Safety, Operation & Service Manual DIABLINE
Contents
1. Safety Operation amp Service Manual DIABLINE 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 English RJL 100 June 2009 WARNING 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 2009 Ransomes Jacobsen Limited All Rights Reserved RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL TABLE OF CONTENTS A 1 INTRODUCTION eene ntn tnnt 9 A 2 GENERAL DESCRIPTION A 2 1 DESCRIPTION OF THE 11 A 2 2 DIMENSIONS AND TECHNICAL CHARACTERISTICS 12 A 3 SAFETY ADVICE A 3 1 GENE ES 14 3 11 1 INFORMATION FOR THE DRIVER eee 14 A 3 1 2 QUALIFICATIONS OF THE 15 A 3 2 BASIC RULES i et ande tint seen 16 A 3 3 SERVICING 17 A 3 3 4 L2. CE uondo ue4 3461 lt uondo H39HVHOD 9 Y y GB 51 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B 3 2 Electrical diagram with gas generator Motor 12V 21W Electromagnet 24V E Electromagnet 12V Generator GB 52 ISO9001 ISO14001 OHSAS 18001 Ransomes Jacobsen Limited Jacobsen A Textron Company West Road Ransomes Europark Ipswich IP3 9TT 11108 Quality Drive Charlotte English Company Registration No 1070731 NC 28273 USA www ransomesjacobsen com www Jacobsen com
3. 4 Charge the battery if it registers 0 70 charged If battery registers below table values these conditions may exist 1 The battery was left discharged too long 2 The battery has a bad cell Batteries in these conditions should be taken to a specialist for further evaluation or retired from service STATE SPECIFIC GRAVITY OPEN CIRCUIT VOLTAGE OF CHARGE CORRECTED TO 80 F 6 VOLT 8 VOLT 12 VOLT 100 1 277 6 37 8 49 12 73 90 1 258 6 31 8 41 12 62 80 1 238 6 25 8 33 12 50 70 1 217 6 19 8 25 12 37 60 1 195 6 12 8 16 12 24 50 1 172 6 05 8 07 12 10 40 1 148 5 98 7 97 11 96 30 1 124 5 91 7 88 11 81 20 1 098 5 83 7 77 11 66 10 1 073 5 75 7 67 11 51 State of charge as related to specific gravity and open circuit voltage GB 38 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL Watering Flooded batteries only Water should only be added after fully charging the battery Prior to charging there should be enough water to cover the plates If the battery has been discharged partially or fully the water level should also be above the plates Important things to remember Do not allow plates to be exposed to air Do not fill the water all the way up to the cap Do not use water with a high mineral content Use only distilled or deionized water CAUTION The electrolyte is a solution of acid and water so skin contact should be avoided Electrolyte 1 8 Below Bottom of Fill Well Max level charged battery
4. RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL Open the cover of the electronic box under the front seats during the charge for ventilation to gives the charger optimal performance Let open the panel above the batteries to avoid risks of explosion Battery charging must be carried out in an open and well ventilated area Never smoke or bring a naked flame near to or produce sparks in the proximity of a charging battery WARNING A TURN OFF THE VEHICLE BEFORE CHARGING TO AVOID DAMAGES ON THE ELECTRONIC SYSTEM WARNING A ONLY CHECK THE LEVEL OF ELECTROLYTE AND REFILL AFTER CHARGING HAS BEEN CARRIED OUT WARNING A NEVER USE A CHARGER OTHER THAN THAT FITTED TO THE VEHICLE DANGER THE BATTERIES MUST ONLY BE PUT ON CHARGE IN A PROPERLY VENTILATED ENVIRONMENT DO NOT CHARGE IN THE PROXIMITY OF FIRE FLAME OR OTHER SOURCE OF HEAT DURING CHARGING THE BATTERIES DISCHARGE HYDROGEN WHICH IS HIGHLY EXPLOSIVE GB 30 WARNING A NEW BATTERIES ARE ONLY AT THEIR FULL CAPACITY AFTER HAVING BEEN CHARGED DISCHARGED THROUGH ABOUT 30 CYCLES NEVERTHELESS TO OBTAIN THE MAXIMUM LIFE FROM THE BATTERIES DO NOT DISCHARGE THEM MORE THAN 80 A N WARNING AN THE USE OF THE VEHICLE WITH INSUFFICIENTLY CHARGED BATTERIES CAN DEGRADE THE BATTERIES AND THE ELECTRONIC MOTOR DANGER THE BATTERY ELECTROLYTE CAN PRODUCE CHEMICAL BURNS WHEN IN CONTACT WITH THE SKIN PROCEED WITH
5. EXTREME CAUTION WHEN FILLING UP THE ELECTROLYTE OR WHEN CHECKING THE LEVEL OR THE LEVEL OF CHARGE OF THE BATTERY RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A 6 INSTRUCTIONS FOR TRANSPORTING To tie down the vehicle Pull on the hand brake It is essential to block the vehicle wheels ensuring that the chocks are correctly fixed to the bed of the transport vehicle Chock the chassis of the vehicle to ensure that the suspension does not pitch or roll during transport Strap down the vehicle to avoid all risk of bouncing during transport Wood Chocks GB 31 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A 7 TYRES Check that the tyres are correctly inflated sticker on the left of the driver Check for cuts or embedded foreign bodies in the treads Ensure that the wheel nuts are properly tightened IN CASE OF A FLAT TYRE Use the aerosol provided for this eventuality It is situated in the electrical compartment under the seats The jack is situated behind the passenger seat NOTE The jack must be placed only in the following positions NOTE Use only the jack delivered with the vehicle otherwise there is some risks to damage the chassis GB 32 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL Section B GENERAL MAINTENANCE AND SERVICING GB 33 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B 1 GENERAL MAINTENANCE B 1 1 General This section comprises information relative to
6. Te 27 AO24 DRIVING ui sni 27 A 5 2 2 LOADING AND UNLOADING eee 27 A 5 2 3 STARTING PROCEDURE eee emere 27 A 5 2 4 STOP PROCEDURE 1 trot e Pee t tua 27 5 225 EMERGENCY STOP Ec 28 A 5 2 7 CHARGE OF BATTERIES 30 A 6 INSTRUCTIONS FOR 31 GB 3 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A 7 TYRES R 32 B 1 GENERAL MAINTENANCE B 1 1 GENERAL nsi bp V tube eire 34 B 1 2 CLEANLINESS ucro eot repite deant neta tton iden 34 B 1 3 REMOVAL AND REFITTING eee 35 B 1 4 PROGE DURE i biete rrt telae Dea o 35 B 1 5 BATTERIES siia ih i 35 B 1 6 BATTERIES CENTRAL FILLING eee 36 B 1 7 SIMPLE STEPS FOR LONGER BATTERY 37 B 1 8 ELECTRIC WIRES AND CABLES e 41 B 1 9 ELECTRIC MOTOR tet rta D neon e eir eta 41 210 BEARINGS get teed iat Estes ehe 42 BLIT NUTS AND BOLIS iiiter tete eec peer abe censi sud 42 B412 WATERPROOFING iic edet ner rrr reet tee mde aurei 42 B 2 SERVICING B 2 1 WASHING THE VEHICLE erret tone decus 43 B 2 2 LUBRICATION POINTS ccrtc dedu a 44 B 2 3 SUSPENSION PRESSURE tertie 46 B 2 4 STEERING cach delen ee e e e a to tw bm eua tn 47 B 2 5 BRAKE FLUID
7. be set up and ensure that the bearing does not go askew B 1 11 Nuts and Bolts Lock washers lock plates and pins are used to lock the nuts and bolts Always use new nuts and bolts on parts with movable parts When fitting lock washers on aluminium use a flat washer between the lock washer and the part B 1 12 Waterproofing Ensure that joints are fitted with the appropriate gaskets or seals for the lubricants used If it is necessary to fabricate a seal select an appropriate material of a good thickness Make a hole in the correct place An unsuitable seal can cause serious damage GB 42 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B 2 SERVICING B 2 1 Washing the vehicle Whatever is the version of the vehicle if you wash it by water jet don t aim at the batteries area see below because there is risk of acid splashes GB 43 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B 2 2 Lubrication points we ee ee RN s emere I Level Plug Filler Plug B Drain Plug Breather The axle oil be checked ever 6 months and replaced annually using SAE90 gear oil 1 4 Turn on motor shaft Motor retaining bolts Check drive shaft back lash via motor fan If excessive movement U joints are worn out turn Every 6 months release the six motor retaining bolts and lubricate motor and gearbox shaft with HP grease GB 44 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL Lubricate t
8. 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 GB 16 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A 3 3 Servicing AN WARNING 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 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
9. irens anaren 47 2 6 CHARGER sere retro trei irgend deve d eg Pu v 48 B 2 7 MAINTENANCE SCHEDULE eee 49 B 2 8 BREAKDOWN GUID Eisen ttr too d tome edet eden Re oet 50 B 3 ELECTRICAL DIAGRAM B 3 1 ELECTRICAL DIAGRAM 51 B 3 2 ELECTRICAL DIAGRAM WITH GAS GENERATOR 52 GB 4 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL 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
10. B 46 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL WARNING A SUSPENSION PRESSURE CAN T BE CHECKED WHEN THE VEHICLE IS IN THE DRIVING POSITION IF DOUBTS ABOUT INCORRECT PRESSURE YOU CAN DOA VISUAL ESTIMATION WITH HEIGHT PUSH THE VEHICLE FOR SEVERAL METERS TO RELEASE THE SUSPENSION CHECKING PRESSURE MUST BE DONE WITH THE VEHICLE LIFTED OFF THE GROUND TO HAVE SUSPENSION POSITION DOWN WARNING A NEVER REMOVE CAPS OR CONNECT AIR PUMP WHEN THE VEHICLE IS ON THE GROUND DON T EXCEED 15 BAR IN SUSPENSION B 2 4 Steering If any play is felt in the steering wheel contact your dealer B 2 5 Brake fluid The brake fluid level must be checked every two weeks To do this open the lid situated under the passenger and driver seats Only use the fluid recommended by the manufacturer DOT 4 specification RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL GB 47 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B 2 6 Charger B 2 6 1 Charger NG1 battery pack goes hen the charger fitted to the machine cannot detect Two chargers are available Standard charger he pack and will not switch on If this occurs a 13A 7 8 hours remote charger will be required to boost the charge o allow the on board charger to be used Fast charger 16A Note Machine should be charged every day if it When charging Sum has been used whether for 1 hour or 12 hours 0 5 hours Red 5 8 hours Amber lights on char
11. D TO AND EXPOSES OTHERS TO THE RISK OF SERIOUS INJURY 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 GB 15 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL 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
12. DIABLINE SAFETY AND OPERATORS MANUAL A 4 6 Accelerator pedal The accelerator pedal is situated to the right of the brake pedal It must be operated only with the right foot This pedal controls the speed of the vehicle using a potentiometer The more you push on the pedal the more you accelerate the vehicle When the accelerator pedal is fully raised a regenerative braking system slows the vehicle NOTE THE BRAKE PEDAL MUST BE USED TO EFFICIENTLY BRAKE THE VEHICLE A 4 7 Parking brake The parking brake lever is situated between the two seats NOTE THE PARKING BRAKE MUST ALWAYS BE PROPERLY ADJUSTED A 4 8 Emergency stop The emergency stop button usually coloured red is situated between the driver and the passenger seats In case of emergency this cuts off the electrical power Push on the button to cut the supply and pull the button to re establish power GB 21 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A 4 9 Audible alarm Horn It is situated at the end of the left control lever on the left side of the steering column Push on the button to warn then release An audible safety warning signal sounds when the vehicle moves in reverse When reverse is engaged the buzzer sounds to warn personnel that the vehicle is reversing A 4 10 Lighting The lighting switch is situated on the left control lever When it is actuated the headlights on the front of the vehicle are switched on as well as the rear lights Turn the swi
13. DJUST 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 GB 10 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A 2 GENERAL DESCRIPTION A 2 1 Description of the vehicle Driving Position Passanger Cabin Batteries Steering Wheels Motor Reducer Drive Wheels GB 11 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A 2 2 Dimensions and technical characteristics Diabline side mm Wheelbase Length Front overhang Rear overhang Front width Rear track Rear width Drivers Cabin height Passenger Cabin Height Load deck sill height Modular Main deck height 750 Lower deck length GB 12 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL ivi 2AR 2320 x 1450 Turning circle ini 4 25 Road width 2700 Tow hook height 350 Weight 545 Tyres i i 145 70 R13 145 70 R13 Wheelbase mm 2345 Track mm 1270 1310 Height in relation to ground mm 150 mm 165 hydraulic discs electric mechanical Suspension i oleo pneumati Electric motor Electronic speed control Batteries Tow bar Batteries Batteries Range Consumption Charger 220V fitted Useable load RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A 3 SAFETY ADVICE A 3 1 General It is impossible to establish a complete list of safety advice covering all situations In the meant
14. L B 2 7 Maintenance schedule The following table gives a resume of the maintenance periods in normal conditions of use TASKS TO BE CARRIED OUT Check the electrolyte level in the batteries and fill if neces sary distilled water Check brake fluid level Top up if necessary Check tyre pressure 3 5 bars max Check for play in steering Adjust if necessary Check the steering column and rack Cleaning and tightening of all connections cables and wires and lubricate connections Check flexible pipes and lines on brake system wear crack ing and breaks Check axle oil level pf Check tightness of all nuts and bolts of motor axle and bodywork GB 49 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B 3 CIRCUIT ELECTRIQUE B 2 8 Breakdown guide g B 3 1 Circuit standard Steering pulls to right or left Difficult steering Excessive steering play Lack of power or speed abnormally slow Misalignment of front axle in relation to rear defective battery Oil leak On the rear axle the seals are defective or casing loose Axle over full Brake system connectors or bleed screws not prop erly tightened Brake pedal spongy Too much travel in the brake pedal Braking too slow bad braking No response from accelerator peda The MDI indicator does not light up NOTE The table gives a non exhaustive summary of the causes of breakdown It is only an aid and in no way summarises all the possible caus
15. TY AND OPERATORS MANUAL Section A SAFETY AND USE A GB 8 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL 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 GB 9 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL 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 WARNING A DO NOT REPAIR MODIFY OR A
16. UBRIGATION ics tdt tae vus 18 A 3 3 2 BATTERIES uiii mee tese ics 18 A 4 VEHICLE CONTROLS A 4 1 DRIVING POSLE ION edit net levees 19 A 4 2 20 4 3 FORWARD REVERSE CONTROL eee 20 A 4 4 STEERING WHEEL itii be x Pe eia ters 20 A 4 5 BRAKE PEBAL entera tee ier eee teta tpe ien petet itte 20 A 4 6 ACCELERATOR PEDAL dicet ot tein e rene 21 A 4 7 PARKING BRAK Evicted ca iter treten de wena 21 A 4 8 EMERGENGY STOP oa ri 21 A 4 9 AUDIBLE ALARM 22 LIGELNINGO S nitet 22 ASTE INDICATORS Eve Peg ri everest be 22 A 4 12 WINDSCREEN 22 A 4 13 WINDSCREEN WASHER seen emen 22 A 4 14 WINDSCREEN DE ICER 22 AMATS MiDile INDICATOR xtti aie veh et vts 23 AA 16 FUSES iiie a 25 A 4 17 HYDRAULIC DUMP TRUCK CONTROL 024 26 A 4 18 SPECIAL 26 A 5 PROCEDURES FOR USE A 5 1 CHECKS BEFORE USE tario tree eue thats 27 AS CONTROLS uiii treten iei de ciae besser caus 27 A 512 SAFETY EQUIPMENT iiri rrt vec des 27 A 5 1 3 LIGHTING AND SIGNALLING eee 27 A 5 2 ADVICE USE 5 22 dg dont t Lo du
17. and the MDI EEPROM KO Problem with the eeprom EEPROM KO Problem with the configuration of the eprom LOGIC FAILURE 1 Automatic test carried out at start up that has a problem with the speed control level CODES gt 102 L10 to AL12 L15 to AL19 gt gt gt Problem with the measure of the voltage between the speed control and the voltage relayed to the battery Erroneous motor connectionoe VMN NOT OK Motor shorting to earth Power unit fault EVER Automatic test during travel verifies that the current would not be more than the minimum threshold value possibly related to 53 Automatic test check of current signal Defective current collector STBY HIGH Defect in retroactive circuit Defect in the power logic Anomaly in the current field Anomaly in the current collector AL57 to AL58 HIGH NO FIELD CURR Field cables not connected Defect in the field current unit Temperature of speed control too high The temperature of the speed control is greater than 77 and the current is reduced in proportion to this rise The speed control stops at 92 TH PROTECTION The temperature of the speed control is less than 10 the maximum current is reduced to 80 The speed control is at normal temperature ambient idem AL65 The motor temperature is greater than the intervention threshold of the sensor the speed of the motor is reduced MOTOR TEMPERATURE If the alarm go
18. e Inspection Examine the outside appearance of the battery Look for cracks in the container The top of the battery posts and connections should be free of dirt fluids and corrosion If batteries are dirty see Cleaning section Replace any damaged batteries Any fluids on or around the battery may indicate that electrolyte is spilling leaching or leaking out Leaking batteries must be replaced Check all battery cables and connections Look closely for loose or damaged parts Replace any cable that is broken or frayed WARNING Do not smoke near batteries Tighten all wiring connections to the proper specification following page Be sure there is good contact with the terminals WARNING Do not over tighten terminals Over tightening can result in post breakage post melt down or fire RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL Proper Torque Values for Connection Hardware Flooded Automotive 50 70 in lbs Side 70 90 in lbs Wingnut 95 105 in lbs LPT 95 105 in Ibs LT 100 120 in Ibs Gel Button 90 110 in lbs LT 100 120 in lbs Specific Gravity Testing Flooded batteries only 1 Do not add water prior to testing Fill and drain the hydrometer 2 4 times before drawing a sample from the battery Have enough sample electrolyte in the hydrometer to completely support the float Take a reading record it and return the electrolyte to the cell Check all cells in the battery repeating th
19. e steps above Replace vent caps and wipe off any electrolyte that might have been spilled Correct the readings to 80 F Add 004 to readings for every 10 above 80 F Subtract 004 for every 10 below 80 F Check the state of charge using the table on the next page The readings should be within the factory specification of 1 277 007 If any specific gravity reading registers low follow these steps 1 Check and record voltage level s 2 Put batteries on a complete charge Take specific gravity readings again If any specific gravity reading still registers low follow these steps 1 Check voltage level s 2 Perform equalization charge See Equalizing GB 37 If any specific gravity reading still registers lower than the factory specification one or more of these conditions may exist The battery is old and nearing end of life The battery was left discharged too long Electrolyte was lost due to spillage A weak or bad cell is developing The battery was over watered prior to testing Batteries in conditions 1 4 should be taken to a specialist for further evaluation or retired from service Open Circuit Voltage Testing For accurate voltage readings batteries must remain idle no charging no discharging for at least 6 hours and preferably 24 hours 1 Disconnect all loads from the batteries 2 Measure the voltage with a DC voltmeter 3 Check the state of charge with the table below
20. er 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 SAFETY AND USE This part covers the safety of personnel in relation to conditions of use of the vehicle the functioning of the vehicle i 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 GB 6 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL The definitions DANGER ATTENTION and NOTE in this manual are the following 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 GB 7 RANSOMES DIABLINE SAFE
21. es for a given problem GB 50 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B 3 ELECTRICAL DIAGRAM uae1ospuiA 4 4 34 vo Aq gt yazzna lt Aejay 4016 Act dosuas peeds peu er tr wor zr F A Sr SHUM 9r uoniub y Bnid 4oyeo1puy 44 2 e n 1461 4461H B 3 1 Electrical diagram standard u Bnidepei 4 22 weoqdig amp Awe y 940J9q 99 oueBJeui3 YoUMS youms hay 8 1000 1102 plata bd 25 a jooeag 4 uondo 9 Jojoure p
22. es off motor cold Defect with sensor Problem of connection of sensor AL66 BATTERY LOW The battery is below 50 of the nominal value CONTACTOR DRIVER or COIL ircuit defect in general contact control circuit SHORTED he contact winding is short circuiting or not connected AL75tot AL76 The direction of travel is not selected or the hand brake is on or one or more safety ies annexe s special option s is are activated HANDBRAKE orVACC NOT OK The following test gives confirmation keep the button check MDI down page 22 and give a slight push on the accelerator if the vehicle moves forward one of the following is the likely cause A wire in the potentiometer is brokence Defective potentiometer Erroneous starting sequence Problem with the connection between the accelerator pedal and the corresponding entry into the speed INCORRECTSTART contro Wiring error Forward and reverse demanded at the same time Problem with the connection between the accelerator pedal and the corresponding entry into the speed FORW BACK control Wiring error Defect of the potentiometer and the accelerator pedal PEDALWIRE KO Wiring defect Wire broken GB 23 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL NOTE IT IS POSSIBLE THAT AN UNKNOWN CODE IS DISPLAYED IN THIS CASE NOTE THE CODE BEFORE CALLING AFTER SALES SERVICE THAT WILL BE ABLE TO DIAGNOSE THE PROBLEM e Battery charging The warning lights indicate the sta
23. ger 10 15 hours Green 60 70 When fan switches off battery is fully charged 62 63V peak battery voltage If disconnected during charge cycle a warning beep can be heard B 2 6 2 Charger NG3 RED LED shows that the battery is in the initial charging phase 100 YELLOW LED shows that the battery charger has reached 80 of charge 80 T 80 GREEN LED shows that the battery has reached 100 of charge __ START gt ALARMS N 4 An two tone audible message and the flashing LED shows that an Alarm situation has occurred LED State Alarm Type Description Action Battery disconnected or not in conformity Verify the connection and the RED flash Battery Presence nominal voltage The thermal sensor is disconnected during the recharge or it is out YELLOW flash Thermal Sensor working range Verify the connection of the sensor and measure the temperature of the battery GREEN flash Timeout Phase 1 and or Phase 2 have a duration in excess of the maximal al lowed Verify the battery capacity RED YELLOW flash Battery Current Loss of output Current control Failure of the control logic RED GREEN flash Battery Voltage Loss of output Voltage control Battery disconnected or failure of the control logic RED YELLOW GREEN flash Overheating of semiconductors Verify the fan operation When there is an alarm the battery charger stops supplying current GB 48 RANSOMES DIABLINE SAFETY AND OPERATORS MANUA
24. he PTO U joint using the 30 degree grease nipple GB 45 B 2 3 Suspension pressure The standard pressures are Front 13 bars Rear 12 bars To service suspension system use the following process Remove the suspension arm from the vehicle Release compressed air from the ram using the Schroeder valve on the top Compress the ram whilst releasing the air from the ram Using a C spanner or punch remove the collar from the body this is Loctited Pull shaft from body Warning Oil is held within assembly Inspection Ram shaft can get rusty check thoroughly for damage to shaft Assembly is in reverse to the above Once assembled remove the Schroeder valve and purge the oil from the ram Position the piston 1 5 cm from the top and fill with 180ml of oil Allow oil to settle and after one hour refit Schroeder valve and fill with air to pressures shown above How to inflate This operation is done wheel by wheel with an air pump capable of achieving a pressure of 12 bars Raise up the vehicle with the jack supplied or electric lift distribute the efforts under the chassis Be sure the wheel does not touch the ground by spinning it Bring forward the front seats for valves standard access Remove the cap and connect the pump Inflate until the correct pressure is achieved Disconnect the pump with a quick and precise hand move to doesn t lose pressure Put on the cap Lower the vehicle to the ground G
25. ime 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 WARNING 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 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 GB 14 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A 3 1 2 Qualifications OF THE DRIVER WARNING A 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 EXPOSE
26. 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 GB 18 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL 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 r um apre Ir gu ES z m Driving lights MDI warning light indicator Lighting amp i Ventilation horn switch gt Windscreen wiper switch Accelerator pedal Change Time Kilometre Direction warning lights Direction control button Optional Hazard generator flasher
27. ly charge the battery before storing Store the battery in a cool dry location protected from the elements During storage monitor the specific gravity flooded batteries or voltage Stored batteries should be given a boost charge when they show a 70 state of charge or less See table previous page Completely charge the battery before re activating For optimum performance equalize the batteries flooded before putting them back into service See Equalizing RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL section Electrolyte Freezing Point at Various SPECIFIC 5 OF FREEZING GRAVITY CHARGE TEMPERATURE 1 280 100 92 0 F 1 265 92 71 3 F 1 250 85 62 0 F 1 200 62 16 0 F 1 150 40 5 0 F 1 100 20 19 0 F Source BCI Battery Service Manual 1995 States of Charge Charging Correctly charging batteries requires administering the right amount of current at the right voltage Most charging equipment automatically regulates these values Some chargers allow the user to set these values For proper charging refer to the instructions that came with your charging equipment Important things to remember 1 Become familiar with and follow the instructions from the charger manufacturer Batteries should be charged after each period of use Lead acid batteries do not develop a memory and need not be fully discharged before recharging Charge only in well ventilated areas Keep sparks or flames away fr
28. m A Procedure 1 Remove the vent caps and check the electrolyte level the minimum level is to the top of the plates If there is no electrolyte visible add just enough water to cover the plates Replace and tighten all water vent caps Put batteries on a complete charge before adding any more water See Charging section Once charging is completed remove the vent caps and check the electrolyte level Add water until the electrolyte level is 1 8 below the bottom of the fill well Clean replace and tighten all vent caps WARNING Never add acid to a battery Cleaning Check that all vent caps are tight Clean the battery top with a cloth or brush and a solution of baking soda and water Do not allow any cleaning solution or other foreign matter to get inside the battery Rinse with water and dry with a clean cloth Clean battery terminals and the inside of cable clamps with a post and clamp cleaner Reconnect the clamps to the terminals and thinly coat them with petroleum jelly Keep the area around batteries clean and dry Storage Important things to avoid 1 Freezing Avoid locations where freezing temperatures are expected Keeping batteries at a high state of charge also prevents freezing See table next page Heat Avoid direct exposure to heat Sources such as radiators or space heaters Temperatures above 80 F accelerate the battery s self discharge characteristics Procedure Complete
29. om a charging battery Verify charger voltage settings are correct Check electrolyte level See Watering section Tighten all vent caps before charging Do not overcharge or undercharge the GB 39 Equalizing Flooded batteries only WARNING Do not equalize Gel or AGM batteries Equalizing is an overcharge performed on flooded lead acid batteries after they have been fully charged It helps eliminate stratification and sulfation two conditions that can reduce the overall performance of a battery Trojan recommends equalizing only when low or wide ranging specific gravity 015 is detected after fully charging a battery Procedure Verify that batteries are the flooded type Remove all loads from the batteries Connect battery charger Set charger to equalizing mode Start charging batteries Batteries will begin gassing and bubbling vigorously Take specific gravity readings every hour Equalization is complete when specific gravity values no longer rise during the gassing stage NOTE Many chargers do not have an equalization setting so this procedure cannot be used GB 40 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B 1 8 Electric wires and cables The batteries must always be disconnected before working on the electrical system Before removing or disconnecting a bundle of wires or cables mark each one of them to ensure that you can cor
30. our vehicle do not try to manually lever heavy parts when a method of mechanical leverage can be used Do not place and never leave heavy parts in an unstable position When lifting a part of the vehicle or the whole vehicle ensure that it is well wedged and that it s weight is supported by wedges rather than by a lifting system If you encounter difficulties during the removal of a part check that all the screws and nuts have been removed and that an adjacent part is not jamming When assembling or removing a component or a system carry out each stage turn by turn Do not partly assemble a component and then start to assemble another Carry our all the necessary adjustments Always check the work done after having finished to ensure that nothing has been forgotten Check again the various adjustments concerning the functioning of the vehicle before putting it back into service B 1 4 Procedure Place the vehicle in an authorised clean and clear environment Before working on the vehicle make sure the proper shut down procedures have been carried out Block the vehicle according to the type of work Disconnect the batteries before starting work Provide a fire extinguisher Before putting the vehicle back in service follow the safety guidelines Carry out the functional checks in a clear and authorised area B 1 5 Batteries Remove batteries from vehicle before cleaning with a brush using a bicarbonate of soda solution Rinse with clear water Afte
31. r cleaning dry the batteries and cover the leads and terminals with an anti corrosive or grease If the vehicle remains unused during a long period of time the batteries must be removed They must be stored in a dry and temperate environment preferably on wood blocks Never store on concrete A small WARNING PROLONGED EXPOSURE OF THE VEHICLE TO TEMPERATURES BELOW ZERO CAN REDUCE BATTERY LIFE GB 35 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B 1 6 Batteries central filling Thanks to this system you can easily make the batteries water level Connect the removable tank to the mouth located on the right of the batteries compartment and keep it higher than it Open the tap and wait until the red roller stop Close the tap and disconnect the can NOTE We recommend checking the electrolyte levels every 15 days hot weather or every 3 weeks regular use If the check point gauges on top of the caps are red the level is full if they are half or not visible they need topping up GB 36 B 1 7 Simple Steps For Longer Battery Life Copyright Trojan Inc used with permission Equipment Trojan recommends the following equipment for use in battery care and maintenance Wrench Post Cleaner Distilled Water Baking Soda Voltmeter Petroleum Jelly Hydrometer Goggles amp Gloves CAUTION Always wear protective clothing gloves and goggles when handling 066 batteries and electrolyt
32. rectly reconnect them Make sure that each connection is clean to avoid bad contacts NOTE Open the lid under the seats to give access to the fuses B 1 9 Electric Motor TM To ensure the cooling air flow is maintained across the motor the rear motor cover should be checked Traction Motor Brush 29 for correct fitting when removed The motor brushes should be checked on a six monthly basis check wear line 3 Plate fitted correctly GB 41 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B 1 10 Bearings Once a bearing is removed cover it to keep out dirt and abrasive matter Clean the bearings in a solvent and leave them to dry The bearings can be dried with compressed air but avoid turning them too fast Dispose of the bearings if they show any sign of discoloration marking deformation or overheating If the bearing is usable smear it with oil or grease and cover it with clean waxed paper Do not unpack a bearing until just before its use The life of a bearing is considerably reduced if it is not correctly lubricated Dirt in a bearing can stop it turning on its axle The track of the bearing can become the axle or the housing which can result in a lot of repair work Do not fit bearing with a hammer Where possible use a press and ensure that the pressure is applied directly on the ring which must be fixed in relation to its housing If you use a hammer equip yourself with a tube of the same diameter as the ring to
33. safe to use The non exhaustive list of checks that follows has been provided in order that the user can carry out all the checks before taking the vehicle into use Check the state of charge of the battery ensure that the connections and cables are correctly fastened and show no signs of corrosion A 5 1 1 CONTROLS Check the functioning of all the vehicle controls Carry out a detailed check of the brake system A 5 1 2 SAFETY EQUIPMENT Make sure that all the safety equipment functions correctly A 5 1 3 LIGHTING AND SIGNALLING Ensure that all the lights function correctly especially if you are working at night Equally check indicators and the flashing light if you are to go on a public road A 5 2 Advice on use 5 2 1 DRIVING Slow down when you approach a crossing or a traffic zone Do not drive in a dangerous or carefree manner Do not drive in a dangerous area unless the vehicle has been authorised for that area In the case of any accident or problem contact your superior A 5 2 2 LOADING AND UNLOADING Do not load an object if there is a risk that it can fall from the vehicle Do not exceed the maximum load stated by the manufacturer Be extremely careful when the load exceeds the height length or width of the vehicle Make sure that the load is correctly distributed and fastened during transportation Do not carry more than the authorised number of persons in the vehicle 5 2 3 STARTING PROCEDURE Check that the emergency
34. starter switch switch GB 19 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL Handbrake stop Forward back control for seat 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 NOTE WARNING A THE STARTER KEY CAN ONLY BE WITHDRAWN WHEN IT IS IN THE THE STARTER KEY MUST BE IN 0 POSITION THE 0 POSITION EACH TIME THE NOTE CERTAIN CONTROLS ARE OPTIONAL A 4 3 Forward Reverse control DRIVER LEAVES THE VEHICLE This is a 3 position switch Itis 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 NOTE WHEN THE PEDAL IS ACTIVATED SO ARE THE BRAKE LIGHTS ON THE BACK OF THE VEHICLE GB 20 RANSOMES
35. stop is out Place the starter key in position 1 Put the Forward Reverse button in the required position Release the parking brake Push gently on the accelerator pedal 5 2 4 STOP PROCEDURE Pull on the parking brake Place the start key in position 0 Put the Forward Reverse button in neutral position Remove the start key If necessary place chocks under the wheels GB 27 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A 5 2 5 EMERGENCY STOP Pull the emergency stop switch to establish electrical supply to the vehicle WARNING A BEFORE RESTARTING IT IS NECESSARY TO ELIMINATE THE PROBLEM THAT CAUSED THE EMERGENCY STOP GB 28 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A 5 2 6 TOWING A N WARNING A WARNING COMPLETELY UNLOAD THE IF THE VEHICLE BECOMES VEHICLE BEFORE BEING TOWED STUCK USE AN APPROPRIATE TRACTOR TO RETRIEVE IT DO NOT TRY TO MOVE IT UNDER IT S OWN POWER AS THIS WILL Z WARNING A DAMAGE THE DRIVE SHAFT TOWING IS LIMITED TO EXTREMELY SHORT DISTANCES AND TO A SPEED NOT EXCEEDING 8KM H AS IT CAN CAUSE SERIOUS DAMAGE TO THE DRIVE SYSTEM The parking brake must be released when the vehicle is being towed The tow hook is found behind the passenger seat and screws to the base of the mounting on the bumpers the emergency stop button must be pressed in when you do this to eliminate damage to the controller GB 29 A 5 2 7 CHARGE OF BATTERIES During the charge
36. tch one click to switch on the sidelights and turn two clicks to switch on the main lights Pull the lever upward for Full beam Turn the switch to position 0 to switch everything off A 4 11 Indicators Please signal all changes of direction left and right using the left switch lever Push the lever forwards to indicate a change of direction to the right and pull the lever towards the rear to signal a change to the left A 4 12 Windscreen wiper This is the right hand switch lever Pull the lever towards the rear to activate the wiper blade in single sweeps Push the lever towards the front one click to activate the wiper blade with interrupted sweeps and push two or three clicks to activate in slow and rapid continuous sweeps A 4 13 Windscreen washer This is the windscreen wiper switch Pull the lever upward to activate the washer by impulse keep in this position to have a continuous function Release the lever to stop the windscreen washer The washer reservoir is situated to the right of the battery compartment A 4 14 Windscreen de icer heater This is a switch situated in the centre of the dashboard GB 22 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A 4 15 indicator This is an indicator in the form of luminous warning lights and a liquid crystal display situated on the dashboard The MDI indicator provides information on DESIGNATION SIGNIFICANCE Problem with the dialogue between the speed control
37. te of battery charge WARNING A DO NOT CONTINUE TO RUN WHEN THE RED LIGHT SHOWS PUT THE VEHICLE ON CHARGE e THE HOURS OF USE RECORDER Indicates the number of hours of use of the vehicle GB 24 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A 4 16 Fuses To check and or change one or more fuses open the lid situated under the passenger driver seats Indicators Hazard Head lights main Horn Dipped lights Trailer connection Convertor Emergency Side Main lights Speedometer Stop switch dashboard Cab revolving Ventilator hazard light reverse buzzer Windscreen wiper washer GB 25 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A 4 17 Hydraulic dump truck control D24 This box is situated in the cabin behind the driver WARNING A WHEN THE DUMP TRUCK IS IN USE OR DURING MAINTENANCE OF THE HYDRAULIC SYSTEM ENSURE THAT THE SYSTEM IS SECURED AND THAT NO ONE RISKS BEING INJURED A 4 18 Special operations For all questions relating to vehicles fitted with special equipment please consult the technical service department of Ransomes Jacobsen Limited GB 26 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL A 5 PROCEDURES FOR USE A 5 1 Checks before use Carry out a complete systematic inspection of the vehicle before use Look for possible non operational equipment leaks or other defects which necessitate immediate action to make the vehicle
38. the maintenance and general procedures Qualified personnel must carry out maintenance operations and or repairs carried out on your vehicle To find the frequency of maintenance study the table of scheduled maintenance The following procedure aims to help you diagnose a break down and possibly to resolve the problem To determine the problem To establish the list of possible causes To make the functional checks To make the checks in a logical sequence to determine the cause causes To consider the life remaining in a part against the cost of replacement and labour To make the necessary repairs To check again to make sure nothing has been forgotten To make a functional test of the replaced part in it s system B 1 2 Cleanliness In order to preserve the life of your vehicle it is important that spare parts are always kept clean Each time some oil or lubricant escapes from disconnected pipes or sections it is important that the joints are cleaned to prevent foreign bodies getting into the pipe work The same conditions apply to the cleanliness of mechanical parts Clean and inspect all the parts Ensure that the openings are not blocked Cover them to protect them from dust or liquids Ensure that the parts to be changed are clean before installing them Remove all traces of corrosion from the parts that are to be fitted with new components GB 34 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL B 1 3 Removal and refitting While servicing y
39. 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 44 0 1473 270000 Fax 44 0 1473 276300 www ransomesjacobsen com GB 5 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL 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 prop
40. 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 The batteries must be disconnected also the charger plug and the starter key removed After having carried out servicing or repair operations Replace all covers that have been removed Reconnect the batteries Remove all chocks and or supports 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 GB 17 RANSOMES DIABLINE SAFETY AND OPERATORS MANUAL 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
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