TransTank DieselSergeant Service manual

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

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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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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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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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• 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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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

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CAUTION! Ensure the electrical cables are connected correctly. Always
connect the negative power cable’s alligator clip to the negative terminal
first, followed by the positive.
• Uncoil and connect the pump’s electrical cable’s alligator clips to the power supply, ensuring each clip is
connected to the correct terminal – black clip to NEGATIVE, red clip to POSITIVE, refer to Figure 4.
• At the rear of the pump, press the control switch to ON. The pump will start operating, with the diesel
bypassing back into the DieselSergeant’s tank.
CAUTION! Do not allow the pump to run in bypass mode for more than two (2)
minutes.
• At the dispensing nozzle, squeeze the supply trigger. The nozzle will shut off automatically when the
equipment’s tank is full.
CAUTION! The pump has a maximum duty cycle of 30 minutes of continuous
operation. After 30 minutes, turn the pump to OFF for at least 30 minutes
before next use.
• After completing the filling operation or 30 minutes of continuous use (whichever comes first), press the
pump’s control switch to OFF.
• Withdraw the filling nozzle and coil the hose, taking care to prevent kinks or tangles and return it to its
stowage location.
NOTE! Always disconnect the positive power cable’s alligator clip from the
power supply first, followed by the negative.
• Unclip the pump’s electrical cable from the power supply and stow the cable.
• Disconnect, recoil and stow the blue earth lead (if not premanently connected).
Figure 4 – Battery Connection – Electric Pump

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Risk Assessment
Task Hazard Risk Control Measure/Mitigation
Partially fill the tank
with diesel, connect
the 12V cable to the
power supply (electric
pump option), start the
pump (electric or petrol
options) and test the
unit
Manual handling; slips, trips
or falls; petrol; diesel fumes;
fingers jammed
Medium Concentrate on task; follow safe manual handling
techniques:
• Don’t lift on your own if > 20kg, bend knees &
keep back straight; Keep fingers clear;
• Keep unit at least 8m away from overhead
powerlines;
• Fire extinguisher nearby;
• Follow warning stickers on tanks; Wear PPE
for petrol & diesel fumes-mask & gloves;
• Tank mounting to comply with relevant codes
and transport authority requirements.
Check weather
conditions, select
appropriate PPE for
refueling operations
Manual handling; slips, trips
or falls; petrol; diesel fumes
Low • Wear PPE for petrol & diesel fumes
• Follow safe manual handling techniques: don’t
lift on your own if >20kg, bend knees & keep
back straight.
Fill diesel tank As above; diesel fume drift,
diesel spillage, emission
of vapours or flammability;
weather; untrained visitors;
tank used for non-diesel
products
High As above
• User trained in accordance with relevant
requirements
• Wear hearing protection if noise >85 dBa;
• Follow the relevant Environment Protection
Authority requirements;
• Fire extinguisher present – CO2 or powder;
• Keep visitors away from the job unless
wearing full PPE;
• Check load secure; “DIESEL ONLY” sticker
on
• Don’t overload - diesel weighs 0.85kg for
every 1 litre
• Keep hose tidy
Transportation and use
of unit
As above; loss of load;
noise; exceed load limit of
vehicle; hose entanglement;
exhaust fumes; terrain &
slopes
High As above;
• Wear hearing protection if noise > 85 dBa;
• Follow the manufacturer’s safe operation
instruction for the vehicle and 12 volt transfer
from vehicle to unit;
• Don’t overload – diesel weighs 0.85kg for
every 1 litre;
• Secure unit to vehicle;
• Check earth strap;
• Hoses tidy.
Clean up, maintenance
& storage
As above Low As above;
• Wear PPE for clean up;
• follow state legislation & AS 2865: 2001 Safe
Working in a Confined Space Guidelines;
• Store unit in a dry, well ventilated area.

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Maintenance
Your DieselSergeant Refueling Unit requires minimal maintenance but regular cleaning and checks will ensure
safe and reliable service over its lifetime. Periodic checks and inspections will identify any potential issues,
enabling timely rectification and minimising downtime.
Periodic Checks
CAUTION! In dusty, dirty or smoky environments, cleaning, inspection and
servicing of the unit on a regular basis is essential. The cleaning, inspection
and servicing must be undertaken more frequently in harsh conditions to
avoid damage or destruction of equipment.
The following checks and cleaning operations should be undertaken on a regular basis. The frequency of
these activities will depend on the nature of the operating environment and the operational hours of the
DieselSergeant unit. Refer to the maintenance schedule tables below for details of maintenance intervals.
• Clean the unit and inspect it for any signs of damage or wear. Replace any safety labels if they are damaged
or illegible.
• Check all hoses, fasteners and fittings are firmly secured, tighten if necessary.
• Unwind the hose from the optionally fitted hose reel fully to check that hose is in good order. Pressurise
the line and check operation of the dispensing nozzle, including auto shut-off function. Rewind the hose
onto the reel, ensuring it retracts all the way.
• Check the condition of the electrical pump’s 12V cable and connectors.
• If the DieselSergeant is to be stored for an extended period, ensure the tank and all pipelines are empty
and are not pressurised. Store the unit is a clean, dry and well-ventilated area.
Maintenance Schedule
The following tasks are be conducted in accordance with each of the schedules. All scheduled tasks are to
be undertaken concurrently. For example, at the three month maintenance interval, all task listed are to be
undertaken, in addition to the daily, weekly and monthly tasks.
NOTE! Maintenance is important. Keep a record of all maintenance tasks
conducted on the DieselSergeant unit.
TTi recommends photocopying these schedules in order to keep a detailed log of all maintenance tasks. A
copy of these schedules will be required to support any warranty claim.

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DieselSergeant™
Daily Tasks
The following tasks are to be undertaken daily, or prior to each use, of the DieselSergeant unit.
No. Task Notes
1Inspect the DieselSergeant for any signs of damage or wear Clean, repair or replace
2Inspect electric pump’s cable and connectors Repair or replace
Weekly Tasks
The following tasks are to be undertaken each week or 10 operating hours, whichever occurs first.
No. Task Date Signed
1All Daily tasks
Monthly Tasks
The following tasks are to be undertaken each month or 20 operating hours, whichever occurs first.
No. Task Date Signed
1All Daily and Weekly tasks
2Check for damaged electrical cable on electric pump
3Check hose by unwinding fully
4Check security of mounting system
Three Monthly Tasks
The following tasks are to be undertaken every three months or 50 operating hours, whichever occurs first.
No. Task Date Signed
1All Daily, Weekly and Monthly tasks
2Check all hoses, fasteners, nozzles and fittings
Six Monthly Tasks
The following tasks are to be undertaken every six months or 100 operating hours, whichever occurs first.
No. Task Date Signed
1All Daily, Weekly, Monthly and 3-Monthly tasks
Twelve Monthly tasks
The following tasks are to be undertaken every twelve months or 200 operating hours, whichever occurs first.
No. Task Date Signed
1All Daily, Weekly, Monthly, 3-Monthly & 6-Monthly tasks
2Drain tank and flush

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Two-Yearly tasks
The following tasks are to be undertaken every 24 months or 500 operating hours, whichever occurs first.
No. Task Date Signed
1All Daily, Weekly, Monthly, 3-Monthly, 6-Monthly and
12-Monthly tasks
Trouble Shooting
If a fault develops with the DieselSergeant, the following trouble shooting table provides guidance to identify
and rectify the problem.
Problem Possible cause Remedy
Motor does not run No electrical power to pump Ensure correct connection to battery
or power supply.
Check for blown fuse
Check fuse holder for loose
connection
Motor runs slowly with
low fuel flow
Low voltage supply Test power supply and ensure
adequate voltage
Motor runs, but no fuel
delivery
Tank level too Low Add fuel to tank
Clogged suction line Clean suction line and filters
Filter air leak in suction line Check all joints for leaks
Pump makes
a squealing or
scratching sound
while running
Dirt or debris in pump chamber Clean impeller and vanes.

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Warranty
Warranty Policy
TTI will, at its option, repair or replace without charge any part covered by this warranty which is found to be
defective in material and/or workmanship within one (1) year after date of sale to the original retail purchaser.
If the product is used for rental purposes, this warranty is limited to ninety (90) days.
Upon request, the customer will make the defective part available for inspection and/or return the defective
part to TTi, transportation charges prepaid. All parts and components are covered by this warranty except
the following, which are warranted separately by their respective manufacturers:
• ⦁engines
• ⦁gearboxes
• ⦁pumps
• ⦁regulators.
TTi does not assume any warranty obligation, liability or modification for these items, which are covered
exclusively by the stated warranty of the respective manufacturers.
What this Warranty Does Not Cover?
This warranty does not cover:
• defects caused by depreciation or damage caused by incorrect mounting, normal wear, accidents,
improper maintenance, improper use or abuse of the product, alterations or failure to follow the instructions
and warnings provided.
• Any charges for making service calls, clean up time and transport charges.
• The use of non-genuine parts on equipment supplied by TTi. This will automatically negate any warranty.
How to Obtain Service Under this Warranty?
Warranty service can be arranged by contacting your dealer, or by contacting TTi directly on 1800 816 277.
Proof of warranty registration and date of purchase may be required to verify warranty coverage. Any defective
parts returned to TTI must be accompanied by a Return Goods Note. This form can be obtained by contacting
Product Support on 1800 816 277 or emailing [e-mail].
Warranty Limitations
Warranty limitations are as follows:
1. There is no other express warranty. Any warranty that may be implied from this purchase including
merchantability and fitness for purpose is hereby limited to the duration of this warranty and to the extent
permitted by law. Any and all implied warranties are excluded.
2. TTI will not be liable for any incidental, consequential or special damages and/or expenses in connection
with the purchase or use of this equipment, to the extent permitted by law.
3. Only the warranty expressed in this limited warranty shall apply and no dealer, distributor or individual
is authorised to amend, modify, or extend this warranty in any way. Accordingly, additional statements,
whether oral or written, do not constitute warranties by TTi, and should not be relied upon.

www.tti.com.au
1800 816 277
[email protected]
PO Box 137, Nathalia, VIC, 3638
Murray Valley Hwy, Nathalia, VIC 3638
Proudly Built By:
Signature Date Signature Date
Quality Checked By: