a small variance in the overall dimensions of the tank, therefore, calibration markings
should be used as a guide only.
An earth cable is fitted to the lid of the tank for connection to the vehicle’s chassis or the optional steel frame.
The lid of the DieselSergeant tanks incorporates an integral lockable filler cap with an inlet filter. Mounted to
the top of the tank is a breather, to prevent damage to the tank structure when discharging diesel fuel.
Pump
The DieselSergeant is fitted with a Dieselflo 12V electric pump, delivering fuel at 40L/min. The pump has an
integrated bypass valve, enabling the pump to run when the dispensing nozzle is not squeezed. The pump is
mounted on the DieselSergeant tank’s lid.
Hose and Nozzle
The DieselSergeant is supplied with a 4m 19mm diameter high quality diesel grade hose with crimped fittings
as standard when supplied with a pump. The hose is fitted with an auto shut-off dispensing nozzle.
Flow Meter
As standard equipment, a mechanical 4-digit flow meter is mounted adjacent to the pump.
Pump Power Supply
Power to the 12V electric pump is supplied by the tow vehicle via integral 4m long cable and alligator clips.

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DieselSergeant™
Steel Frames
The 220 and 400 litre DieselSergeant tanks are available with optional skid frames, fully welded steel and hot-
dip galvanised for long-lasting protection. The frames incorporate forklift pockets.
Machine Limitations
The DieselSergeant unit is subject to operating limitations. It is the operators’ responsibility to ensure that
this equipment is being operated safely and within these limitations.
Driving Stability
The DieselSergeant unit is heavy when filled with diesel. To maintain stability while operating this unit:
• Ensure the vehicle or trailer tyres are inflated to their correct pressure at all times. Underinflated tyres can
cause excessive lateral motion of the tyre, which may cause a rollover.
• Allow extra room for braking and turning when the tank is full.
• Ensure any side gradient (slope) is accounted for, especially when the DieselSergeant tank is full, as the
unit will have a higher centre of gravity.
Operating Instructions
Before first use
Your DieselSergeant Cartage Tank is delivered fully assembled. Before use, it needs to be set up using the
following instructions:
• Complete the warranty registration online at www.tti.com.au/warranty-registration, or use the Warranty
Registration Card at the back of this handbook.
• Store this handbook, along with the Tank Quality Check Form and pump unit’s manual in the provided
leather pouch, in a safe and easily accessible place for future reference.
NOTE! The operator must fully understand all aspects of this handbook. Do
not operate the DieselSergeant if you are unfamiliar with its operation until
you have read this handbook.
• Read and thoroughly understand this handbook, paying particular attention to all safety requirements,
before using the DieselSergeant for the first time.
• Check that all fittings, hoses and electrical leads, where applicable, are secure following transit, and are
not damaged in any way.
• Inspect the tank for any damage or abrasions.
CAUTION! The unit must be securely mounted to the vehicle. Failure to do
so may result in the unit moving or falling off the moving vehicle. Warranty
is conditional on the unit being correctly mounted.

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DieselSergeant™
• Position your DieselSergeant onto the vehicle and mount securely to the tray. If using tie-down straps,
they must be rated to at least the total mass of the unit when filled with diesel. There are two tie-down
recesses across the 400L tank, and one recess across the 220L unit. Alternatively, the tanks incorporates
horizontal mounting holes on its base, to enable a bolt and bracket system to secure the unit to the vehicle.
• If the DieselSergeant is supplied with an optional steel frame, ensure the steel frame is securely mounted
to the vehicle.
• Fill the DieselSergeant’s tank with diesel, refer to the Filling the Tank procedure below.
Filling the Tank
The DieselSergeant tank is filled as follows:
CAUTION! The DieselSergeant unit is designed for diesel fuel use only. It
must not be used for chemicals or petrol.
CAUTION! Ensure the filling area is in an open, well ventilated space. Ensure
the static lead is properly connected to a metal earth point.
• Position the DieselSergeant near the diesel fuel supply point.
• If not premanently connected to the vehicle’s chassis, uncoil the blue earth (static) lead and connect it to
the vehicle’s tray or an earthed object.
• Unscrew the filler cap from the tank’s top opening, refer to Figure 2.
• Inspect the inlet filter for any sign of contaminants. If dirty, lift the filter out and clean it before reinserting it.
• Insert the diesel supply nozzle and commence filling the DieselSergeant tank.
CAUTION! To prevent overflow, do not leave the filling operation unattended.
• Observe the diesel level directly in the tank. When the tank is filled, close the diesel’s supply nozzle and
remove.
• Replace the DieselSergeant’s filler cap.
• Disconnect, recoil and stow the blue earth lead (if not permanently connected).

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DieselSergeant™
Figure 2 – Tank Filling Operation
Operation
The DieselSergeant is operated as follows, refer to Figure 3:
CAUTION! Ensure the filling area is in an open, well ventilated space. Ensure
the static lead is properly connected to a metal earth point.
• Park the DieselSergeant’s vehicle near the equipment to be refueled.
• Uncoil the blue earth (static) lead and connect it to the vehicle’s tray or an earthed object.
• Remove the DieselSergeant’s hose and nozzle from its stowed position, then insert the nozzle into the
equipment’s fuel tank.
Figure 3 – Transfer Operation