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Maintenance manual T225/T230

Publisher

MAFI-Transport-Systeme GmbH

Hochhäuser Strasse 18

D-97941 Tauberbischofsheim

Telephone: +49 9341/899-0

Fax: +49 9341/899-108

E-mail: [email protected]

Document type

Maintenance manual
Original Maintenance manual

Production number

326xxxx

Issue date

5.2012

Language

English

Copyright

© 2004, MAFI-Transport-Systeme GmbH

This documentation and all parts thereof are copyright
protected. 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,
translations, microfilming, and the storage and processing in
electronic systems.

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Summary of Contents for Trac T225

Page 1: ...Maintenance manual MAFI Trac T225 T230 Terminal Trac get it rolling Production no 326xxxx ...

Page 2: ...tion number 326xxxx Issue date 5 2012 Language English Copyright 2004 MAFI Transport Systeme GmbH This documentation and all parts thereof are copyright protected 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 translations microfilming ...

Page 3: ...rsonal safety gear 23 Warning signs on the MAFI Trac 24 Your MAFI Trac 27 Product description 28 Exterior view 29 Interior view 31 Maintenance work 33 Maintenance schedule 34 Lubricating points 38 Tilting driver s cab 44 Motor 50 Cooling system 52 Air filter 60 Fuel system 62 Drive train 66 Compressed air system 77 Hydraulic system 82 Fifth wheel fifth wheel coupling 88 Wheels and tyres 90 Air con...

Page 4: ...2 Maintenance manual T225 T230 Disposing of operating materials 112 MAINTENANCE CERTIFICATES 117 General information 118 Maintenance certificate 119 ...

Page 5: ...Maintenance manual T225 T230 3 VEHICLE IDENTIFICATION Vehicle identification plate Production number ...

Page 6: ...tion plate Fig 1 Mounting location The vehicle identification plate is attached behind the driver s seat 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 C26 003 007A 5 11 C00 017 001A 2 ...

Page 7: ...ification plate The production number of your MAFI Trac is Specify the production number in all written communication with MAFI Providing this number simplifies answering your questions and ordering parts Door key Ignition key Please write down the key number of the door and ignition keys here to ensure that you can easily reorder keys 3 2 6 0 x x x Door key Ignition key ...

Page 8: ...6 Maintenance manual T225 T230 ...

Page 9: ...USER INSTRUCTIONS Maintenance manual T225 T230 7 USER INSTRUCTIONS About this Maintenance manual Content overview Warranty Liability MAFI Service Safety instructions Graphical aids Symbols ...

Page 10: ...aintenance manual z That after familiarising yourself theoretically with the operating 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 warnings z Adhere to the generally applicable regulations for t...

Page 11: ... using this maintenance 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 maintenance tasks and the intervals in which they need to be performed Operating materials This chapter contains information on ope...

Page 12: ...s out warranty and liability claims for personal injury and material damage if they result from one or more of the following z Unintended 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 journal 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 regulations ...

Page 14: ...ribed 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 M a t e r i a l d a mag e A symbol together w...

Page 15: ...rmed X 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 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 14 Additional information This tip provide...

Page 16: ...g 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 23 Note tip This symbol marks general notes ...

Page 17: ...Maintenance manual T225 T230 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 prerequisite for safe handling and fault free operation of the MT In addition you will find further safety instructions in other chapters 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 thos...

Page 19: ...on the foldaway seat of the MT 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 directives please consult your nearest MAFI representative Refittings attachments and retrofittings on the MT may only be done upon c...

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: ...ns 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 If the parking brake fails a parked MT can roll away and injure persons X Secure the MT additionally with blocks Driving with towed loads D A N G E R Dang er of injur y Inappropriate driving behaviour in difficult opera...

Page 22: ... the MT X The MT must always be coupled to the stationary semi trailer 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 may tip over or slide and become out of control X Only drive on inclines or ramps that are authorised traffic routes and are safe for driving X Be sure that the ground is sufficiently clean and provides enough ...

Page 23: ... 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 poisoning if the fumes are inhaled X Start up the engine only in well ventilated rooms X Otherwise vent the engine s exhaust fumes to the outside X If possible avoid starting the engine in closed rooms ...

Page 24: ...y qualifications for the respective tasks z The MT may be operated only by trained qualified personnel as 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 operating personnel of the MT in the same scope and with the same care whilst using this main...

Page 25: ... 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 26: ...ns are part 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 representative Fig 4 Attachment warning signs Part 1 1 Warning sign Fifth wheel 2 Warning sign Engine coolant 3 Warning sign Electric voltage 4 Warning sign Tightening torque 2 3 4 11 C26 000 013A 5 ...

Page 27: ... Maintenance manual T225 T230 25 Fig 5 Attachment warning signs Part 2 1 Warning sign Hot surfaces 2 Warning sign Danger of falling 3 Warning sign Battery 4 Warning sign Cabin tilting 5 Warning sign Cabin lowering 11 C26 000 014A 8 4 2 3 5 ...

Page 28: ...SAFETY WARNING SIGNS ON THE MAFI TRAC 26 Maintenance manual T225 T230 ...

Page 29: ...Maintenance manual T225 T230 27 YOUR MAFI TRAC Product description Exterior view Interior view ...

Page 30: ...ndustrial 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 ausgelegt und abgestimmt ...

Page 31: ...tics compartment 2 Windscreen washer tank 3 Hand pump for lifting lowering the driver s cab 4 Sling points front 5 Main battery switch 6 Battery compartment with main fuses 7 Fifth wheel with saddle plate 8 Service door transmission 9 Maintenance opening engine 10 Connection strip 11 C26 000 010A 5 2 3 4 5 6 7 8 9 10 1 ...

Page 32: ...anual T225 T230 Fig 7 View right side 1 Exhaust 2 Cabin door 3 Equalising reservoir engine coolant 4 Sling points front 5 Ladder 6 Oil viewing window for hydraulic oil 7 Hydraulic tank Fuel tank 8 Sling point rear 1 2 3 4 11 C26 000 011A 4 8 7 5 6 ...

Page 33: ...l T225 T230 31 Interior view Fig 8 Interior view 1 Steering wheel 2 Operator control panel 3 Operator control panel for heater ventilation air conditioner 4 Central electric box 5 Pedals 6 Joystick for fifth wheel 7 Driver seat 7 11 C26 067 060A 6 ...

Page 34: ...32 Maintenance manual T225 T230 ...

Page 35: ...E WORK Maintenance schedule Lubricating points Tilting 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 36: ...r 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 53 Check cooling system X X X X page 54 Change coolant2 X page 55 Check cooler block for damage X X X X page 58 Check cooler block bearings X X X X X page 52 Air filtering Check air filter X X X X X page 60 Replace air filter ca...

Page 37: ...X X X Manufacturer s operating manual Front axle Check and adjust wheel hub bearing play X X Manufacturer s operating manual Check and adjust steering knuckle pin play X X X Manufacturer s operating manual Lubricate bottom steering knuckle connection X X X X X Manufacturer s operating manual Compressed air system Check compressor Monthly page 77 Check replace compressed air line X page 78 Check re...

Page 38: ...wheel fifth wheel coupling Check for wear Monthly Manufacturer s operating manual Lubricate grease pockets locking mechanism and bearing Weekly page 38 Wheels Tyres Check tyre pressure and the tyres for damage Daily page 91 Check wheel rims for damage Weekly page 91 Check wheel bolts and nuts for damage and firm fit X X X X X page 91 Vehicle battery Check acid level Weekly page 97 Check battery ch...

Page 39: ...ing manual Filter mat fresh air circulation X X X X Manufacturer s operating manual Check V belt tension and compressor mounting X X X X Manufacturer s operating manual 1 After every 2000 operating hours the maintenance tasks are repeated starting at 500 operating hours 2 Carry out the maintenance work at least once a year 3 When using synthetic transmission oil extend the oil change interval to 2...

Page 40: ... 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 lubrication points of the brake shaft bearing and the bottom steering knuckle connection of the front axle must always be lubricated manually because they cannot be serviced by the central lubrication system The front axle needs to ...

Page 41: ...of hydraulic cylinder 9 2 2 Axles Top steering knuckle connection 11 1 2x1 Bottom steering knuckle connection 11 3 2x1 Axle suspension Front bearing of front axle 10 1 2x1 Rear bearing of front axle 10 2 2x2 Bearing of rear axle 10 3 2x1 Driver s cab Top hinge of driver s door 12 1 1 Bottom hinge of driver s door 12 1 1 Brake Linkage adjuster front axle 11 1 2x1 Brake camshaft bearings front axle ...

Page 42: ...MAINTENANCE WORK LUBRICATING POINTS 40 Maintenance manual T225 T230 Fig 9 Lubricating points 2 1 11 C26 050 001A 1 ...

Page 43: ...MAINTENANCE WORK LUBRICATING POINTS Maintenance manual T225 T230 41 Fig 10 Lubricating points 1 2 3 3 2 1 11 C26 050 001A 2 ...

Page 44: ...RK LUBRICATING POINTS 42 Maintenance manual T225 T230 Fig 11 Lubricating points Always comply with the specification for lubricants in the documentation of the manufacturer for the front axle 1 11 C26 050 001A 3 2 3 ...

Page 45: ...MAINTENANCE WORK LUBRICATING POINTS Maintenance manual T225 T230 43 Fig 12 Lubricating points 1 11 C26 050 001A 5 ...

Page 46: ... Tilting driver s cab To ease access for working on the motor and transmission the cabin can be tilted Tilt the driver s cab with the hand pump The pump lever for this is located in the driver s cab beside the cabin doors see Figure 13 Fig 13 Pump lever 11 C26 003 003A 2 ...

Page 47: ...tween the driver s cab and the vehicle frame X Only trained personnel may tilt the cabin WA R N I N G Dang er of injur y Until it is completely tilted the driver s cab is not secured against sinking again If the driver s cab falls backwards this can cause serious physical injury X Tilt the driver s cab until the end stop C A U T I O N Material damag e Loose objects can damage the interior and glas...

Page 48: ...n level ground X Apply the parking brake X Put the transmission into neutral X Switch off the engine X Remove all loose objects from the driver s cab X Take the pump level out of the driver s cab X Loosen and remove the hexagon head screw 1 Fig 15 Hand pump driver s cab 1 Closure 2 Valve lever 3 Pump lever 1 1 1 11 C26 000 018A 3 A B B A 11 C26 021 003A 4 3 ...

Page 49: ...X Pump until you no longer feel any counter pressure After this the driver s cab tilts forward on its own into the final position The driver s cab is secured in this final position and cannot tilt back onto the maintenance area for the motor Fig 17 Tilted driver s cab in the final position X Wait until the driver s cab is secure in the final position only then can you begin with the maintenance wo...

Page 50: ...e are no persons between the driver s cab and the vehicle frame Fig 18 Hand pump driver s cab 1 Closure 2 Valve lever Fig 19 Valve lever positions 1 DOWN 2 UP X Insert the pump lever into the opening 1 X Turn the valve lever 2 to the DOWN position X Pump with the pump lever 3 The driver s cab tilts back X Pump until you no longer feel any counter pressure After this the driver s cab tilts back on ...

Page 51: ...fixating the cabin 1 Hexagon head screws X Wait until the driver s cab is securely lowered into the final position and the cylinders relieved X Tighten the hexagon head screw 1 again 3 The driver s cab is locked X Store the pump lever beside the door in the driver s cab 1 1 1 11 C26 000 018A 3 A B B A ...

Page 52: ...of injur y Rotating motor parts can catch pull in and thereby crush or maim body parts X Allow all motor parts to come to a stop before beginning with test and maintenance work on the motor X Wear closed and close fitting work clothing Take off watches necklaces and scarves Wear a hairnet if your hair is long X Make sure that the engine cannot be switched on Checking motor bearings Fig 21 Engine b...

Page 53: ... MAX or MIN limits X Use only authorised types of oil Only check the oil level when the motor is at operating temperature and not running Make sure the MT is parked on level ground Fig 23 Oil dip stick and oil filler neck 1 Oil filler nozzle 2 Oil dip stick X Pull out the oil dip stick 2 X Wipe the oil dip stick 2 with a clean lint free cloth X Reinsert the oil dip stick 2 completely X Pull the oi...

Page 54: ...ler block bearings Fig 24 Cooler block bearings Visually inspect the elastic bearing elements of the cooler block Look for deformations damage and fractures Have the repairs carried out by qualified technicians Defective bearing elements should always be replaced in pairs 11 C26 061 004A 4 ...

Page 55: ...system only when the coolant s temperature is below 90 C X Unscrew the cap at the equalising reservoir slowly and allow the pressure to escape completely before opening X Wear suitable protective gloves clothing and goggles when handling coolant Fig 25 Equalising reservoir X Check the coolant level The coolant level should always lie between the MIN and MAX markings X Refill with coolant if necess...

Page 56: ...rough the vents of the cooler cap z Damaged cylinder head gasket z Defective cooler cap Coolant temperature Excessively high temperature indication can be caused by any of the following z Coolant level too low z Air in the cooling system z Plugged cooling system z Defective fan or fan drive z Defective thermostat z Defective coolant thermometer z Error in the injection system and or the turbocharg...

Page 57: ...en the cooling system only when the coolant s temperature is below 90 C X Unscrew the cap at the equalising reservoir slowly and allow the pressure to escape completely before opening 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 WA R N I N G Dang er of injur y A falling underrun prote...

Page 58: ...cap from the drain valve Fig 27 Cooler drain hose X Screw the supplied hose onto the drain valve 3 The drain valve opens and the coolant can drain off X Collect the coolant in a suitable container Cleaning 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 water If the cooling system is heavily corroded or cont...

Page 59: ...e ventilation of the heating system is thereby ensured during the filling X Slowly fill coolant through the opening of the equalising reservoir 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 Turn the motor off ...

Page 60: ...r cooler motor 3 Transmission oil cooler Check the cooler block from the front Screw off the front panelling of the MT first X Carry out a visual inspection of the cooler block from the front Look for soiling by insects or foreign objects The soiling prevents an unhindered airflow through the cooler Only clean the cooler with water and a mild grease dissolving detergent Never use a high pressure c...

Page 61: ...r cooler water cooler and transmission oil cooler and clean any soiling there Fig 31 Cooler block X Tilt the driver s cab see Tilting driver s cab on page 44 X Blow compressed air 4 bar max from behind through the cooler block If the temperature of the coolant is still too high after maintenance remove the cooler block and take it apart 11 C26 061 004A 1 ...

Page 62: ...ped with an additional security cartridge secondary element Checking air filter Fig 32 Checking air filter 1 Clamps 2 Filter cartridge 3 Housing cover X Stop the engine and withdraw the ignition key X Clean the area around the housing cover 3 of the air filter X Check the air filter for external damage X Loosen the clamps 1 and remove the housing cover 3 X Check the housing cover 3 for signs of so...

Page 63: ...ver 3 of the air filter X Loosen the clamps 1 and remove the housing cover 3 X Clean the housing cover X Pull out the filter cartridge 2 X Clean the inside of the housing with a lint free cloth paying special attention to the sealing surfaces X Insert the new filter cartridge 2 while making sure it is positioned properly X Press the filter cartridge 2 into the housing X Place the housing cover 3 o...

Page 64: ...k fuel lines for leaks and external damage Have leaky nicked or defective coolers replaced by qualified technicians Installation location of fuel filter and fuel pre filter with water separator Fig 34 Installation location of filter 1 Fuel filter 2 Fuel pre filter with water separator Both filters are located on the right side of the transmission under the cover 11 C26 060 011A 4 ...

Page 65: ... 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 35 Fuel pre filter with water separator 1 Viewing window 2 Water level sensor plug 3 Water drain valve with self aeration X Place a suitable collection container underneath the fuel pre filter X Pull the plug of the wat...

Page 66: ...MAINTENANCE WORK FUEL SYSTEM 64 Maintenance manual T225 T230 Replacing fuel pre filter element This section is in progress ...

Page 67: ...nd creating sparks must be avoided when handling fuels X Avoid fuel from coming into contact with skin or clothing X Do not breathe in fuel fumes We recommend cleaning the fuel tank at low fill levels X Park the MT on level ground X Stop the engine and withdraw the ignition key X Place a suitable collection container underneath drain plug X Unscrew the drain plug completely Have a new seal ready a...

Page 68: ...r power to the wheels Only the rear axle 4x2 is driven Lubricating the front axle The brake shaft bearings and the bottom steering knuckle connections must always be lubricated manually even when there is a built in central lubrication system Lubricating points and lubricating cycle see section Lubricating points on page 38 Always observe lubricant specifications in the documentation of the manufa...

Page 69: ...ange z Conduct an 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 hot check z Conduct a hot check when th...

Page 70: ...otor for the first time after the commissioning or an oil change for the cold check make sure there is enough oil in the transmission C A U T I O N Transmission damag e If the oil level is too high or too low this can result in damage to the transmission X Before you start the motor for the first time check the oil level with the oil dip stick X Make sure the oil level is in the HOT CHECK range 3 ...

Page 71: ...HECK range X Check the oil level with the oil dip stick before you start the motor for the first time Make sure the oil level is in the HOT CHECK range while the oil is cold and the motor is at standstill X Refill oil into the oil filler nozzle if necessary If the oil level is correct you can start with the cold check 1 2 3 4 11 C25 060 006A 4 ...

Page 72: ...damag 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 temperature a too high oil level may damage the transmission X Make sure the oil level is in the COLD CHECK range 4 during the cold check X The oil level should never exceed the COLD FULL or drop below the COLD ADD marking of the oil dip st...

Page 73: ...zle 2 Oil dip stick 3 HOT CHECK range 4 COLD CHECK range 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 Conduct the hot check at the first opportunity once the operating temperature has been reached The operating temperature is reached when the display ...

Page 74: ...OT CHECK range 4 during the hot check 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 A c c i d e n t h a z a rd If you leave the MT while the motor is running the MT can start rolling unintentionally and seriously injure persons X Always be sure to shift the transmission into neutr...

Page 75: ... 4 COLD CHECK range X Pull the oil dip stick out again The oil level should 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 transmission venting is not plugged If you still determine greater deviations contact the...

Page 76: ...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 display in the operating panel for the transmission In order to read out the oil level without error 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 runni...

Page 77: ... 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 litre 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 is too short oL EL Engine speed Low Motor speed is t...

Page 78: ...n at 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 customer service to rectify the fault Ending the oil level check X Press both arrow keys 1 and 2 until N N is visible in the display ...

Page 79: ...ension of driver s seat Checking compressor Fig 44 Compressor 1 Intake 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 intake line and the connections for leaks Look for fractures nicks and deformations Have defective lines replaced by qualified technicians Checking intake line Fig 45 Intake line 1 Intake lin...

Page 80: ...ce the compressed air line when there are some oil carbon deposits X If there are 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 Checking compressed air tank Fig 47 Compressed air tank 1 Circuit 1 Compressed air brake of the rear axle 2 Circuit 2 Compressed air brake of th...

Page 81: ...he compressed air line behind the cooling coil By dewatering the air dryer very little condensation water reaches the air dryer cartridge Fig 48 Dewatering valve compressed air line X Park the MT on level ground X Stop the engine 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 ou...

Page 82: ...equipped with a dewatering valve for draining away condensation Fig 49 Dewatering valve X Park the MT on level ground X Stop the engine 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 s...

Page 83: ...mitted compressed air X Make sure that the compressed air system is depressurised X Carry out the maintenance only on depressurised systems X Make sure that the engine cannot be switched on X Park the MT on level ground X Stop the engine and withdraw the ignition key X Release the pressure from the compressed air system all circuits X Tilt the cabin see Tilting driver s cab on page 44 X Unscrew th...

Page 84: ...rom 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 Checking the 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 ...

Page 85: ...el and is marked with the symbol for emergency release The block is mounted to the bottom side of the chassis at the level of the steps The hexagon socket screw for the emergency release is accessible from the right side of the vehicle 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 ...

Page 86: ... of the return filter X Place a suitable collection container underneath Note the filling quantity see Filling quantities on page 109 X Screw out the oil drain plug and let the oil drain into the collection container Fig 55 Return filter tank X Screw the oil drain plug back in X Fill new hydraulic oil through the return oil filter Note the filling quantity see Filling quantities on page 109 X Chec...

Page 87: ...he ignition key X Loosen the bolts for the filter housing cover 2 and remove the filter housing cover 2 X Remove the filter cartridges 1 X Clean the magnet If metal chips are found on the magnet have technicians inspect the hydraulic system X Insert a new filter cartridge 1 X Replace the O ring at the filter housing cap 2 X Tighten the bolts for the filter housing cover 2 onto the filter housing 1...

Page 88: ...e oil level you need to lower the driver s cab completely Fig 57 Oil filling screw 1 Oil fill screw 2 Opening for pump lever X Position the opening for the pump lever downwards so that the opening inside the hand pump is released X Remove the oil fill screw The oil level has to reach the lower edge of the hole X Refill oil into the oil filler screw if necessary Use hydraulic oil of the same specif...

Page 89: ... 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 Replace hydraulic hoses every five years at the latest to avoid hydraulic hoses that become porous by ageing Check the hydraulic hoses and connection pieces for z leaks z porosity z damages such as nicks and abrasion z proper moun...

Page 90: ...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 emergency h...

Page 91: ...Release button 2 Lock control light 3 Kingpin control light X Lock the fifth wheel coupling with a reference king pin 3 The control light 2 should light up X Press both switches 1 simultaneously in the instrument panel to unlock the fifth wheel coupling 3 The control light 2 should go out If the result of the function test is negative check if any of the electrical lines or switches are faulty or ...

Page 92: ...es Fig 59 Tightening order X Be sure to retighten all wheel nuts with the specified tightening torque before the initial operation and after the wheel exchange X Retighten the torque of the wheel nuts after the first drive under load at the latest though after 24 operating hours X Tighten wheel nuts crosswise see Fig 59 Make sure tightening torques for the wheel nuts are correct Use a torque wrenc...

Page 93: ... wheel nuts Tyre inflating connection Fig 61 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 compressed air tanks Tyre pressure X Start the motor X Remove the protection cap from the tyre inflating connection X Attach the tyre inflating hose not part of the scope of delivery X Inflate the tyre...

Page 94: ...r condenser Fig 62 Air conditioner condenser The air conditioner condenser is installed in front of the front right wheel X Screw off the air grate on the right side of the vehicle X Check the air conditioner condenser for signs of soiling X Clean the air conditioner condenser if required Soiled fins in the air conditioner condenser can cause the air conditioner to turn off due to over heating X A...

Page 95: ...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 If the coolant level 3 is too low have a specialist refill the air conditioner Checking the humidity X Check the colour of the indicator bead 3 The indicator bead is orange The humidity of the coolant circuit is OK 3 The indicator bead is colourless The hu...

Page 96: ... accessible via the air grate on the front side of the MT Fig 64 Fresh circulation filter 1 Air grate 2 Air filter element X Screw off the air grate and remove the air filter element The air filter element can be taken out from above through the shaft X Check the air filter element for soiling and replace if necessary X Install the air filter element while making sure it is positioned properly and...

Page 97: ...ig 66 Main battery switch 1 Position ON 2 Position OFF 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 alternator are under voltage even when the main battery switch is turned off That is why repairs to the rotary current alternator can cause damage to the electr...

Page 98: ...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 Use clean water to immediately rinse off any acid 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 99: ...hicle battery on page 97 X Loosen the battery terminals and take them off Note sequence first negative battery terminal then positive battery terminal X Unscrew 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 Note seq...

Page 100: ...eplace defective lenses or glass panels Replacing light bulbs Front lights Fig 69 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 70 Warning beacon X Unscrew and take off the warning beacon glass X Replace the bulb with a bul...

Page 101: ... may never bypass a defective fuse or replace it with a fuse with a higher current Fig 71 Central electric box The electrical fuses for the vehicle are located on the right side of the operator in a fuse box Fig 72 Main fuse In addition to the individual vehicle fuses there is a main fuse It is located in the battery compartment 11 C26 019 008A 5 11 C26 019 006A 3 ...

Page 102: ... a regulator valve At a coupled load of about 14 t the air suspension bellows is compressed so far that the frame lies solidly on the axle At this load the suspension is without effect Checking air suspension bellows X Check the air suspension bellows for signs of external wear soiling and ageing X Check and dewater the compressed air tank see Compressed air system on page 77 11 C26 020 008A 1 ...

Page 103: ...Maintenance manual T225 T230 101 OPERATING MATERIALS General information Fuels Oils Coolant Lubricating greases Filling quantities ...

Page 104: ...n when handling operating materials X Make sure that no operating materials are spilled X Thoroughly rinse skin surfaces that have come in contact 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 U N G Dang er of fire Wh...

Page 105: ...f 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 warranty 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 on biodiesel Cont...

Page 106: ...ns 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 documentati...

Page 107: ...sses can be used in the various temperature ranges The temperature values refer to constant ambient air temperatures If the MT is to be used at temperatures below 25 C special lubricants are required Consult an authorised dealer for recommendations as to a suitable lubricant We recommend using synthetic lubricants only at temperatures below 25 C Designation Standard CF 4 CG 4 API American Petroleu...

Page 108: ...nt an oil of the quality GL5 with the viscosity class SAE 90 is used for filling Fig 75 SAE classes of transmission oil Fig 75 shows which viscosity classes can be used in the various temperature ranges The temperature values refer to constant ambient air temperatures Hydraulic oil For the hydraulic system use hydraulic oil of the HLP ISO VG specification Fig 76 Viscosity classes for hydraulic oil...

Page 109: ...he cooling system is 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 increase the anti freeze protection according to the following table The system should be thoroughly flushed with each changing of the coolant see Changing coolant on page 55 In cases in which no anti freeze is needed for example in the...

Page 110: ...ting greases take into account the usage properties of the greases in addition to the operating and ambient conditions and lubrication cycles z For lubricating the lubricating points use a lithium multi purpose grease according to DIN 51 502 z The battery poles are to be lubricated with acid resistant grease e g Bosch 5700 102025 z For lubricating the front axle always comply with the lubricant re...

Page 111: ... T230 109 Filling quantities Operating material Filling quantity Fuel approx 240 l Oils Motor approx 15 l Transmission approx 18 l Axle transmission differential transmission 18 l Planetary gears wheel hub gears 2 x 1 5 l Hydraulics approx 70 l Coolant approx 40 l ...

Page 112: ...OPERATING MATERIALS FILLING QUANTITIES 110 Maintenance manual T225 T230 ...

Page 113: ...Maintenance manual T225 T230 111 ENVIRONMENTAL NOTES Disposing of operating materials ...

Page 114: ...tally safe disposal of the various operating materials 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 Therefore 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 th...

Page 115: ...raulic oil carefully in 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 during an oil change and fuel filter change...

Page 116: ...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 corresponding 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 as...

Page 117: ...directive 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 authorities Observe the information on environmentally safe disposal of the operating materials in the data sheets of the...

Page 118: ...ENVIRONMENTAL NOTES DISPOSING OF OPERATING MATERIALS 116 Maintenance manual T225 T230 ...

Page 119: ...Maintenance manual T225 T230 117 MAINTENANCE CERTIFICATES General information Maintenance certificate ...

Page 120: ...qualified shop Only maintenance or additional work that has been entered in the certification boxes and confirmed as described above is considered to have been carried out validly Please take into consideration that if the maintenance work is not properly documented the warranty and liability claims towards MAFI become void The maintenance schedule see Maintenance schedule on page 34 contains the ...

Page 121: ...MAINTENANCE CERTIFICATES MAINTENANCE CERTIFICATE Maintenance manual T225 T230 119 Maintenance certificate Fig 1 Certification boxes maintenance work Space for entries and additional work ...

Page 122: ...MAINTENANCE CERTIFICATES MAINTENANCE CERTIFICATE 120 Maintenance manual T225 T230 Fig 2 Certification boxes maintenance work Space for entries and additional work ...

Page 123: ...MAINTENANCE CERTIFICATES MAINTENANCE CERTIFICATE Maintenance manual T225 T230 121 Fig 3 Certification boxes maintenance work Space for entries and additional work ...

Page 124: ...MAINTENANCE CERTIFICATES MAINTENANCE CERTIFICATE 122 Maintenance manual T225 T230 Fig 4 Certification boxes maintenance work Space for entries and additional work ...

Page 125: ...MAINTENANCE CERTIFICATES MAINTENANCE CERTIFICATE Maintenance manual T225 T230 123 Fig 5 Certification boxes maintenance work Space for entries and additional work ...

Page 126: ...MAINTENANCE CERTIFICATES MAINTENANCE CERTIFICATE 124 Maintenance manual T225 T230 Fig 6 Certification boxes maintenance work Space for entries and additional work ...

Page 127: ...MAINTENANCE CERTIFICATES MAINTENANCE CERTIFICATE Maintenance manual T225 T230 125 Fig 7 Certification boxes maintenance work Space for entries and additional work ...

Page 128: ...MAINTENANCE CERTIFICATES MAINTENANCE CERTIFICATE 126 Maintenance manual T225 T230 Fig 8 Certification boxes maintenance work Space for entries and additional work ...

Page 129: ...MAINTENANCE CERTIFICATES MAINTENANCE CERTIFICATE Maintenance manual T225 T230 127 Fig 9 Certification boxes maintenance work Space for entries and additional work ...

Page 130: ...MAINTENANCE CERTIFICATES MAINTENANCE CERTIFICATE 128 Maintenance manual T225 T230 Fig 10 Certification boxes maintenance work Space for entries and additional work ...

Page 131: ...MAINTENANCE CERTIFICATES MAINTENANCE CERTIFICATE Maintenance manual T225 T230 129 Fig 11 Certification boxes maintenance work Space for entries and additional work ...

Page 132: ...MAINTENANCE CERTIFICATES MAINTENANCE CERTIFICATE 130 Maintenance manual T225 T230 Fig 12 Certification boxes maintenance work Space for entries and additional work ...

Page 133: ...MAINTENANCE CERTIFICATES MAINTENANCE CERTIFICATE Maintenance manual T225 T230 131 Fig 13 Certification boxes maintenance work Space for entries and additional work ...

Page 134: ...MAINTENANCE CERTIFICATES MAINTENANCE CERTIFICATE 132 Maintenance manual T225 T230 Fig 14 Certification boxes maintenance work Space for entries and additional work ...

Page 135: ...MAINTENANCE CERTIFICATES MAINTENANCE CERTIFICATE Maintenance manual T225 T230 133 Fig 15 Certification boxes maintenance work Space for entries and additional work ...

Page 136: ...MAINTENANCE CERTIFICATES MAINTENANCE CERTIFICATE 134 Maintenance manual T225 T230 Fig 16 Certification boxes maintenance work Space for entries and additional work ...

Page 137: ...MAINTENANCE CERTIFICATES MAINTENANCE CERTIFICATE Maintenance manual T225 T230 135 Fig 17 Certification boxes maintenance work Space for entries and additional work ...

Page 138: ...MAINTENANCE CERTIFICATES MAINTENANCE CERTIFICATE 136 Maintenance manual T225 T230 Fig 18 Certification boxes maintenance work Space for entries and additional work ...

Page 139: ...MAINTENANCE CERTIFICATES MAINTENANCE CERTIFICATE Maintenance manual T225 T230 137 Fig 19 Certification boxes maintenance work Space for entries and additional work ...

Page 140: ...MAINTENANCE CERTIFICATES MAINTENANCE CERTIFICATE 138 Maintenance manual T225 T230 Fig 20 Certification boxes maintenance work Space for entries and additional work ...

Page 141: ...77 Compressed air tank Checking 78 Dewatering 79 80 Compressor 77 Coolant Adding 57 Draining 56 Cooler block Bearings 52 Cooling system 52 D Dewatering Water separator fuel pre filter 63 Dewatering valve 79 80 Disposing of coolant 114 Disposing of drying agent inserts 113 Disposing of filter cartridges 113 Disposing of hydraulic oils 113 Disposing of maintenance and cleaning agents 115 Disposing o...

Page 142: ...viewing window 82 Operating materials Coolant 107 Filling quantities 109 Lubricating greases 108 Oils 105 T Tilting driver s cab 44 Transmission oil 67 74 Tyres 90 V Vehicle battery 96 W Wheels 90 Wheels 93 ...

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