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MAFI MT 25, Maintenance Manual

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MAFI MT 25 Maintenance Manual Download Page 13

USER INSTRUCTIONS

MAFI SERVICE

Maintenance manual MT 25 / 30 YT

11

MAFI Service

The MT belongs to the class of industrial trucks.

According to the Sections 37, 38, 39 Accident Prevention reg-
ulations “Industrial Trucks” (BGV 27D) industrial trucks shall be 
checked by a specialist as necessary, however, at least once 
a year. The results of the test are to be recorded in a test jour-
nal.

Carefully keep and file the test journal, for it is important as 
documentation for the Employers Vehicle Liability Insurance 
Association.

MAFI also offers maintenance contracts as well as an annual 
service check for the safety examination legally required under 
Sections 37, 38, 39 of the German accident prevention regu-
lations “Industrial Trucks” (BGV 27D).

Our trained personnel provide fast and competent mainte-
nance and repairs.

Summary of Contents for MT 25

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

Page 2: ...mber 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 pro tected 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 particularly applies to reproductions...

Page 3: ...21 Personal safety gear 22 Warning signs on the MAFI Trac 23 Your MAFI Trac 25 Product description 26 Exterior view 27 Interior view 29 Maintenance work 31 Maintenance schedule 32 Lubricating points 36 Tilt driver s cab 39 Motor 42 Cooling system 45 Air filter 52 Fuel system 54 Drive train 56 Compressed air system 66 Hydraulic system 70 Fifth wheel Fifth wheel coupling 74 Wheels and tyres 77 Air c...

Page 4: ...2 Maintenance manual MT 25 30 YT Disposing of operating materials 98 MAINTENANCE CERTIFICATES 103 General 104 Maintenance certificate 105 ...

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

Page 6: ...ication 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 answer ing 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 ...

Page 8: ...6 Maintenance manual MT 25 30 YT ...

Page 9: ...USER INSTRUCTIONS Maintenance manual MT 25 30 YT 7 USER INSTRUCTIONS On this Maintenance manual Content overview Warranty Liability MAFI Service Safety instructions Graphical aids Symbols ...

Page 10: ... this Maintenance manual z That after familiarising yourself theoretically with the oper ating elements and maintenance procedures of the MT you practice these before actually using the MT z You do not activate any switches or try out any operating procedures with which you are unfamiliar z Inform other users about all safety instructions and warn ings z Adhere to the generally applicable regulati...

Page 11: ...structions 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 Maintenance work In this chapter you will find information on the various mainte nance tasks and the intervals in which they need to be pre formed Opera...

Page 12: ...alid MAFI rules out war rantee and liability claims for personal injury and material dam age when they resulting from z Inappropriate use of the MT see Intended use on page 17 z Ignoring the notes regulations and prohibitions of the Maintenance manual z Arbitrary constructional modifications on the MT z Poor monitoring of parts that are subject to wear z Improper and late maintenance ...

Page 13: ...st once a year The results of the test are to be recorded in a test jour nal Carefully keep and file the test journal for it is important as documentation for the Employers Vehicle Liability Insurance Association MAFI also offers maintenance contracts as well as an annual service check for the safety examination legally required under Sections 37 38 39 of the German accident prevention regu lation...

Page 14: ...escribed to avoid these dangers WA R N I N G Dang er of injur y A symbol in connection with the word Warning warns about a possibly dangerous situation that endangers the health and life of persons Ignoring these safety instruc tions 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 in connec...

Page 15: ... Several 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 bul let 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 14 Additional information This tip provides you...

Page 16: ...ing This symbol 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 12 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 22 Note tip This symbol marks general notes ...

Page 17: ...Maintenance 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 chap ters of this Maintenance 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 th...

Page 19: ...e 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 attachments and retrofittings on the MT may only be done upon consultation with MAFI Spare parts ancillary attachments extra installations and accessory...

Page 20: ...tions 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 on steep inclines 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 operating c...

Page 21: ... always be coupled to the stationary trailer Driving on ramps and inclines D A N G E R Accident hazard 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 pro vides enough traction Take special car...

Page 22: ...ertain inspection and maintenance work for instance when checking the transmission oil level In closed rooms there is the haz ard then of a life threatening carbon monoxide poisoning 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 23: ...qualifications for the respec tive tasks z The MT may be maintained only by trained qualified per sonnel authorised by the owner z Personnel undergoing training and instruction may maintain the MT only under the supervision of an experienced per son The owner is responsible for training and instructing new main tenance personnel of the MT in the same scope and with the same care whilst using this ...

Page 24: ...u reduce the risk of cut injuries and crushing of hands and fingers by wearing 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 25: ...rt of the operating manual z Ensure the legibility of the warning signs at all times z Replace any damaged or missing signs Replacement signs are available from any MAFI repre sentative 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 26: ...0 YT 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 27: ...Maintenance manual MT 25 30 YT 25 YOUR MAFI TRAC Product description Exterior view Interior view ...

Page 28: ...he 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 29: ...er 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 30: ... 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 31: ... VIEW Maintenance manual MT 25 30 YT 29 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 Foldaway seat 7 Driver s seat 11 C25 067 060A 4 ...

Page 32: ...30 Maintenance manual MT 25 30 YT ...

Page 33: ...NCE WORK Maintenance schedule Lubricating points Tilt driver s cab Motor Cooling system Air filter Fuel system Drive train Compressed air system Hydraulic system Fifth wheel Fifth wheel coupling Wheels and tyres Air conditioner Electrical system Air suspension ...

Page 34: ...er s operating manual Change oil filter X X X X X Manufacturer s operating manual Turbocharger Check turbocharger X Manufacturer s operating manual Check air hoses for leakage X X X X Manufacturer s operating manual Motor electrical system Check complete motor electrical system X X X X X Manufacturer s operating manual Cooling system Check coolant level daily Page 45 Check cooling system X X X X P...

Page 35: ...Check transmission oil level daily Page 57 Change oil and oil filter2 3 X X X Manufacturer s operating manual Axle differential Check oil level X X X X X Manufacturer s operating manual Change oil X X Manufacturer s operating manual Check venting with every oil change Manufacturer s operating manual Planetary gears in the wheels Check oil level X X X X X Manufacturer s operating manual Change oil2...

Page 36: ... operating manual Setting the initial position of the brake shoes after replacing the brake linings Manufacturer s operating manual Check the setting and function of the brake rods adjuster X X X Manufacturer s operating manual Hydraulic Check oil level daily Page 70 Change hydraulic oil2 X Page 72 Change oil filter2 X X Page 72 Check oil level hand pump driver s cab monthly Page 73 Check hydrauli...

Page 37: ...evel weekly Page 82 Check battery charge status charge battery X X X X X Page 82 Check battery poles and connections X X X X X Page 82 Electrical system Check lighting system daily Page 83 Check fuses X X X X Page 84 Air suspension Check air suspension bellows X X X Page 86 Air conditioning unit See manufacturer specifications for inter vals Manufacturer s operating manual 1 The maintenance tasks ...

Page 38: ...oupling If your MT is equipped with a central lubrication system then check if any fresh grease leaks out of the lubricating points and if there is enough lubricating grease in the reserve tank The lubricating points at the cardan shaft always needs to be lubricated by hand because they cannot be serv iced by the central lubrication system Front and rear axle need to be relieved during lubrica tio...

Page 39: ...xles Top steering knuckle connection 9 5 2 Bottom steering knuckle connection 9 6 2 Axle suspension Front bearing of front axle 10 1 2x1 Rear bearing of front axle 10 2 2x2 Outer bearing of rear axle 10 3 2x1 Inner bearing of rear axle 10 4 2x1 Driver s cab Driver s door top hinge 9 3 1 Driver s door bottom hinge 9 4 1 Brake Linkage adjuster front axle 9 6 2 Brake shaft bearing front axle 9 6 2 Li...

Page 40: ...MAINTENANCE WORK LUBRICATING POINTS 38 Maintenance manual MT 25 30 YT Fig 9 Lubricating points Fig 10 Lubricating points ...

Page 41: ...raised completely cannot be secured against lowering There is a danger of being crushed due to lowering of the driver s cab X Lift the driver s cab until the end stop X Use the pump lever to secure against unintentional lowering C A U T I O N Material damag es Loose objects can damage the interior and glass panels during lifting lowering of the driver s cab X Make certain that no loose objects are...

Page 42: ...the opening 1 The pump lever is located in the pneumatics compartment X Bring the valve lever 2 to the OFF position X Pump with the pump lever 3 The driver s cab is lifted X Pump until the end stop is reached Fig 14 Securing the driver s cab X Insert the pump lever into the openings 1 and 2 3 The driver s cab is secured against unintentional lower ing ...

Page 43: ...ab 1 Opening 2 Valve lever X Insert the pump lever into the opening 1 X Bring the valve lever 2 to the DOWN position X Pump with the pump lever 3 The driver s cab is lowered X Pump until the end stop is reached 3 The driver s cab locks automatically X Store the pump lever in the pneumatics compartment Fig 16 Hexagon head screws for fastening the cabin 1 Hexagon head screws X Insert the hexagon soc...

Page 44: ...le protective gloves and cloth ing that protects you from hot motor parts WA R N I N G Dang er of injur y Rotating motor parts can catch pull in and thereby crush or maim body parts Allow all motor parts to come to a stop before beginning with test and maintenance work on the motor X Allow all motor parts to come to a stop before begin ning with test and maintenance work on the motor X Wear closed...

Page 45: ...ill C A U T I O N Motor damag e An oil level that is too high or too low can damage the motor X Make sure the oil level never goes above MAX or falls below MIN X Use only motor oil that has been authorised Check the oil only when the motor is at standstill and still warm from operation Make sure the MT is parked on level ground The oil dip stick and the oil filler neck are located behind the drive...

Page 46: ...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 all the way back in X Pull the oil dip stick out again 2 The oil level should lie between the MIN and MAX mark ings X Refill motor oil into the oil filler nozzle 1 if necessary 11 C25 003 008A 2 11 C25 060 004A 3 ...

Page 47: ...ld skin and eyes X Open the cooling system only when the coolant s tem perature is below 90 C X Unscrew the cap at the equalising reservoir slowly and allow the pressure to escape completely before open ing X Wear suitable protective gloves clothing and goggles when handling coolant Fig 20 Equalising reservoir X Check the coolant level The coolant level should always lie between the MIN and MAX ma...

Page 48: ...g system z air or exhausts in the cooling system that force the coolant out through the vents of the cooler cap z damaged cylinder head gasket z defective cooler cap Coolant temperature A too high temperature indication can be caused by z coolant level too low z air in the cooling system z plugged cooling system z defective fan fan drive z defective thermostat z defective coolant thermometer z err...

Page 49: ...n the cooling system only when the coolant s tem perature is below 90 C X Unscrew the cap at the equalising reservoir slowly and allow the pressure to escape completely before open ing WA R N I N G Dang er of poisoning There is a danger of poisoning when you swallow cool ant X Never swallow coolant X Never pour coolant into drinking containers WA R N I N G Dang er of injur y A falling underrun pro...

Page 50: ...rew the fas tening screws for that X Unscrew the protection cap from the drain valve Fig 23 Cooler drain hose X Screw the supplied hose onto the drain valve 3 Open the drain valve and the coolant can drain off X Collect the coolant in a suitable container Clean the cooling system The cooling system needs to be cleaned each time the coolant is changed You can rinse out the cooling system with clear...

Page 51: ...ditioning unit The ventilation of the heating system is thereby ensured dur ing the filling X Slowly fill coolant through the opening of the equalising res ervoir until the fill level lies between the MIN and MAX markings Make sure that no air bubbles develop and that the air in the system can escape through the opening X Start the motor Run the motor at low speed 3 The cooling system is vented X ...

Page 52: ... a visual inspection of the charge air cooler from the front Look for soiling by insects or foreign objects The soiling pre vents an unhindered airflow through the cooler Clean the cooler only with water and a mild grease dissolving detergent Never use high pressure cleaners or compressed air for cleaning That damages the cooler X Check the pipe fins for damage due to stone impact X Check if the s...

Page 53: ...ed from soiling from behind Fig 27 Cooler block 1 Charge air cooler 2 Combination cooler motor transmission oil X Tilt the driver s cab see Tilt driver s cab on page 39 and secure the driver s cab X Blow compressed air 4 bar max from behind through the cooler block If the temperature of the coolant is still too high even after carrying out the maintenance then the cooler block needs to be removed ...

Page 54: ...g 28 Check air filter 1 Clamps 2 Filter cartridge 3 Housing cap X Stop the motor and withdraw the ignition key X Clean the area around the housing cap 3 of the air filter X Check the air filter for external damage X Loosen the clamps 1 and remove the housing cap 3 X Check the housing cap 3 for soiling and clean the area around the housing cap if necessary X Replace the housing cap 3 and fasten it ...

Page 55: ...around the housing cap 3 of the air filter X Loosen the clamps 1 and remove the housing cap 3 X Clean the housing cap X Pull the filter cartridge 2 out X Clean the inside of the housing with a clean cloth paying special attention to the sealing surfaces X Insert the new filter cartridge 2 the right way around X Press the filter cartridge 2 into the housing X Replace the housing cap 3 and fasten it...

Page 56: ...heck fuel lines for leaks and external damage Have leaky nicked or defective coolers replaced by qualified technicians Location of fuel filter and fuel pre filter with water separator Fig 30 Installation location of fuel filters 1 Fuel filter 2 Pre filter with water separator Both filters are located under the cover of the transmission on the right side 11 C30 060 011A 4 ...

Page 57: ...smoking and creating sparks must be avoided when handling fuels X Avoid fuel from coming into contact with skin or cloth ing X Do not breath in fuel fumes We recommend cleaning the fuel tank at low fill levels X Park the MT on level ground X Stop the motor and withdraw the ignition key X Place a suitable collection container underneath drain plug X Unscrew the drain plug completely Have a new seal...

Page 58: ...rs differential gears of the axle wheel hub gears transfer the motor power to the wheels Only the rear axle 4x2 is driven Lubricate cardan shaft Cardan shafts are rotating components They need to be lubri cated manually even if a central lubrication system is installed Lubricating points and lubricating cycle see section Lubricat ing points on page 36 ...

Page 59: ... oil level check just before the motor is started the first time after the commissioning or the oil change to make sure that the filled in amount of oil is sufficient for the cold check z Conduct a cold check after the first motor start and cold transmission oil to make sure that the amount of oil is enough for a reliable operation until the warm check z Conduct a hot check when the oil is at oper...

Page 60: ...time check the oil level with the oil dip stick X Make sure the oil level is in the HOT CHECK range 3 while the oil is cold and the motor is at standstill X Use only authorised types of transmission oil Fig 33 Oil dip stick 1 Oil filler nozzle 2 Oil dip stick 3 HOT CHECK range 4 COLD CHECK range X Check the oil level with the oil dip stick before you start the motor for the first time Make sure th...

Page 61: ...he wheels additionally with blocks Fig 34 Oil dip stick 1 Oil filler nozzle 2 Oil dip stick 3 HOT CHECK range 4 COLD CHECK range C A U T I O N Tr a n s m i s s i o n d a m ag e During the cold check the oil is still cold and has less expansion as oil at operating temperature Due to the greater expansion of the oil at operating tem perature at too high oil level may damage the transmis sion X Make ...

Page 62: ...e speed in shift position N for about one minute X Pull the oil dip stick out X Wipe the oil dip stick with a clean lint free cloth X Reinsert the dip stick completely X Pull the oil dip stick out again The oil level should lie in the COLD CHECK range between the COLD ADD and COLD FULL markings X If necessary refill oil into the oil filler nozzle or drain oil At the first opportunity conduct the h...

Page 63: ...ck X The oil level should never exceed the HOT FULL or drop below the HOT ADD marking of the oil dip stick X Use only authorised types of transmission oil WA R N I N G Accident hazard If you leave the MT while the motor is running the MT can start rolling unintentionally and seriously injure per sons X Always be sure to shift the transmission into neutral N before exiting the MT and apply the park...

Page 64: ...hould lie in the HOT CHECK range between the HOT ADD and HOT FULL markings X If necessary refill oil into the oil filler nozzle or drain oil Check the oil level 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 cus tomer service to have the fault rectified During the daily oil l...

Page 65: ... the oil level mode X Use only authorised types of transmission oil The transmission is equipped with an oil level sensor You can read out the oil level and the oil level sensor errors on the dis play in the operating panel for the transmission In order to read out the oil level without error the following con ditions must be met z The MT is parked on level ground z The transmission is shifted int...

Page 66: ...R R N D S E L E C T MODE 11 C25 067 084A 9 1 2 3 Oil level indicator Explanation oL ok Oil level is OK Oil Level ok oL Lo 1 Oil level 1 litres too little Low low oL Lo 2 Oil level 2 litres too little etc oL HI 2 Oil level 2 litres too much High high oL HI 3 Oil level 3 litres too much etc Oil level sensor error Cause oL 0X Settling time too short Setting time too oL EL Engine speed Low Motor speed...

Page 67: ...t the sensor check the oil level with the oil dip stick In case the oil level is correct but the error at the sensor oL FL is still displayed contact cus tomer service to rectify the fault Ending the oil level check X Press both arrow keys 1 and 2 until N N is displayed in the display ...

Page 68: ...z air suspension of the rear axle Check compressor Fig 37 Compressor 1 Suction line 2 Compressed air line 3 Compressor X Carry out a visual inspection of the compressor Check for leaks X Check the compressed air line suction line and the connec tors for leaks Look for fractures nicks and deformations Have defective lines replaced by qualified technicians Check suction line Fig 38 Suction line X Lo...

Page 69: ... some oil car bon deposits X In case of heavy oil carbon deposits have the compressor additionally checked by a specialist X Reinstall the compressed air line X Connect the compressed air line with the fasteners 1 Check compressed air tank Fig 40 Compressed air tank 1 Circuit 1 Compressed air brake of the rear axle 2 Circuit 2 Compressed air brake of the front axle 3 Circuit 3 Parking brake traile...

Page 70: ...ewatering valve by which you can drain the condensation water Fig 41 Dewatering valve X Park the MT on level ground X Stop the motor and withdraw the ignition key X Open the valve by pulling the ring in the direction of the arrow 3 The water can drain X Keep the ring pulled until no more water comes out Check in case of heavy water collection whether the function of the air dryer cartridge is stil...

Page 71: ... a year WA R N I N G Dang er of injur y When working on compressed air system there is a risk of injury from suddenly emitted compressed air X Make sure that the compressed air system is depres surised X Carry out the maintenance only on depressurised sys tems X Make sure that the motor cannot be switched on X Park the MT on level ground X Stop the motor and withdraw the ignition key X Release the...

Page 72: ...a danger of injury from hydraulic oil spraying out suddenly at high pressure X Make sure that the hydraulic system is depressurised X Carry out the maintenance only on the depressurised hydraulic system X Make sure that the engine cannot be switched on Check 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 co...

Page 73: ...me at the level of the steps The emergency release cock is accessible from the right side of the vehicle It is secured by a lock nut WA R N I N G Dang er of injur y There is a danger of injury if body parts get crushed when lowering the fifth wheel X Make sure that nobody is near the fifth wheel or near the trailer X Make sure that the trailer is lowered fully onto its sup ports and secured agains...

Page 74: ...new hydraulic oil through the oil filter Note the filling quantity see Filling quantity on page 96 X Check the level of the fill level and check the hydraulic sys tem for leaks Use only clean oil and a clean container for filling the system Replace hydraulics filter Fig 47 Oil filter 1 Filter cartridge 2 Filter housing cap X Park the MT on level ground X Stop the motor and withdraw the ignition ke...

Page 75: ... hoses and connection pieces WA R N I N G Dang er of injur y With damaged hydraulic hoses and connection pieces there is a danger of injury from hydraulic oil spraying out suddenly at high pressure X If there are oil spots under the MT check immediately where the leak comes from X Rectify the cause for the leak immediately X Pay attention to firmly seated hydraulic hoses and connection pieces X Re...

Page 76: ...ing locks automatically when the king pin is inserted It can be released by compressed air WA R N I N G Dang er of being crushed Persons can be injured when the fifth wheel is lowered unintentionally X When working beneath the fifth wheel be sure to secure it with sufficiently sized supports e g wooden beams In case of an emergency the fifth wheel coupling can be opened mechanically by the emergen...

Page 77: ...control light 2 needs to be lit X Press both switches simultaneously 1 to unlock the fifth wheel coupling 3 The control light 2 should go out If the result of the function test is negative then check if there is a defect at the electrical lines and switches or whether the position of the sensor needs to be reset Setting sensor Fig 50 Limit switch X Check the gab 5 mm between sensor and switching p...

Page 78: ...w locking screw with Loctite 242 and tighten the screw using the specified torque from 730 to 750 Nm Do not retighten screws that have been glued with Loc tite Replace any screws that become loose with new screws X Check the tightness of the axle bearing The axle bearing should be in the middle between the bearing supports Lateral play of 0 5 to 1 5 mm is permitted One sided displacement or the ex...

Page 79: ...erformed by qualified technicians only Checking the tightening torques Fig 52 Tightening order X Be sure to retighten all wheel nuts with the specified torque before the initial operation and 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 X Tighten wheel nuts crosswise see Fig 52 Make sure tightening tor...

Page 80: ... bolts wheel nuts Tyre inflating connection Fig 54 Tyre inflating connection The tyre inflating connection can be used for filling the tyres in an emergency The tyre inflating connection is located in the pneumatics com partment Tyre pressure X Start the motor X Remove the protection cap from the tyre inflating connec tion X Attach the tyres inflating hose not part of the scope of deliv ery X Infl...

Page 81: ...ditioner condenser can cause the air conditioner to turn off due to over heating Checking the dryer collector unit The dryer collector unit is installed in front of the right wheel arch in the bumper Fig 56 Dryer collector unit 1 Viewing window 2 Indicator bead 3 Coolant level too low 4 Coolant level OK Checking the coolant level X Check the level of the indicator bead When the coolant level 3 is ...

Page 82: ...d by a rubber mat Fig 58 Main battery switch 1 ON position 2 OFF postion A main battery switch breaks the electrical connection of the vehicle battery to the electrical consumers WA R N I N G Electric shock The cable and the connection of the rotary current alter nator are under voltage even when the main battery switch is turned off That is why repairs to the rotary current alternator can cause d...

Page 83: ...n contact with skin and eyes X Avoid contact with skin eyes or clothing X Wear suitable protective gloves as well as protective clothing and goggles X Rinse acid sprays immediately with clean water and consult a doctor WA R N I N G Explosion dang er Gases emitted from batteries may explode and thereby injure persons X Fire naked flames smoking and creating sparks must be avoided near batteries ...

Page 84: ...cid level of vehicle battery on page 82 X Loosen the battery terminals and take them off Note sequence first negative battery pole then positive battery pole X Screw out the sealing plugs X Connect the charger Note sequence first connect the positive battery poles then negative battery poles of battery and charger X Switch on the charger X Once the battery is charged disconnect the charging device...

Page 85: ... the function of the reverse lights when reverse gear is put in and or the swivel seat is turned 180 for driving in reverse Replacing light bulbs Front lights Fig 61 Front lights X Loosen the fastening screws and remove the lens or glass panel X Replace the bulb with a light of the same type X Replace the lens or glass panel and tighten them with the fastening screws Warning beacon Fig 62 Warning ...

Page 86: ...appropriate amperage A burned out fuse may therefore never be bypassed or exchanged for a fuse of a higher current intensity Fig 63 Central electric box 1 Crew on key 2 lock 3 unlock Fig 64 Central electric box The electrical vehicle fuses are located to the right of the oper ator in a compartment 11 C25 019 008 3 11 C25 019 008A 4 ...

Page 87: ...L SYSTEM Maintenance manual MT 25 30 YT 85 Fig 65 Main fuse In addition to the individual vehicle fuses there are two main fuses They are located behind the batteries in the pneumatics and battery compartiment 11 C25 019 006A 3 ...

Page 88: ... is without effect Fig 67 Air suspension button You can lower the vehicle frame in order to take up parked low trailers Lowering is done by letting out the air of the air sus pension bellows of the rear axle X Carry out a function inspection Deflate the air suspension bellows by pressing the air sus pension button After releasing the button the air suspen sion bellows are inflated again X Check th...

Page 89: ...Maintenance manual MT 25 30 YT 87 OPERATING MATERIALS General information Fuels Oils Coolant Lubricating greases Filling quantities ...

Page 90: ... operating materials X Make sure that no operating materials are spilled X Thoroughly rinse skin surfaces that have come in con tact with operating materials X In the event of contact with the eyes rinse out eyes for 10 to 15 minutes with clear water and consult a doctor immediately X Seek medical help immediate if operating material has been swallowed WA R N I N G Dang er of fire When handling fu...

Page 91: ...e documentation of the motor manufacturer z Only fuels according to DIN EN 590 with nationally adapted environmental and cold requirements may be used If other fuels are used that do not meet these standards then the warrantee becomes void z Kerosene heating oils and marine diesel fuels may under no circumstances be used as fuel for the diesel motor z Not every diesel motor is suitable for running...

Page 92: ...s in time before the beginning of the winter season Deviations are possible during the transition period and in various countries z Petroleum may be added at below 20 C z In case summer diesel fuel is necessary then petroleum can be added Keep the addition of petroleum as low as possible depending on the ambient temperature Follow the instructions on the mixing ratio prescribed in the d ocumentati...

Page 93: ...S QSB 6 7 172 kW 230 hp The MT motor has been filled at our plant with an oil of viscosity class SAE 15W 40 Designation Standard CF 4 CG 4 API American Petroleum Institute E 3 ACEA Association des Constructeurs Euro péene d Automobiles Designation Standard CH 4 Cl 4 API American Petroleum Institute E 5 E 7 ACEA Association des Constructeurs Euro péene d Automobiles ...

Page 94: ...Fig 68 SAE class motor oil Fig 68 shows which viscosity classes can be used in the var ious temperature ranges The temperature values refer to constant ambient air temper atures If the MT is to be used at temperatures below 25 C special lubricants are required Consult an authorised dealer for rec ommendations as to a suitable lubricant We recommend using synthetic lubricants only at tem peratures ...

Page 95: ...MT has been filled in the plant with an oil of the viscosity class SAE SAE 90 with GL5 quality Fig 69 SAE classe transmission oil Fig 69 shows which viscosity classes can be used in the var ious temperature ranges The temperature values refer to constant ambient air temper atures Hydraulic oil For the hydraulic system use hydraulic oil of the HLP ISO VG specification Fig 70 Viscosity classes hydra...

Page 96: ... is usually delivered filled with a mixture of tap water and concentrated coolant with anti freeze protection to 25 C If the MT is driven at temperatures below 25 C then increase the anti freeze protection according to the following table The system should be thoroughly flushed with each changing of the coolant see Change coolant on page 47 In cases in which no anti freeze is needed for example in...

Page 97: ...tional temperatures When selecting suitable lubricating greases the usage proper ties of the greases need to be taken into account in particular in addition to the operational conditions ambient conditions and lubrication cycles z For lubricating the lubricating points use a lithium multi pur pose grease according to DIN 51 502 z The battery poles are to be lubricated with acid resistant grease e ...

Page 98: ...0 YT Filling quantities Operating material Filling quantity Fuel approx 240 l Oils Motor See manufacturer specifications Transmission approx 35 l Axle gears differential transmission 18 l Planetary gears wheel hub gears 2x 1 5 l Hydraulic approx 85 l Coolant approx 40 l ...

Page 99: ...Maintenance manual MT 25 30 97 ENVIRONMENTAL NOTES Disposing of operating materials ...

Page 100: ...ly safe disposal of the various operating materi als Used oils Used oil needs to be taken care of when motor or transmission oil is changed Used oil belongs to the water endangering materials There fore special requirements are valid concerning handling and disposal z Make especially sure that no used oil can get into the sewer system or in the earth z Utilize secure collection containers when the...

Page 101: ...ulic oil carefully in used collecting containers Do not mix with other operating materials z Deposit the collecting container with the hydraulic oil at a collection point for used oil processing z Observe the regulations of the local authorities Filter cartridges and inserts and drying agent inserts The filter cartridges and inserts need to be taken care of dur ing an oil change and fuel filter ch...

Page 102: ...the refrigerant clean it and refill it into the air conditioner z This service may be provided by specialist companies only with the necessary technical equipment and the corre sponding technical certification z The disposal of refrigerants is the exception because refrigerants normally are cleaned by the recycling station and are refilled then z Basically the refrigerant needs to be disposed of a...

Page 103: ...irective and be registered at the federal environmental agency These agents need to be made of biodegradable washing active substances z Collect the residues in the original containers and drop them off at the collection point z Observe the regulations of the responsible local authori ties Observe the information on environmentally safe dis posal of the operating materials in the data sheets of th...

Page 104: ...ENVIRONMENTAL NOTES Disposing of operating materials 102 Maintenance manual MT 25 30 ...

Page 105: ...Maintenance manual MT 25 30 YT 103 MAINTENANCE CERTIFICATES General Maintenance certificate ...

Page 106: ... shop Because only those maintenance and additional works are considered as validly carried out that have been entered in the certification boxes and confirmed as described above Don t forget that if the maintenance certifications are not re corded the guaranty and liability claims towards MAFI be come void The maintenance schedule see Maintenance sched ule on page 32 contains the maintenance inte...

Page 107: ...MAINTENANCE CERTIFICATES Maintenance certificate Maintenance manual MT 25 30 YT 105 Maintenance certificate Fig 1 Certification boxes maintenance work Space for entries and additional work ...

Page 108: ...MAINTENANCE CERTIFICATES Maintenance certificate 106 Maintenance manual MT 25 30 YT Fig 2 Certification boxes maintenance work Space for entries and additional work ...

Page 109: ...MAINTENANCE CERTIFICATES Maintenance certificate Maintenance manual MT 25 30 YT 107 Fig 3 Certification boxes maintenance work Space for entries and additional work ...

Page 110: ...MAINTENANCE CERTIFICATES Maintenance certificate 108 Maintenance manual MT 25 30 YT Fig 4 Certification boxes maintenance work Space for entries and additional work ...

Page 111: ...MAINTENANCE CERTIFICATES Maintenance certificate Maintenance manual MT 25 30 YT 109 Fig 5 Certification boxes maintenance work Space for entries and additional work ...

Page 112: ...MAINTENANCE CERTIFICATES Maintenance certificate 110 Maintenance manual MT 25 30 YT Fig 6 Certification boxes maintenance work Space for entries and additional work ...

Page 113: ...MAINTENANCE CERTIFICATES Maintenance certificate Maintenance manual MT 25 30 YT 111 Fig 7 Certification boxes maintenance work Space for entries and additional work ...

Page 114: ...MAINTENANCE CERTIFICATES Maintenance certificate 112 Maintenance manual MT 25 30 YT Fig 8 Certification boxes maintenance work Space for entries and additional work ...

Page 115: ...MAINTENANCE CERTIFICATES Maintenance certificate Maintenance manual MT 25 30 YT 113 Fig 9 Certification boxes maintenance work Space for entries and additional work ...

Page 116: ...MAINTENANCE CERTIFICATES Maintenance certificate 114 Maintenance manual MT 25 30 YT Fig 10 Certification boxes maintenance work Space for entries and additional work ...

Page 117: ...MAINTENANCE CERTIFICATES Maintenance certificate Maintenance manual MT 25 30 YT 115 Fig 11 Certification boxes maintenance work Space for entries and additional work ...

Page 118: ...MAINTENANCE CERTIFICATES Maintenance certificate 116 Maintenance manual MT 25 30 YT Fig 12 Certification boxes maintenance work Space for entries and additional work ...

Page 119: ...MAINTENANCE CERTIFICATES Maintenance certificate Maintenance manual MT 25 30 YT 117 Fig 13 Certification boxes maintenance work Space for entries and additional work ...

Page 120: ...MAINTENANCE CERTIFICATES Maintenance certificate 118 Maintenance manual MT 25 30 YT Fig 14 Certification boxes maintenance work Space for entries and additional work ...

Page 121: ...MAINTENANCE CERTIFICATES Maintenance certificate Maintenance manual MT 25 30 YT 119 Fig 15 Certification boxes maintenance work Space for entries and additional work ...

Page 122: ...MAINTENANCE CERTIFICATES Maintenance certificate 120 Maintenance manual MT 25 30 YT Fig 16 Certification boxes maintenance work Space for entries and additional work ...

Page 123: ...MAINTENANCE CERTIFICATES Maintenance certificate Maintenance manual MT 25 30 YT 121 Fig 17 Certification boxes maintenance work Space for entries and additional work ...

Page 124: ...MAINTENANCE CERTIFICATES Maintenance certificate 122 Maintenance manual MT 25 30 YT Fig 18 Certification boxes maintenance work Space for entries and additional work ...

Page 125: ...MAINTENANCE CERTIFICATES Maintenance certificate Maintenance manual MT 25 30 YT 123 Fig 19 Certification boxes maintenance work Space for entries and additional work ...

Page 126: ...MAINTENANCE CERTIFICATES Maintenance certificate 124 Maintenance manual MT 25 30 YT Fig 20 Certification boxes maintenance work Space for entries and additional work ...

Page 127: ...n 48 Fill 49 Cooler air conditioner 79 Cooling system 45 D Dewater Compressed air tank 68 Dewatering valve 68 disposing of coolant 100 disposing of drying agent inserts 99 disposing of filter cartridges 99 disposing of hydraulic oils 99 disposing of maintenance and cleaning agents 101 Disposing of operating materials 98 disposing of operating materials 98 disposing of paper filter inserts 99 dispo...

Page 128: ...olant 94 Filling quantity 96 Lubricating greases 95 Oils 91 R Replace Air filter cartridge 53 Replacing Light bulbs 83 S Suction line 66 T transmission oil 57 63 Tyres 77 V Vehicle battery 81 W Wheels 77 ...

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