TransTank Portable Diesel Captain Tank Pod Instruction Manual

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Trans Tank Portable Diesel Captain Tank Pod

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. Trans Tank 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 TTi DieselCaptain Portable Diesel Refuelling Unit (DieselCaptain), which will provide many years of reliable service when operated and maintained in accordance with this manual.
TTi manufacture a range of Diesel Captain units, from 100 through to 1,200 litre tanks, supplied with different capacity pumps. This manual describes the operation and maintenance procedures applicable to all units, noting additional requirements to the larger units where necessary. All TTi Diesel Captain tanks are rotationally moulded from quality diesel grade polyethylene, purpose designed and manufactured to high standards. The Diesel Captain tanks incorporate a lockable filler cap with strainer and an innovative breather system fitted as standard. All Diesel Captain come standard with an auto shut- off nozzle; with the pump featuring a 40-minute duty cycle for continuous dispensing. All pumps contain an internal bypass to allow operation for short periods with the dispensing nozzle closed.
Included with your Diesel Captain is the following documents:

1. Operator’s Handbook (this manual, which includes the Warranty Registration Card)
2. Integral pump manufacturer’s handbook
3.  Tank Quality Check Form. This is your verification that the unit has been quality checked, and verifies the serial number affixed to the unit.

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.

General Safety Instructions

1. This unit is designed and manufactured solely for the purpose of carrying and pumping diesel fuel. Under no circumstances should it be used for any other purpose.
2. Only authorised and trained personnel are to operate this equipment.
3. Personal Protection Equipment (PPE) must be worn at all times.
4.  Avoid diesel contact with skin and eyes, and avoid breathing vapours or mists. Refer to the relevant Safety Data Sheet (SDS).
5.  Do not operate this equipment while under the influence of alcohol or any drugs that could impair your capabilities in any way.
6. Ensure the capacity of the vehicle is suitable for the loaded mass of the DieselCaptain. Refer to the vehicle’s operator manual for safe working loads, correct secure points and relevant safety instructions. As a guide, one litre of diesel weighs approximately 0.85 kilograms (kg), therefore a full 1,000 litre DieselCaptain will weigh in excess of 1,000kg.
7. The unit must securely restrained when being transported on a vehicle.
8. This Diesel Captain must not be lifted when partially or completely filled unless supported by an appropriate mounting frame or pallet. This unit is not suitable for stacking.
9.  The Diesel Captain must never be left unattended while dispensing fuel or being filled with diesel.
10. Always store the DieselCaptain in a well-ventilated area, and way from any heating or ignition sources. It must not be stored in any garage attached to a dwelling.
11. When filling the tank, attach the earthing strap to the vehicle tray or an earthed object.
12.  Any spillage 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 diesel.
13. 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.
14. The DieselCaptain has the following safety labels affixed to the underside of the pump cover. These labels should be kept clean and legible, and replaced if damaged.

IMPORTANT
DIESEL FUEL ONLY
CAUTION

• Do not exceed vehicle manufacturers loading, towing or lifting specifi cations and regulations.
• Ensure tank is fi rmly secured in an appropriate manner.
• Use caution at all times, particularly when driving on rough or steep terrain.
• Comply with chemical manufacturers safety requirements and all relevant legislation.

Statement of Suitability

•  All TTi diesel tanks are manufactured Nathalia, Victoria and are suitable for the transportation of diesel fuel within Australia.
• The tank material has been tested to ensure it meets the mechanical and chemical resistance requirements of International Regulations ECE R34.01 Annex 5 Section 5.0 and European Directive 2000/8/EC.
•  The anti-static lead supplied on all TTi diesel tanks exceeds the requirements of AS1940-2004 and AS2809.2-2008. The filler caps and vents comply with AS 1940-2004.
•  Diesel fuel is NOT classified as a Dangerous Good, according to the Australian Code for the Transport of Dangerous Goods by Road and Rail, as stated in SDS provided by fuel companies.
•  Diesel fuel is NOT classified as a Flammable Liquid in Australia; it has the lower classification of ‘Combustible Liquid C1’, as stated in SDS provided by fuel companies.
• TTi diesel tanks meet the requirements of VSB6 National code of practice for Heavy Vehicle Modifications, section M fuel systems. TTi diesel tanks are classed as permanent mounted fuel tanks and do not require removal for re-fuelling.
•  TTi diesel tanks do not require a dangerous goods license when transporting diesel fuel. Dangerous goods notices are not required to be displayed when transporting diesel fuel.

General Information

Specifications

Description
The TTi Diesel Captain is designed to carry and dispense diesel fuel using the self-contained pump and fuel dispensing system. The DieselCaptain has the following features, refer to .

• Recommended Mounting Frame Design
• Component Identification
• Filling Operation

Tank
All TTi tanks are constructed from UV resistant, diesel grade, 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 integral filler cap with inlet filter is lockable, with the pump cover incorporating a padlock-able latch. Mounted to the top of the tank is a breather, to prevent damage to the tank structure when discharging diesel fuel.
Liquid Locker Safety Baffle System
The optional Liquid Locker baffle system within the tank demonstrates measurable improvements in braking performance and dynamic stability and controllability, and is available for 800L and above tanks. The system has been independently tested, with the report available upon request.
Pump
The Diesel Captain is optionally fitted with a range of 12V electric pumps, depending on the unit’s tank capacity. Fuel delivery ranges from 40L/min through to 80L/min. The pump has an integrated bypass valve, enabling the pump to run when the dispensing nozzle is not squeezed.
Hose and Nozzle
The Diesel Captain is supplied with either a 4m or 6m 3/4” diameter high quality diesel grade hose with crimped fittings, or 6M 1” diesel hose. The hose options are all fitted with an auto shut-off dispensing nozzle.
Flow Meters
Optionally available is a mechanical 5-digit electronic flow meter, mounted next to the dispensing nozzle.
Pump Power Supply
Power to the 12V electric pump options is supplied by the tow vehicle via integral 4m long cable and alligator clips.
Steel Frames
All Diesel  Captain tanks are available with optional skid frames, fully welded steel and hot-dip galvanised for long-lasting protection.
Machine Limitations
The Diesel Captain 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 Diesel Captain 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 DieselCaptain tank is full, as the unit will have a higher centre of gravity.

Operating Instructions

Before first use

Your Diesel Captain is delivered fully assembled. Once unpacked and before use, it needs to be setup following the instructions below:

1. Complete the warranty registration online at www.tti.com.au/warranty-registration, or use the Warranty Registration Card at the back of this handbook.

2. Store this handbook, along with the Tank Quality Check Form, 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 Diesel Captain if you are unfamiliar with its operation until you have read this handbook.

3.  Read and thoroughly understand this handbook, paying particular attention to all safety requirements, before using the Diesel Captain for the first time.

4. Check that all fittings, hoses, tank breather and electrical leads are secure following transit, and are not damaged in any way.

5. Inspect the tank for any damage or abrasions that may occur during transit.
   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.

6.  Position your Diesel Captain onto the vehicle and mount securely using tie-down straps located into the tie-down recesses on both sides of the tank, refer to Error! Reference source not found. The tie-down straps must be rated to at least the total mass of the unit when filled with diesel. A recommended frame design for mounting the Diesel Captain is shown at Figure 1, available as an option from TTi.

CAUTION
 The unit has pump options allowing for different voltages. Warranty is conditional on the unit being connected to the correct power supply.
The Diesel Captain is fitted with a DC electric powered pump and supplied with a 4m power cable fitted with alligator clips for direct connection to a battery. Ensure the pump is rated for the correct battery voltage, either 12 or 24 volts. A 240-volt AC pump option is also available. If the unit is to be mounted permanently to a vehicle, it is recommended that it is directly connected to the vehicle power system by a qualified auto electrician. The installation must incorporate a fuse in accordance with the pump manufacturer’s instructions (refer to the included pump handbook). The main components of the Diesel Captain are illustrated at. Component Identification

Operation

Filling the Diesel Captain
The unit’s tank is filled as follows:
WARNING
 Ensure the filling area is in an open, well ventilated space. Ensure the static lead is properly connected to a metal earth point.

1. If fitted, unlock and remove the padlock securing the Diesel Captain’s cover, then open the cover to access the pump and associated components.

2.  Uncoil and connect the static lead (earth strap), refer to Figure 3, to a suitable earth point, such as a metal part of the vehicle’s tray or chassis.

3.  If fitted, unlock and remove the padlock securing the filler cap.

4.  Remove the filler cap and inspect the internal filler neck filter Filling Operation
   is clean. If any contaminates are detected, lift the filter out and clean it.
   CAUTION The Diesel Captain must never be left unattended while being filled with diesel.

5.  Insert the filling nozzle and fill the tank, ensuring it does not overflow.

6.  Remove the filling nozzle and replace the tank filler cap.

7.  Disconnect the static lead, carefully coiling and stowing it adjacent to the pump.

8. Close the Diesel Captain’s cover and if necessary, secure it with the padlock removed previously.

Transferring Diesel
Fuel from the Diesel Captain is transferred from its integral tank to the tank being refilled as follows. Always ensure the refuelling operation takes place in a well-ventilated area.
NOTE
 Ensure the static lead is properly connected to a metal earth point.

1. Uncoil and connect the static lead (earth strap), refer to Figure 3, to a suitable earth point on the vehicle or equipment being filled, such as a metal part of the chassis.

2.  Check that the breather located on the top of the tank is clear and not obstructed in any way.
   CAUTION Always connect the negative power cable’s alligator clip to the power supply first, followed by the positive. Ensure the clips are connected securely to the correct terminals.

3.  If not hardwired to the vehicle, uncoil the DieselCaptain’s 4m power cable and connect the alligator clips to a battery Battery Connection
   or power supply in the following order:

   • a. Connect the blue negative lead to the negative terminal on the battery first, then
   • b. Connect the red positive lead to the positive terminal on the battery.

4.  If fitted, unlock and remove the padlock securing the filling nozzle.

5.  Remove the filler cap from the tank to be filled and insert the filling nozzle.
   CAUTION The Diesel Captain must never be left unattended while transferring diesel.

6.  Switch the pump ON and depress the filling nozzle trigge. Pump Switch and Filling Nozzle
   Fill the tank with the required quantity of fuel, or until the auto-shut nozzle cuts off the supply. Do not attempt to overfill the tank, as this may cause a diesel spillage.

7. Switch the pump OFF and withdraw the filling nozzle. Coil the hose, taking care to prevent kinks or tangles and return it to its home on the DieselCaptain. If necessary, secure the filling nozzle with the padlock removed previously.

8.  If any diesel spillage has occurred, clean it up in accordance with relevant environmental and safety requirements.
   CAUTION Always disconnect the positive power cable’s alligator clip from the power supply first, followed by the negative.

9.  If not hardwired to the vehicle, disconnect the alligator clips from the battery or power supply in the following order:

   • a. Disconnect the red positive lead to the positive terminal from the battery first, then

   • b. Disconnect the blue negative lead to the negative terminal on the battery.

10.  Carefully coil the power cable and stow it in position on top of the pump.

11. Disconnect the static lead, carefully coiling and stowing it adjacent to the pump.

12.  Close the Diesel Captain’s cover and if necessary, secure it with the padlock removed previously.

Risk Assessment

Maintenance

Your Diesel Captain 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 minimizing 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 DieselCaptain. 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.
•  Inspect the filling nozzle, hoses, breather vent and fittings for any defects such as cracks, leaks or other signs or wear or damage. Replace any damaged components as necessary.
•  Unwind the hose fully to check that hose is in good order. Pressurise the line and check operation of the dispensing nozzle, including auto shut-off function.
•  Check for any signs of fuel leaks. If detected, investigate and rectify immediately.
• Check the condition of the electrical pump’s 12 cable and connectors.
•  If the Diesel Captain is to be stored for an extended period, ensure the tank and all pipelines are empty and are not pressurized. 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 Diesel Captain 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.
Daily Tasks
The following tasks are to be undertaken daily, or prior to each use, of the Diesel Captain unit. Weekly Tasks
The following tasks are to be undertaken each week or 10 operating hours, whichever occurs first. Monthly Tasks
The following tasks are to be undertaken each month or 20 operating hours, whichever occurs first. Three Monthly Tasks
The following tasks are to be undertaken every three months or 50 operating hours, whichever occurs first. Six Monthly Tasks
The following tasks are to be undertaken every six months or 100 operating hours, whichever occurs first. Twelve Monthly tasks
The following tasks are to be undertaken every twelve months or 200 operating hours, whichever occurs first. Two-Yearly tasks
The following tasks are to be undertaken every 24 months or 500 operating hours, whichever occurs first.

Maintenance Tasks

The Diesel Captain has been designed and built for minimal maintenance requirements, however to ensure a long and reliable unit life, the following tasks must be undertaken on a periodic basis. The frequency of these activities will depend on the nature of the operating environment and the operational hours of the Diesel Captain.
CAUTION
 Ensure the pump is disconnected from its power supply before undertaking any maintenance.

1. Unscrew the filler cap and withdraw the inlet filter. Clean the filter and replace it back into the filler neck. If the filter is damaged, discard it and replace it with a new inlet filter.
   NOTE The pump does not pick up the diesel in the very bottom of the tank. Over time, contaminants may build up in the bottom of the tank, depending on the quality of fuel obtainable.

2. Periodically, drain the tank to remove any contaminants that may build up in the bottom of it. Undertake this when the tank is empty using the following procedure:

   • Position the Diesel Captain such that a container can be placed underneath the drain bung, refer to Figure 6, and the unit is on a slope to facilitate complete draining.
   •  Loosen and remove the filler cap.
   • Loosen and remove the bung, taking care not to spill any diesel, refer to . Tank Drain Bung
   • Once all diesel has drained out, clean around the drain point and the bung, then replace it and tighten firmly.

3.  The vanes in the head of the pump will wear over time and require replacement. To extend the life of the vanes, ensure that the filters are kept clean and the tank free on contaminants. If a reduced flow rate is noticeable, or a squealing sound is heard, the pump will require immediate attention to prevent permanent damage to the pump.
   NOTE The pump’s strainer procedure is only applicable to the 60 litre per minute pump, optionally fitted to Diesel Captain units 400 litres and above.

4.  Periodically inspect the pump’s integrated strainer as a clogged strainer will reduce fuel flow and affect the life of the pump:

   •  Unscrew the plug-in head of the pump and remove the gauze mesh strainer.
   • Clean and check it thoroughly before replacing it. If damaged in any way, discard it and replace it with a new strainer.

5.  If the pump is squealing, clean the impeller and vanes as follows:

•  Remove the end cover by undoing the three socket head screws and lifting off cover.
•  Clean the impellor and vanes, taking care to remove any particles caught between the ends of the vanes and the housing.
•  Refit the cover, ensuring the screws are not overtightened.

Troubleshooting

If a fault develops with the Diesel Captain, the following trouble shooting table provides guidance to identify and rectify the problem.

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:

1. 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.
2.  Any charges for making service calls, clean up time and transport charges.
3.  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 ProductSupport@tti.com.au.

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.

References

• Trans Tank® International (TTi) » Helping to Develop & Protect the Land
• Warranty - Trans Tank® International (TTi)

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