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SAFETY

QUALIFICATIONS OF THE OPERATING PERSONNEL

Operating Manual MT 25 / 30 YT

Qualifications of the operating personnel

The owner is responsible for making sure that the employed
personnel possess the necessary qualifications for the
respective tasks.

The MT may be operated only by trained, qualified person-
nel authorised by the owner.

Personnel undergoing training and instruction may operate
the MT only under the supervision of an experienced
person.

The owner is responsible for training and instructing new
operators of the MT in the same scope and with the same care
whilst using this Operating Manual.

Summary of Contents for MT 25

Page 1: ...Operating Manual MAFI Trac MT 25 30 YT Terminal Trac get it rolling Production no 3280798 ...

Page 2: ... 3280798 3280799 3280801 3280802 3280832 Issue date 11 2012 Language English Copyright 2004 MAFI Transport Systeme GmbH This documentation and all parts thereof are copyright protect ed Any use or change made outside the strict limitations of the copyright law without the consent of MAFI Transport Systeme GmbH is not permitted and is punishable by law This particu larly applies to reproductions tr...

Page 3: ...Your MAFI Trac 27 Product description 28 Exterior view 29 Interior view 31 Operation 33 Opening and closing 34 Seating 37 Steering wheel 40 Rear view mirrors 45 Pedals 47 Heating Ventilation Air conditioning 48 Lighting 51 Instrument panel 54 Operating panel for automatic transmission 65 Multi function display 74 Vehicle electrical system 80 Practical features 82 Fire extinguisher optional 83 Hand...

Page 4: ...ystem 122 Fifth wheel coupling 123 Starting aid optional 124 Indicators on the multi function display 125 Towing 127 Emptying the fuel pre filter of the water separator 130 Inflating tyres 131 Technical data 133 Dimensions standard model 134 Weights 136 General specifications 137 Hydraulic system 138 Brake system 139 ...

Page 5: ...Operating Manual MT 25 30 YT 3 VEHICLE IDENTIFICATION Vehicle identification plate Production number ...

Page 6: ...cation plate Fig 1 Mounting location The vehicle identification plate is attached on the right side of the vehicle frame Fig 2 Vehicle identification plate On the vehicle identification plate you will find information on z vehicle type z production number z weights z cargo z battery 11 C25 003 007A 3 ...

Page 7: ...on number of your MAFI Trac is Specify the production number in all written communica tion with MAFI Providing this number simplifies answering your questions and ordering parts Door key Ignition key Please write down here the key number of the door and ignition keys to ensure that you can easily reorder keys 3 3 3 3 3 2 2 2 2 2 8 8 8 8 8 0 0 0 0 0 7 7 8 8 8 9 9 0 0 3 8 9 1 2 2 Door key Ignition k...

Page 8: ...6 Operating Manual MT 25 30 YT ...

Page 9: ...Operating Manual MT 25 30 YT 7 USER INSTRUCTIONS On this Operating Manual Content overview Warranty Liability Safety instructions Graphical aids Symbols ...

Page 10: ...this Operating Manual z practice using the operating elements and operating procedures of the MT after familiarising yourself with them theoretically and before actually using the MT z you do not activate any switches or try out any operating procedures with which you are unfamiliar z that you inform other users of all safety and warning instructions z adhere to the generally applicable regulation...

Page 11: ...ions In this chapter you will find information on using this Operating Manual Safety In this chapter you will find information on safety You will learn about remaining risks Your MAFI Trac In this chapter you will find an overview of your MT Operation In this chapter you will find information on operating the controls Handling In this chapter you will find information on working with the MT Transp...

Page 12: ...rules out warrantee and liability claims for personal injury and material damage when they result from the following z inappropriate use of the MT see Intended use on page 17 z ignoring the notes regulations and prohibitions of the Operating Manual z arbitrary constructional modifications on the MT z poor monitoring of parts that are subject to wear z improper and late maintenance and repair ...

Page 13: ... described to avoid these dangers WA R N I N G Dang er of injur y A symbol together with the word Warning warns about a possibly dangerous situation that endangers the health and life of persons Ignoring these safety instructions can result in serious injury possibly even death X Be sure to observe the measures described to avoid these dangers C A U T I O N Material damag es A symbol together with...

Page 14: ...everal symbols draw your attention to a sequence of tasks 3 The preceding symbol marks the result of a task that had been carried out Lists Lists without a compelling order are displayed as lists with bullet points z entry 1 z entry 2 Cross references Cross references indicate where further information can be found on the topic see Symbols on page 13 Additional information This tip provides you wi...

Page 15: ...bol marks safety instructions that must definitely be observed A detailed description of the safety instructions can be found in the section Safety instructions on page 11 Regulations Symbols of this type mark notes on using personal safety gear A detailed description of the notes can be found in the section Personal safety gear on page 23 Note tip This symbol marks general notes ...

Page 16: ...14 Operating Manual MT 25 30 YT ...

Page 17: ...Operating Manual MT 25 30 YT 15 SAFETY General information Intended use Other dangers Qualifications of the operating personnel Personal safety gear Warning signs on the MAFI Trac ...

Page 18: ...s chapter is a basic pre requisite for safe handling and fault free operation of the MT In addition you will find further safety instructions in other chapters of this Operating Manual that also must be closely observed The safety instructions come before the operational instructions Safety instructions on third party components can be found in the respective third party documentation Follow those...

Page 19: ...y be seated on the foldaway seat only for the purpose of instructing and training the driver Please observe the engineering shop directive VMDA Guideline for the intended and proper use of industrial trucks and the accident prevention regulation Industrial Trucks BGV D27 If your MT is to be used for work not specified in these direc tives please consult your nearest MAFI representative Refittings ...

Page 20: ...porting extra persons on the MT or in the driver s cab z Moving or carrying loads that exceed the maximum permissible load z Transporting loads at speeds greater than the permitted maximum z Moving or transporting loads that cannot be safely secured by the available MT couplings ...

Page 21: ...on the MT repaired immediately by qualified technicians This concerns especially changes that can become a danger to persons and property Parking WA R N I N G Dang er of injur y A parked MT can roll away when the parking brake breaks down and injure persons X Additionally secure the MT with blocks Driving with towed loads D A N G E R Dang er of injur y Inappropriate driving behaviour in difficult ...

Page 22: ... must always be coupled to the stationary trailer Driving on ramps and inclines D A N G E R A c c i d e n t h a z a rd When driving on ramps and inclines the MT can tip or slide and thus get out of control X Drive up or down ramps and inclines only that are signposted as traffic routes and that can be negoti ated safely X Be sure that the ground is sufficiently clean and provides enough traction T...

Page 23: ...rtain inspection and maintenance work for instance when checking the transmission oil level In closed rooms there is the hazard then of a life threatening carbon monoxide poi soning if the fumes are inhaled X Start the engine on in well ventilated rooms X Otherwise vent the motor s exhausts to the outside X If possible avoid starting the motor in closed rooms ...

Page 24: ...ecessary qualifications for the respective tasks z The MT may be operated only by trained qualified person nel authorised by the owner z Personnel undergoing training and instruction may operate the MT only under the supervision of an experienced person The owner is responsible for training and instructing new operators of the MT in the same scope and with the same care whilst using this Operating...

Page 25: ... reduce the risk of cut injuries and crushing of hands and fingers by wear ing work gloves Safety boots Wear safety boots while working on the MT You reduce the risk of crushing of feet and toes by wearing safety boots Ear protection Wear ear protection while working on the MT By wearing ear protection you prevent damage to your hearing ...

Page 26: ... are part of the Operating Manual z Ensure the legibility of the signs at all times z Replace any damaged or missing signs Replacement signs are available from any MAFI representative Fig 4 Attachment warning signs part 1 1 Warning sign Fifth wheel 2 Warning sign Articulated shaft 3 Warning sign Rotating machinery 4 Warning sign Coolant 5 Warning sign Electric voltage 11 C25 000 013A 3 ...

Page 27: ... Manual MT 25 30 YT 25 Fig 5 Attachment warning signs part 2 1 Warning sign Battery 2 Warning sign Fifth wheel 3 Warning sign Cabin tilt 4 Warning sign Cabin support 5 Warning sign Cabin lowering 6 Warning sign Tightening Torque 11 C25 000 014A 5 6 ...

Page 28: ...SAFETY WARNING SIGNS ON THE MAFI TRAC 26 Operating Manual MT 25 30 YT ...

Page 29: ...Operating Manual MT 25 30 YT 27 YOUR MAFI TRAC Product description Exterior view Interior view ...

Page 30: ...e MT is an industrial truck with fifth wheel coupling It is designed for the special usage requirements in z terminal traffic in ports z shipping postal and railway terminals z loading cargo cars from semi trailers z industrial use with the Cargotrailer system lift trucks and semi trailers ...

Page 31: ...r s side 1 Transmission cover 2 Front sling points 3 Fifth wheel with saddle plate 4 Cover 5 Main battery switch 6 Pneumatics compartment and Battery compartment with main fuses 7 Ladder 8 Hand pump for lifting lowering the driver s cab 9 Exterior rear view mirror 10 Connection column 11 C25 000 010A 3 ...

Page 32: ...Fig 7 View right side 1 Warning beacon 2 Exterior rear view mirror 3 Equalising reservoir for motor coolant 4 Windscreen washer tank 5 Cabin door 6 Exhaust 7 Ladder 8 Oil viewing window for hydraulic oil 9 Hydraulic tank fuel tank 10 Fifth wheel with saddle plate ...

Page 33: ...R VIEW Operating Manual MT 25 30 YT 31 Interior view Fig 8 Interior view 1 Joystick for fifth wheel 2 Steering wheel 3 Operator control panel 4 Pedals 5 Central electric box 6 Fold away seat 7 Driver s seat 11 C25 067 060A 4 ...

Page 34: ...32 Operating Manual MT 25 30 YT ...

Page 35: ... Opening and closing Seating Steering wheel Rear view mirrors Pedals Heating Ventilation Air conditioning Lighting Instrument panel Operating panel for automatic transmission Multi function display Vehicle electrical system Practical features ...

Page 36: ...ocking unlocking cabin door Fig 9 Cabin door 1 unlock 2 lock Door operation Handling the door outside Fig 10 Handling the door outside Open X Unlock the door X Press in the cylinder lock X Pull the door open by the door handle 3 The door is opened Close X Push the door by the handle in the direction of the arrow until the door latches in 3 The door is closed ...

Page 37: ...ose X Pull the door by the door handle 2 to the inside until the door latches in 3 The door is closed Latching in the door WA R N I N G Dang er of being crushed An unsecured cabin door could move freely and thus injure you X Make sure that the cabin door is always latched X Push the cabin door into the lock to stop it banging closed Securing Fig 12 Latching in the door 1 Latch 2 Catch X Swing the ...

Page 38: ... is released Windows Fig 14 Window driver s side Open X Release the catch X Keep the catch pressed down and slide the window in the direction of the arrow 1 X Latch in the window in the desired position Close X Release the catch X Keep the catch pressed down and slide the window in the direction of the arrow 2 X Latch in the window in the desired position The window can be latched in in various po...

Page 39: ... adjustment 4 Rear seat tilt adjustment 5 Back rest tilt Lateral adjustment Use lever 1 to adjust the seat s position laterally towards the steering wheel and pedals X Lift the lever 1 3 The seat s catch is released X Adjust the position X Let go of the lever 1 3 The seat is locked in position Longitudinal adjustment Use lever 2 to adjust the seat s position towards the steering wheel and pedals X...

Page 40: ...to the rear with lever 4 X Lift the lever 3 The seat s catch is released X Adjust the seat tilt X Release the lever 3 The seat is locked in position Angle adjustment of back rest The angle of the back rest can be adjusted by lever 5 X Lift the lever 5 3 The back rest s catch is released X Adjust the back rest s angle X Let go of the lever 5 3 The back rest is locked in position ...

Page 41: ...not twisted X The tongue has to click audibly into the belt lock X When installing a new seat belt make sure you use only seat belts approved by MAFI Fig 16 Seat belt 1 Belt lock 2 Release 3 Tongue of the lock Putting on the belt X Pull the seat belt across your hips X Press the lock tongue 3 into the belt lock 1until you hear it click in X Pull the seat belt tight Releasing the belt X Press butto...

Page 42: ...fficult to manoeuvre can injure persons Personal injury and property damage may result X Move the MT only when the motor is running X Do not let the MT roll while the motor is not running Steering wheel adjustment The steering wheel is adjustable in height and angle WA R N I N G A c c i d e n t h a z a rd When adjusting the steering the vehicle is not safely manoeuvrable An MT that is difficult to...

Page 43: ... catch is released X Adjust steering column height X Turn the lever to position 1 3 The steering column is latched into position Angle adjustment Fig 19 Angle adjustment 1 Releasing the catch 2 Latching in the steering column X Turn the lever to position 2 3 The steering column catch is released X Adjust the steering column angle X Turn the lever to position 1 3 The steering column is latched into...

Page 44: ...ipers Turn indicator High beam headlamp Fig 20 Operation 1 Turn indicator left 2 High beam headlamp 3 Horn 4 Turn indicator right Turn indicator Fig 21 Function indicator turn indicator 1 Trailer 2 Vehicle X Press the combination switch in the direction of the arrow 1 or 4 3 The function indicators on the multi function display flash The combination switch remains in its position after the turn ha...

Page 45: ...when there is oncom ing traffic X Press the combination switch in the direction of the arrow 2 3 High beam is switched on The function indicator lights up on the multi function display 2 blue X Press the combination switch again in the direction of the arrow 2 3 Dipped beam is switched on Front windscreen wiper Fig 23 Operation 1 Windscreen washer 2 Windscreen wiper off 3 Intermittent wiper 4 Norm...

Page 46: ...3 Intermittent wiping is active X Turn the switch to position 4 3 Normal wiping is active X Turn the switch to position 5 3 Fast wiping is active Operating the windscreen washer X Press the switch in the direction of the arrow 1 3 The windscreen washer is in operation as long as you press the switch ...

Page 47: ...w mirror control unit 1 Rear view mirror downwards 2 Rear view mirror inwards 3 Rear view mirror upwards 4 Rear view mirror outwards Rear view mirror heater optional Fig 25 Switch for rear view mirror heater Both outer mirrors can be heated The control switch is located in the instrument panel Switching the heater on X Press the switch 3 The mirrors are heated continuously Switch off the heater on...

Page 48: ... damag e The wide angle rear view mirror doesn t reflect objects and distances to scale You can damage property when driving in reverse with wide angle rear view mirrors because you cannot judge distances and sizes of objects well X When driving in reverse look backwards or turn the seat to face the rear so that you can judge distances better ...

Page 49: ...hazard Loose objects in the cabin can block the pedals This can cause you to lose control of the MT and could lead to accidents X Do not to store loose objects in the driver s cab X Secure loose objects so that they cannot obstruct the pedals Brakes X Press one of the brake pedals 2 3 The MT is braked Starting up Accelerating X Press the accelerator 1 3 The MT accelerates ...

Page 50: ...r s seat Fig 29 Operation 1 Blower off 2 Maximum blower output 3 Switch air conditioning unit optional 4 Heater completely closed 5 Heater completely open Set ventilation The ventilation can be set in four steps by the blower switch X Turn the blower switch in the direction of the arrow 2 level 3 maximum blower output X Turn the blower switch in the direction of the arrow 1 level 0 blower off Air ...

Page 51: ...ir conditioner X Regardless of the time of year switch the air condi tioner on for about fifteen minutes at least once a month to keep it operational X Observe the maintenance intervals recommended by the manufacturer Heater X Turn the heater switch in the direction of the arrow 5 3 Heating output is increased X Turn the heater switch in the direction of the arrow 4 3 Heating output is reduced Aux...

Page 52: ...erior Some nozzles can be set manually and thus change the direction of the airflow Adjusting the airflow direction Fig 31 Adjusting the airflow 1 Main outlet nozzles 2 Drum type outlet nozzles X Swivel the outlet nozzles or the fins of the drum type outlet nozzles in the desired direction Notes on the optimal setting z To defrost the windows keep the main outlet nozzles closed z To heat the cabin...

Page 53: ...ng light is switched on X Press the switch to stage 2 3 The headlight is switched on The status of the headlight is indicated in the multi function display Hazard lights Fig 33 Switch for hazard lights Switch the hazard lights on whenever you have to stop in an emergency You can thereby warn others about possible dangers The switch for the hazard lights is installed in the instrument panel Switchi...

Page 54: ...he switch 3 The warning beacon is switched on Operational spotlight rear Fig 35 Operational spotlight switch Use the rear operational spotlight when coupling and uncoupling in the dark You increase safety The switch is installed in the instrument panel Switching on the operational spotlight X Press the switch 3 The operational spotlight is switched on 11 C25 067 009A 5 11 C25 067 011A 5 ...

Page 55: ...rument panel Switching on the operational spotlight X Press the switch 3 The operational spotlight is switched on Interior lighting A combined interior lamp reading lamp is installed in the cabin ceiling Operation The lighting and the reading lamp can each be controlled by a switch Fig 37 Lighting 1 Lighting switch 2 Reading lamp switch 3 Swivelling reading lamp 2 ...

Page 56: ...verview Fig 38 Instrument panel 1 Control elements 2 Multi function display 3 Ignition 4 Combination lever 5 Steering wheel 6 Gear shift lever for transmission 7 Heating Ventilation Air conditioning 8 Joystick for fifth wheel 9 Driver s seat 8 7 1 2 3 1 4 5 9 11 C25 067 038A 8 6 ...

Page 57: ... the ignition key to position I X Wait until the preheating light goes out X Turn the ignition key to position III 3 The motor starts X Release the ignition key 3 The ignition key goes automatically back to position I 11 C25 067 039A 4 0 Ignition off all electrical loads are switched off ignition key can be withdrawn I MT is ready for operation ignition is on electrical loads such as radio two way...

Page 58: ...ea In this case immediately switch off the engine and have the vehicle checked at qualified specialist shop to determine and eliminate the cause of the warning If the red warning light 2 illuminates then z a serious engine malfunction is present z the engine has to be turned off immediately When the red warning signal occurs immediately turn off the engine Tow the MT out of the work area and have ...

Page 59: ...ne problem one of the warning lights go on If you read the error codes the engine has to be turned off and the ignition key has to be in the I position X Turn the ignition key to position 0 3 The engine and the ignition are turned off X Turn the ignition key to position I 3 The ignition is switched on X Press the Diagnostics on off switch 2 to ON 3 The error reading is activated X Scroll the Diagn...

Page 60: ...tiple errors are present if further error codes are found and read when scrolling with the Diagnostics selection rocker switch Consult the manufacturer s instruction manual for nformation on the diagnostic function and the meaning of the flash sequences Thereby the three digit number represents the flash code and the displayed colour represents the warning light that was glowing while the engine w...

Page 61: ... normally between 700 and 750 rpm Adjusting the idle speed Set the MT onto an even surface activate the parking brake and let the engine run in idle position with the transmission in neutral X Press the rocker switch upwards 3 The idle speed increases X Press the rocker switch downwards 3 The idle speed is reduced Press the rocker switch up or down until the motor runs smooth again However keep th...

Page 62: ... warning signal the motor switches off automatically When the acoustic signal is given the control light Bypassing the safety switch off lights up C A U T I O N Material damag es Bypassing the safety switch off can lead to serious damage of the motor X Only bypass the safety switch in a case of emergency The safety switch off can be bypassed when leaving a danger zone Fig 44 Button with control li...

Page 63: ...when the MTL is parked stand ing horizontally level If the control light illuminates frequently within a short period have the cause for the warning inspected by a qualified garage immediately to avoid engine dam ages Parking brake Fig 46 Parking brake switch Apply the brakes X Press the switch at bottom 3 The function indicator on the multi function display is lit The parking brake is engaged Rel...

Page 64: ...ial lock may only be switched on when the MT is stationary Fig 48 Control light for rear axle differential lock Activating the rear axle differential lock X Press the MODE key 1 MODE ON LED indicator 2 is lit 3 The control light Rear axle differential lock lights up when the rear axle differential lock is switched on Release rear axle differential lock X Press the MODE key 1 MODE ON LED indicator ...

Page 65: ...ame is lowered After releasing the button the air suspension bellows are inflated again and the vehicle frame is raised again to the normal level Joystick for fifth wheel Fig 51 Joystick for fifth wheel 1 Joystick 2 Button 3 Lowering 4 Lifting You can lift and lower the fifth wheel using the joystick The button 2 of the joystick has no function in the standard model Lowering X Press the joystick i...

Page 66: ... Locking kingpin control light Both control lights glow if the kingpin and the fifth wheel coupling are locked Unlock X Press both switches at the same time 3 The control lights go out The fifth wheel coupling and the kingpin are opened or unlocked You can unhitch Radio optional Fig 53 Audio system Consult the manufacturer s instruction manual for infor mation on how to operate the audio system 5 ...

Page 67: ...n 7 Mode ON LED indicator 8 Display Basic rules for operating the automatic transmission Follow the safety instructions to avoid damage to property and accidents with the MT C A U T I O N Material damag es Operating errors can damage your MT X Apply the parking brake only when the MT is at standstill X Shift into neutral N only when the MT is standing and applied parking brake or main brake X Chan...

Page 68: ...when the MT is at standstill Apply the main brake or the parking brake and shift the transmission into neutral position Display during driving Fig 55 Two part display during driving 1 SELECT 2 MONITOR During driving the two part display indicates the highest achievable gear of the selected driving gear on the left side next to SELECT 1 Generally this display corresponds to the key selection on the...

Page 69: ...n Fig 57 Neutral position N idle position X Start the engine When the motor is started the control unit automatically preselects the neutral position N 3 The motor runs at idle speed The motor can only be started in the neutral position N When you want to shift from reverse R or normal drive D into neutral N make sure that the wheels stand still and that the parking brake or main brake is applied ...

Page 70: ... the button D In the driving gear D the transmission shifts automatically from the first to the fourth gear After selecting the driving gear D the lowest programmed gear start up gear is inserted for this driving gear The shifting procedure depends on the motor speed and the load of the MT Always shift from the neutral position and with wheels standing still into the driving gear D M O N I T O R R...

Page 71: ...r driving program Down arrow lower driving program The current driving range is displayed by the display on the right side MONITOR The selected driving range is displayed by the display on the left side SELECT The arrow keys can be activated during driving MODE key Fig 60 Additional function 1 MODE key 2 MODE ON LED indicator The MODE key features an additional function Within the MODE key is the ...

Page 72: ...AUTOMATIC TRANSMISSION 70 Operating Manual MT 25 30 YT The MODE key is assigned with the additional function for switching on and off the rear axle differential lock For further information see Rear axle differential lock on page 62 ...

Page 73: ... the MT on a level surface apply the parking brake and shift the transmission into neutral The oil has to be at operating temperature for the oil level check Read oil level X Press the two arrow keys 1 and 2 once at the same time You can read out the oil level or an error message on the oil measuring in the display 5 For further information on reading out the oil level from the Oil level mode disp...

Page 74: ... MODE KEY 3 you can open the error codes of d2 to d5 The error code consists of a letter and a four digit number e g P0722 Example of an error code display d1 P 07 22 This means that the error code P0722 is stored in d1 If there is no error the displays shows the following d1 The list of error codes can be found in the documentation of the transmission manufacturer Opening diagnostics mode X Park ...

Page 75: ...the other by pressing the MODE key By pressing the MODE ON key 4 you can differ between the current and saved error codes z The MODE ON LED indicator is lit when the displayed error code is active i e is current z The MODE ON LED indicator goes out when the displayed error code is inactive i e has been saved Ending diagnostics mode To exit the diagnostics mode perform one of these three steps z Do...

Page 76: ...I FUNCTION DISPLAY 74 Operating Manual MT 25 30 YT Multi function display Overview Fig 63 Multi function display 1 Control and warning function indicators 2 Illuminated LCD 3 Buttons warning and activation indicators ...

Page 77: ... h or mph z motor rpm speed Pressure indicator Fig 65 Pressure indicator 1 Button Brake pressure 2 Buttons Transmission oil pressure 3 Button Motor oil pressure 4 Pressure indicator With the buttons 1 2 and 3 you can read the pressures de scribed below The value is shown in the display at position 4 All pressures are shown in bar Switch 1 z air reserve pressure circuit 1 z air reserve pressure cir...

Page 78: ...sired position 1 2 or 3 3 The corresponding air reserve pressure is shown in the LCD display The selected indicator remains active until you switch to a new indicator On board voltage indicator Fig 67 On board voltage indicator 1 On board voltage indicator 2 On board voltage indicator button The on board voltage indicator shows the current charging voltage of the vehicle battery The display indica...

Page 79: ...at could damage the MT are indicated by an LED under the relevant button and a warning signal sounds see Indicators on the multi function display on page 125 Selecting the temperature indicator X Press switch 1 3 The transmission oil temperature is displayed in the LCD display X Press switch 2 3 The motor coolant temperature is displayed in the LCD display The selected indicator remains active unt...

Page 80: ...on page 125 Information selection X Press button 1 3 The number of operating hours is indicated in the LCD display The selected indicator remains active until you switch to a new indicator or switch off the ignition Fuel gauge Fig 70 Fuel gauge 1 Fuel gauge button 2 Fuel gauge You can check the fuel supply with button 1 If there are deviations from the specifications or other malfunc tions on the ...

Page 81: ...form about the status of certain controls Warning indicators Fig 72 Warning indicators 1 Malfunction air reserve pressure combo message circuit 1 to 3 2 Transmission fault 3 Motor malfunction 4 Intake air filter blockage The warning indicators notify you about conditions that should not be ignored otherwise damage to the MT can be done Information on cause and repair can be found in chapter SELF H...

Page 82: ...ge the generator the electrical equipment and the controllers X Do not turn off the main battery switch while the motor is running Switching the main battery switch Fig 73 Main battery switch 1 ON position 2 OFF position X Turn the main battery switch horizontally 3 The electrical connection is made X Turn the main battery switch vertically 3 The electrical connection is interrupted Switch the mai...

Page 83: ...icle fuses are located to the right of the operator in a compartment The exact layout can be read from the supplied circuit diagram External start socket optional Fig 75 External start socket The external start socket is located on the left side of the vehi cle between the entrance steps The socket can be used to give or receive starting aid 11 C25 019 008 3 ...

Page 84: ...pen X Pull the flap in the direction of the arrow 1 Remove X Press the ashtray downwards arrow direction 2 opening it at the same time Sun screen The roller sun screen on the front windscreen safeguards you from being dazzled while driving Fig 78 Sun screen Lowering roller screen X Pull the roller screen down in the direction of the arrow 1 to the desired position Lifting roller screen X Pull brie...

Page 85: ...OPERATION FIRE EXTINGUISHER OPTIONAL Operating Manual MT 25 30 YT 83 Fire extinguisher optional Fig 79 Fire extinguisher The fire extinguisher is attached to the cabin floor next to the driver s seat ...

Page 86: ...OPERATION FIRE EXTINGUISHER OPTIONAL 84 Operating Manual MT 25 30 YT ...

Page 87: ... Manual MT 25 30 YT 85 HANDLING Starting check Starting the engine Shifting gears Driving instructions Turning off the motor Working with coupling equipment Operation with container chassis Winter operation Care ...

Page 88: ...elow WA R N I N G Dang er of injur y Neglected or insufficient inspections can lead to con siderable personal injury and property damage X Carry out all checks carefully X Always follow the instructions on whether to perform the inspections while the motor should be running or off C A U T I O N Material damag es Not following the sequence of checks can damage the MT X First perform all the checks ...

Page 89: ...etighten all wheel nuts with the specified torque before the initial operation or after the wheel exchange X Retighten the torque of the wheel nuts after the first drive under load the latest though after 24 operating hours Fig 80 Tightening order X Tighten the wheel nuts crosswise Make sure tightening torques for the wheel nuts are correct Use a torque key for retightening the wheel nuts Fig 81 T...

Page 90: ...are cold z deformations bulges z damaged wheel rims z missing or loose wheel bolts and nuts z extremely unevenly worn tyres Main battery switch The main battery switch is lpcated on the outside of the pneu matics and battery compartment The switch breaks the elec trical connection of the vehicle battery to the electrical consumers Fig 82 Main battery switch 1 ON position 2 OFF position X Check whe...

Page 91: ...luid X Check underneath the MT if you can see oil and or water pools 3 If this is the case then you need to make a closer inspec tion to find the cause The following sources are possible z oil loss motor transmission axle transmission z loss of coolant motor z battery acid ...

Page 92: ...nd allow the pressure to escape completely before opening X Wear suitable protective gloves clothing and goggles when handling coolant WA R N I N G Dang er of poisoning There is a danger of poisoning when you swallow coolant X Never swallow coolant X Never pour coolant into drinking containers Fig 83 Equalising reservoir X Check the motor coolant level The coolant level should always lie between t...

Page 93: ... goes above MAX or falls below MIN X Use only motor oil that has been authorised Fig 84 Transmission cover X Insert the square into the opening arrow X Turn the square 3 The cover is unlocked X Open the cover Fig 85 Oil dip stick and oil filler neck 1 Oil filler neck 2 Oil dip stick X Pull the oil dip stick 2 X Wipe off the oil dip stick 2 with a clean lint free cloth X Insert the oil dip stick 2 ...

Page 94: ...cessary Add anti freeze to the washer water at freezing temper atures to keep the water from freezing Hydraulic oil level The hydraulic oil tank is located on the vehicle s right side To check the oil level you need to lower the fifth wheel completely Fig 87 Oil viewing window X Check the oil level at the oil viewing window The oil level should lie between the MIN and MAX markings X If required re...

Page 95: ...eck the oil level with the oil dip stick or read it out on the display Oil level mode in the operating panel In order to check the oil level precisely the following conditions must be met z The MT is parked on level ground z The transmission is shifted into neutral N z The engine is running at low idle speed z The transmission output shaft stands still i e the MT does not more z The oil temperatur...

Page 96: ...between 60 C and 93 C The operation temperature can be read from the tempera ture indicator in the multi function display The operational temperature is reached when the transmis sion has run under load for at least one hour X Park the MT on level ground for the oil level check X Shift the transmission into neutral N and apply the parking brake X Let the engine run at low idle speed 500 to 800 rpm...

Page 97: ...l several times In case the oil levels deviate from each other make sure that the transmis sion venting is not plugged If you still determine greater deviations contact the customer service to have the fault rectified Only qualified technicians may top up the transmission oil ...

Page 98: ...l check X Shift the transmission into neutral N and apply the parking brake X Let the engine run at low idle speed 500 to 800 rpm Read oil level Fig 91 Operating panel 1 Arrow key down 2 Arrow key up 3 Display Oil level mode X Press the two arrow keys 1 and 2 once at the same time After about two minutes you can read the oil level in the display 3 If one of the above mentioned conditions for oil l...

Page 99: ...y Check the fuel supply level before you drive the MT It is indi cated in the LCD display of the multi function display Refuel when the fuel level is low see Refuelling on page 106 Oil level sensor error Cause oL 0X Settling time too short Setting time too oL EL Engine speed Low Motor speed too low oL EH Engine speed High Motor speed too high oL SN Select Neutral Not in neutral oL TL Temperature L...

Page 100: ...eds to be replaced in regular intervals For more information on maintaining the air dryer read the maintenance manual Central lubrication optional The central lubrication system automatically lubricates all lubricating point on non rotating parts at preset intervals X Check the fill level regularly of the lubricant in the reserve tank X Refill with lubricant if necessary Consult the manufacturer s...

Page 101: ...o be met z The main battery switch needs to be switched on z The gear shift lever for the transmission has to be on NEUTRAL Depending on the type of engine and the ambient tempera tures various start procedures are possible Starting with the cold start system Fig 93 Ignition Switch positions of the ignition lock 11 C25 067 039A 4 0 Ignition off All electrical loads are switched off ignition key ca...

Page 102: ...on I Starting without the cold start system Fig 95 Ignition Switch positions of the ignition lock Starting procedure X Make sure that the transmission is shifted to the Neutral position X Turn the ignition key to position III 3 The motor starts X As soon as the engine begins to run release the ignition key 3 The ignition key goes back to position I 11 C25 067 076A 4 11 C25 067 039A 4 0 OFF all ele...

Page 103: ...perating errors can damage your MT X Apply the parking brake only when the MT is at standstill X Shift into neutral N only when the MT is standing and applied parking brake or main brake X Change the driving direction forwards or reverse only when the MT is standing still and the motor is at idle speed X Always shift into neutral position N before switching off the motor WA R N I N G Accident haza...

Page 104: ...own for a longer period then the main battery switch has to be switched to OFF to prevent the bat tery from discharging Checks before driving Carry out the following checks before you start driving the MT z Make sure that no persons are situated in the danger area of the MT D A N G E R Dang er of injur y People can be severely injured by being crushed during shunting X Always make sure that there ...

Page 105: ...ard Loose objects in the cabin can block the pedals This can cause accidents owing to losing control of the MT X Do not to store loose objects in the driver s cab X Secure loose objects so that they cannot obstruct the pedals Use the storage net for instance Driving with towed loads The driver is responsible for safely loading the cargo z Always adjust the speed to the circumstances when driving w...

Page 106: ...the ground is sufficiently clean and provides enough traction Take special care on snow and ice X The vehicle must be driven at reduced speed on inclines X Drive carefully when crossing steep inclines Fig 96 Driving on ramps and inclines z With coupled load drive uphill with the load in front if possible pushing z When driving down hill drive with the tractor in front If for operational reasons it...

Page 107: ...acles is more difficult X Drive with adjusted speed when the rear axle differential lock is engaged X Note that the steering radius is greater The driver can use the switch any time However the rear axle differential lock may only be switched on when the MT is stationary The rear axle differential lock stays engaged as long as you hold the rear axle differential lock button down see Rear axle diff...

Page 108: ...l level is too low The fuel tank is located on the vehicle s right side D A N G E R Dang er of injur y Fuel is easily flammable and harmful to health X Fire naked flames and smoking are prohibited when handling fuels X Avoid fuel from coming into contact with skin or clothing X Do not breath in fuel fumes C A U T I O N M o t o r d a m ag e s You can damage the injection system and starter if you t...

Page 109: ...g off the motor too early can cause heat to build up and damage the motor X Do not turn the motor off immediately when you have just subjected the MT to high loads X Run the motor at idle speed for a few more minutes with the transmission in neutral Fig 98 Ignition X Turn the ignition key to position 0 11 C25 067 039A 4 ...

Page 110: ...er run onto the MT X The MT must always be hitched to the stationary trailer D A N G E R Dang er of injur y If the fifth wheel coupling is not properly locked the trailer can run loose and injure persons X Be sure the fifth wheel coupling control light is lit The fifth wheel coupling is properly locked then C A U T I O N Material damag es Obstacles above the trailer can cause damage when lifting w...

Page 111: ... supply lines First discon nect the supply line red then the brake line yel low Hitching procedure Fig 99 Connections 1 Electrical connection 2 Supply line red 3 Brake line yellow X Lower the fifth wheel coupling until you can drive underneath the semi trailer The kingpin needs to lock in properly X Drive carefully in reverse The kingpin and the fifth wheel coupling have to lock in and the control...

Page 112: ...ling head of the supply line red the semi trailer is braked by that Then after that disconnect the coupling head of the brake line yellow X Hook the coupling heads into the intended holding fixtures You thereby protect the coupling heads from soiling and damage X Engage the reverse gear and release the parking brake X Roll backwards slightly with the MT X Press both switches simultaneously 1 on th...

Page 113: ...l experience with handling a gooseneck X Make sure that work with a gooseneck is done only by trained personnel Transporting roll trailers WA R N I N G Accident hazard On bumpy roads the roll trailer can come off the goose neck and cause injuries and damages X Drive slowly on rough roads X Drive the gooseneck into the roll trailer Always be sure that you are driving in straight X Lift the roll tra...

Page 114: ...owing the MT itself WA R N I N G Dang er of injur y There is a danger of considerable injury and damage when you use towing and shunting couplings to pull trailers X Do not pull trailers with tow bars using towing and shunting couplings X Trailers with tow bars may be coupled only to trailer equipment approved for this application Fig 102 Towing coupling front Fig 103 Towing coupling rear ...

Page 115: ...uip ment on page 108 The following notes must be observed during the hitching and unhitching of the MT with the saddled container chassis C A U T I O N Material damag es If hitching or unhitching the container chassis improp erly damages to the chassis and or the MT s air sus pension may occur X Make sure that the container chassis stands on the supports during the loading and unloading proce dure...

Page 116: ...ould adapt the operating materials in the MT to low temperatures z Use winter diesel or add a flow enhancing additive to the fuel otherwise This prevents paraffin from coagulating in the fuel which can reduce or block the fuel supply z Use a motor oil suitable for the ambient temperature Oil should be changed by qualified technicians z The motor coolant has to contain enough anti freeze agent to p...

Page 117: ... speed and without load after washing You can use a high pressure cleaner to clean the MT C A U T I O N Proper ty damag e Incorrect handling of the high pressure cleaner can cause paint damage or short circuits X Keep the cleaner nozzle at a distance of at least 50 cm from the painted surfaces during cleaning X Never use a high pressure cleaner with a cone nozzle X Do not spray perpendicular onto ...

Page 118: ...HANDLING CARE 116 Operating Manual MT 25 30 YT ...

Page 119: ...Operating Manual MT 25 30 YT 117 TRANSPORT Loading onto a flatbed trailer Loading with a crane ...

Page 120: ...nger distances Make sure that the transport equipment can carry the weight of the MT see Vehicle identification plate on page 4 D A N G E R Dang er of injur y Ignoring safety regulations when transporting the MT can lead to considerable personal injury or property damage X Only transport the MT when there is no load coupled to it X Attach the safety devices only to points intended for this ...

Page 121: ...ing on the cover of the transmission has to be removed WA R N I N G Dang er of being crushed Removing a pneumatic spring means that the cover of the transmission can fall shut and injure you X Always wear your own personal protective equipment when attaching hoisting gear Removing pneumatic spring Fig 104 Removing pneumatic spring 1 Transmission cover 2 Nut X Open the cover 1 X Release the nut 2 o...

Page 122: ...ng points 2 Transmission cover Fig 106 Rear sling point X Attach the hoisting equipment to the points intended for this 3 The MT can be hoisted now carefully and loaded away During lifting the MT tilts forward slightly so that the hoisting equipment cannot damage the driver s cab ...

Page 123: ... Manual MT 25 30 YT 121 SELF HELP Electrical system Fifth wheel coupling Starting aid optional Indicators on the multi function display Towing Emptying the fuel pre filter of the water separator Inflating tyres ...

Page 124: ...eck the fuses The exact layout of the fuses can be read from the supplied circuit diagram X If necessary replace the defective fuse with a new fuse of the same type and strength D A N G E R Dang er of fire By inserting stronger fuses you may risk burning cables X Always note for what amperage the electrical loads are made for X Always replace the defective fuses with fuses of the same type and str...

Page 125: ...danger of crushing of body parts when unhitching the fifth wheel coupling in an emergency X Make sure that nobody is near the trailer X Make sure that the trailer is lowered fully onto its supports and secured against rolling away X Set the trailer down on its supports X Secure the trailer against rolling away X Disconnect all electrical and brake lines see Working with coupling equipment on page ...

Page 126: ...OPTIONAL 124 Operating Manual MT 25 30 YT Starting aid optional External start socket Fig 109 External start socket In case the starter batteries are discharged the MT can be started with the help of the external start socket ...

Page 127: ...erature of motor coolant LED flashes Liquid level too low X Check system for leaks have qualified technicians rectify cause for liquid loss if necessary X Check liquid level and refill if necessary Overheating due to working under heavy load X Switch transmission to NEUTRAL X Run the motor at idle speed until it drops back to normal temperatures Insufficient air flow rate through the radiator X Cl...

Page 128: ...ce repair Intake air filter warning indicator lights up Intake air filter is blocked X Replace air filter see maintenance manual Parking brake function indicator lights up red even though the parking brake is released Air pressure in reserve tank 5 2 bar or Sensor defective X Check system for leaks X Allow motor to run until air pressure in reserve tank is 5 2 bar X Have qualified technicians rect...

Page 129: ...dan shaft between drive axle and transmission needs to be dismantled C A U T I O N Tr a n s m i s s i o n d a m ag e If you tow the MT for longer distances while the motor is not running and the cardan shaft installed the trans mission will be significantly damaged due to missing oil lubrication X Dismantle the cardan shaft before towing for longer distances If there isn t sufficient compressed ai...

Page 130: ...braked MT can roll away and run over persons X Secure the MT against rolling away before you release the spring loaded component of the parking brake with the emergency release unit X Secure the MT against rolling away X Turn out the screw bolt 1 of the emergency release unit completely on all wheels with spring brake actuator ...

Page 131: ...g becomes more difficult during towing and the brakes do not work The accident hazard is increased X Make sure that the tractor that is towing the MT can safely brake the weight of the MT X When towing use a towing rod that is strong enough Ropes and chains are not permitted X Drive only at low speed ...

Page 132: ...n handling fuels WA R N I N G Dang er of injur y and poisoning Fuels can cause poisoning and irritate the skin if they are inhaled or make contact with body parts X Wear protective clothing when working with fuels Fig 112 Fuel pre filter with water separator 1 See Thru Plastic Bowl 2 Self venting drain valve X Place a suitable collection container underneath the fuel pre filter X Open the self ven...

Page 133: ...y The tyre inflating connection 1 is located in the pneumatics compartment X Start the motor X Remove the protection cap from the tyre inflating connection 1 X Attach the tyre inflating hose not part of the scope of delivery X Inflate the tyres X Drive to the garage and inflate the tyres to the specified pressure The output of the compressor is not enough to inflate the tyres to the specified tyre...

Page 134: ...SELF HELP INFLATING TYRES 132 Operating Manual MT 25 30 YT ...

Page 135: ...Operating Manual MT 25 30 YT 133 TECHNICAL DATA Dimensions standard model Weights General specifications Hydraulic system Brake system ...

Page 136: ... MODEL 134 Operating Manual MT 25 30 YT Dimensions standard model Fig 114 Dimensions of the MT 25 Dimensions depending on wheel base Wheel base Standard Extended WB 3000 mm 3500 mm L 5372 mm 5872 mm RT 2020 mm 2520 mm RS 2080 mm 2580 mm ...

Page 137: ...ons of the MT 25 Dimensions depending on tyres Values A D may be reduced by 50 mm at lowered rear axles air suspension Tyres 10R20 11R22 5 11R20 12R22 5 315 60R22 5 A 925 mm 940 mm 880 mm B 1060 mm 1075 mm 1015 mm C 1590 mm 1605 mm 1545 mm D 2025 mm 2024 mm 1980 mm E 3200 mm 3215 mm 3155 mm ...

Page 138: ...TS 136 Operating Manual MT 25 30 YT Weights MT 25 MT 30 Empty weight 4 x 2 7 500 kg 7 500 kg Permissible 5th wheel load at 6 km h with standard tyres 25 000 kg 32 000 kg System weight trac trailer load 80 000 kg 90 000 kg ...

Page 139: ...2 kW 172 kW Mercedes MTU OM 906 LA at 2200 min 1 170 kW 170 kW Starting tractive force in 1st gear standard motor 120 kN 133 kN Continuous sound intensity level in cabin DIN 45635 part 36 72 dB A 72 dB A Fuel tank approx 260 l approx 260 l Tyres standard Air tyres with inner tube 10 00 R 20 Tubeless air tyres 11 00 R 20 Fifth wheel coupling standard 2 inch king pin 2 inch king pin Electrical syste...

Page 140: ...inders for front axle steering Two double action hydraulic cylinders step type optional for lifting the fifth wheel coupling MT 25 MT 30 Pump supply rate at 2200 min 1 70 l min 70 l min Max continuous pressure Steering 170 bar 170 bar Hydraulic lift system 210 bar 250 bar Hydraulic oil tank approx 90 l approx 90 l ...

Page 141: ...nual MT 25 30 YT 139 Brake system Two circuit brake system with dual line trailer brake connection MT 25 30 Front axle pneumatically actuated Rear axle pneumatically actuated Parking brake spring loading unit acting on the rear and front axle ...

Page 142: ...TECHNICAL DATA BRAKE SYSTEM 140 Operating Manual MT 25 30 YT ...

Page 143: ...2 lighting system 88 loss of oil or fluid 89 main battery switch 88 motor coolant 90 motor oil level 91 transmission oil level 93 wheels tyres 88 windscreen washer water level 92 Instrument panel Coolant liquid level 61 Releasing the fifth wheel coupling 64 Rocker switch 59 Warning lights 56 instrument panel air cushioned rear axle 63 hazard lights 51 headlight 51 ignition 55 joystick for fifth wh...

Page 144: ...onnection 131 semi trailer unhitching 110 starting aid 124 starting check 86 102 steering wheel 40 steering wheel adjustment 40 storage 82 sun screen 82 T technical data brake system 139 dimensions 134 general specifications 137 hydraulic system 138 weights 136 Tightening torques of the wheel nuts 87 towing and shunting coupling 112 trailers hitching 108 transport flat bead 118 loading 119 tyre pr...

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MAFI MT 25, Operating Manual

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