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MAFI - Trac MT 25 / 30 YT Terminal Trac Production no.: 3280798 ...get it rolling...
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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, translations, microfilm- ing, and the storage and processing in electronic systems.
Intended use ..............17 Other dangers ..............18 Qualifications of the operating personnel ......21 Personal safety gear ............22 Warning signs on the MAFI Trac ........23 Your MAFI Trac ............25 Product description ............26 Exterior view ..............27 Interior view ................
The vehicle identification plate is attached on the right side of the vehicle frame. 11-C25-003-007A-3 Fig. 2: Vehicle identification plate On the vehicle identification plate you will find information on: vehicle type production number weights cargo battery Maintenance manual MT 25 / 30 YT...
VEHICLE IDENTIFICATION PRODUCTION NUMBER Production number The production number identifies your MAFI Trac. It is stamped on the vehicle identification plate. The production number of your MAFI Trac is: production number S p e c i f y t h e i n a l l w r i t t e n c o m mu n i c a - t i o n w i t h M AF I .
USER INSTRUCTIONS USER INSTRUCTIONS On this Maintenance manual Content overview Warranty / Liability MAFI Service Safety instructions Graphical aids Symbols Maintenance manual MT 25 / 30 YT...
ON THIS MAINTENANCE MANUAL On this Maintenance manual General information This Maintenance manual (MM) is a part of the MAFI Trac. In the following the MAFI Trac is shortened to MT. Here, you will learn how to properly maintain and handle the MT.
Operating materials This chapter contains information on operating materials that are used in the MT. Maintenance certificates In this chapter, you will find certification boxes to certify the maintenance tasks that have been preformed. Maintenance manual MT 25 / 30 YT...
WARRANTY / LIABILITY Warranty / Liability Generally the “General sales terms and delivery conditions” of MAFI-Transport-Systeme GmbH are valid. MAFI rules out war- rantee and liability claims for personal injury and material dam- age when they resulting from: Inappropriate use of the MT (see “Intended use”...
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”...
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 Note, tip This symbol marks general notes. Maintenance manual MT 25 / 30 YT...
SAFETY General information Intended use Other dangers Qualifications of the operating personnel Personal safety gear Warning signs on the MAFI Trac Maintenance manual MT 25 / 30 YT...
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 those safety instructions as well. Maintenance manual MT 25 / 30 YT...
Refittings, attachments, and retrofittings on the MT may only be done upon consultation with MAFI. Spare parts, ancillary attachments, extra installations, and accessory components have to be authorised by MAFI before use. Inappropriate use Transporting extra persons on the MT or in the driver's cab.
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 Maintenance manual. Maintenance manual MT 25 / 30 YT...
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. Maintenance manual MT 25 / 30 YT...
The MT is an industrial truck with fifth wheel coupling. It is designed for the special usage requirements in terminal traffic in ports, shipping, postal, and railway terminals, loading cargo cars from semi-trailers, industrial use with the Cargotrailer system, lift trucks, and semi-trailers. Maintenance manual MT 25 / 30 YT...
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 Maintenance manual MT 25 / 30 YT...
2) Carry out the maintenance work at least once a year. 3) When using synthetic transmission oil, extend the oil change interval to 2000 operating hours or change the oil change at least every two years. Maintenance manual MT 25 / 30 YT...
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2) Carry out the maintenance work at least once a year. 3) When using synthetic transmission oil, extend the oil change interval to 2000 operating hours or change the oil change at least every two years. Maintenance manual MT 25 / 30 YT...
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2) Carry out the maintenance work at least once a year. 3) When using synthetic transmission oil, extend the oil change interval to 2000 operating hours or change the oil change at least every two years. Maintenance manual MT 25 / 30 YT...
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2) Carry out the maintenance work at least once a year. 3) When using synthetic transmission oil, extend the oil change interval to 2000 operating hours or change the oil change at least every two years. Maintenance manual MT 25 / 30 YT...
Fig. 12: Hexagon head screws for fastening the cabin 1 Hexagon head screws Park the MT on level ground. Apply the parking brake. Remove all loose objects from the driver's cab. Loosen and remove the hexagon socket screws 1. Maintenance manual MT 25 / 30 YT...
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The driver's cab is lifted. Pump until the end stop is reached. Fig. 14: Securing the driver's cab Insert the pump lever into the openings 1 and 2. The driver's cab is secured against unintentional lower- ing. Maintenance manual MT 25 / 30 YT...
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Store the pump lever in the pneumatics compartment. Fig. 16: Hexagon head screws for fastening the cabin 1 Hexagon head screws Insert the hexagon socket screws 1 back in. Screw the hexagon socket screws 1 tight. Maintenance manual MT 25 / 30 YT...
M a ke s u r e t h a t t h e e n g i n e c a n n o t b e sw i t c h e d o n . Maintenance manual MT 25 / 30 YT...
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The oil dip stick and the oil filler neck are located behind the driver's cab, under the transmission cover. Open the cover using a square key. The square key has been placed by the manufacturer in the storage bin of the driver seat. Maintenance manual MT 25 / 30 YT...
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Insert the oil dip stick 2 all the way back in. Pull the oil dip stick out again 2. The oil level should lie between the “MIN” and “MAX” mark- ings. Refill motor oil into the oil filler nozzle 1 if necessary. 11-C25-060-004A-3 Maintenance manual MT 25 / 30 YT...
Check the coolant level. The coolant level should always lie between the “MIN” and “MAX” markings. Refill with coolant if necessary. Use with a mixture of water and anti-freeze/corrosion pro- tection agent. 11-C25-061-005A-3 Maintenance manual MT 25 / 30 YT...
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H ave t h e l e a ks a n d d e fe c t s r e p a i r e d by q u a l i f i e d t e c h n i - c i a n s. Maintenance manual MT 25 / 30 YT...
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A l way s we a r g l ove s a n d s a fe t y b o o t s w h e n r e m ov i n g t h e u n d e r r u n p r o t e c t i o n d ev i c e. Maintenance manual MT 25 / 30 YT...
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- i f i e d t e c h n i c i a n s. Maintenance manual MT 25 / 30 YT...
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Check the coolant level once more, add more coolant if nec- essary and start motor again. Close the cooling system with the cap at the expander tank. The system needs to be filled completely. Maintenance manual MT 25 / 30 YT...
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H ave d e fe c t i ve c o o l e r s r e p l a c e d by q u a l i f i e d t e c h n i- c i a n s. Maintenance manual MT 25 / 30 YT...
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- t i o n . Maintenance manual MT 25 / 30 YT...
Loosen the clamps 1 and remove the housing cap 3. Check the housing cap 3 for soiling and clean the area around the housing cap if necessary. Replace the housing cap 3 and fasten it with the clamps 1. Maintenance manual MT 25 / 30 YT...
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Insert the new filter cartridge 2 the right way around. Press the filter cartridge 2 into the housing. Replace the housing cap 3 and fasten it with the clamps 1. Maintenance manual MT 25 / 30 YT...
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 Maintenance manual MT 25 / 30 YT...
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Have a new seal ready at hand. Allow a couple of litres of fuel drain to rinse out the contam- ination. Screw the drain plug back in with a new seal. Check the drain plug for leaks. Maintenance manual MT 25 / 30 YT...
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 Maintenance manual MT 25 / 30 YT...
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A p r e c i s e o i l l eve l t e s t i s o n l y p o s s i bl e w h e n t h e M T i s par ked o n leve l gr ou nd. 11-C25-060-006A-3 Maintenance manual MT 25 / 30 YT...
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Refill oil into the oil filler nozzle if necessary. If the oil level is correct, you can start with the cold check. 11-C25-060-006A-4 Maintenance manual MT 25 / 30 YT...
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U s e o n l y a u t h o r i s e d t y p e s o f t ra n s m i s s i o n o i l . Park the MT on level ground. Shift the transmission into neutral N and apply the parking brake. Let the engine run at low idle speed (500 to 800 rpm). Maintenance manual MT 25 / 30 YT...
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6 0 ° a n d 9 3 ° h a s b e e n r e a c h e d . Maintenance manual MT 25 / 30 YT...
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Park the MT on level ground for the oil level check. Shift the transmission into neutral N and apply the parking brake. Let the engine run at low idle speed (500 to 800 rpm). Maintenance manual MT 25 / 30 YT...
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T h e o il h a s t o b e a t o p e ra t i n g t e m p e ra t u r e fo r a n ex a ct o il l eve l c h e ck . Maintenance manual MT 25 / 30 YT...
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The oil temperature lies between 60 °C and 93 °C maxi- mum. The transmission oil needs to settle, which means that the MT has not moved for at least two minutes. Maintenance manual MT 25 / 30 YT...
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Temperature Low Oil temperature too low oL TH Temperature High Oil temperature too high oL SH Outputspeed High Drive shaft is turning (MT is moving) oL FL Sensor Failure Error at the sensor Maintenance manual MT 25 / 30 YT...
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. Ending the oil level check Press both arrow keys 1 and 2 until “N - N” is displayed in the display. Maintenance manual MT 25 / 30 YT...
Remove the suction line. Check the inside of the hose for damage and contractions. Replace the suction line in case of damage. Reinstall the suction line. Fasten the suction line with the hose clamps 1. Maintenance manual MT 25 / 30 YT...
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Carry out a visual inspection of the compressed air tanks. Check the compressed air tanks for damages and leaks. Check the compressed air tanks for corrosion. Check the mounting straps for proper tightness. Maintenance manual MT 25 / 30 YT...
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“R e p l a c e a i r d r ye r c a r t r id g e ” o n p a g e 6 9 Maintenance manual MT 25 / 30 YT...
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Screw the air dryer cartridge off by turning it to the left. Screw the new air dryer cartridge on and tighten the air dryer cartridge by hand. Screw in the safety screws (if available). Maintenance manual MT 25 / 30 YT...
The oil level should lie between the “MIN” and “MAX” mark- ings. Refill hydraulic oil into the oil filler nozzle if necessary, “Change hydraulic oil” on page Use hydraulic oil of the same specifications, see “Oils” on page Maintenance manual MT 25 / 30 YT...
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Loosen the lock nut. Open the emergency release cock by turning it counter- clockwise. The fifth wheel lowers all the way. Close the emergency release cock by turning it clockwise. Tighten the lock nut. Maintenance manual MT 25 / 30 YT...
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If metal chips are found on the magnet, have technicians inspect the hydraulic system. Insert a new filter cartridges 1. Replace the O-ring at the filter housing cap 2. Screw the filter housing cap 2 onto the filter housing. Maintenance manual MT 25 / 30 YT...
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. Check the hydraulic hoses and connection pieces for Leaks, Porosity, Damages, such as nicks and abrasion, Proper mounting. Replace porous and damaged hydraulic hoses immediately with new hydraulic hoses. Tighten loose connections. Maintenance manual MT 25 / 30 YT...
C o n s u l t t h e o p e ra t i n g m a nu a l fo r i n fo r m a t i o n . Maintenance manual MT 25 / 30 YT...
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Check the gab (5 mm) between sensor and switching plate. Correct the gap if necessary. Use the fastening nuts for the adjustment 1. Check its proper function by locking and releasing the fifth wheel coupling several times. Maintenance manual MT 25 / 30 YT...
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H ave t h e d a m a g e d o r s eve r e l y wo r n b e a r i n g s r e p l a c e d by q u a l i f i e d t e c h n i c i a n s. Maintenance manual MT 25 / 30 YT...
Make sure tightening torques for the wheel nuts are correct. Use a torque key for retightening the wheel nuts. Fig. 53: “Tightening Torque” plate The tightening torque for the wheel nuts is inscribed on the “Tightening Torque” plate. Maintenance manual MT 25 / 30 YT...
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T h e o u t p u t o f t h e c o m p r e s s o r i s n o t e n o u g h t o i n f l a t e t h e t y r e s t o t h e s p e c i f i e d t y r e p r e s s u r e. Maintenance manual MT 25 / 30 YT...
The indicator bead is orange: The humidity of the coolant circuit is OK. The indicator bead is colourless: The humidity of the coolant circuit is too high. The dryer-collector unit must be replaced by a specialist company. Maintenance manual MT 25 / 30 YT...
D i s c o n n e c t t h e ve h i c l e b a t t e r y ' s n e g a t i ve t e r m i n a l b e fo r e r e p a i r i n g t h e a l t e r n a t o r. Maintenance manual MT 25 / 30 YT...
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F i r e, n a ke d f l a m e s, s m o k i n g , a n d c r e a t i n g s p a r k s mu s t b e avo i d e d n e a r b a t t e r i e s. Maintenance manual MT 25 / 30 YT...
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Note sequence – first positive battery pole, then negative battery pole. Check battery poles and connections Connect the battery terminals for corrosion. Check the terminals for proper tightness. Check whether the terminals have been greased sufficiently (special grease). Maintenance manual MT 25 / 30 YT...
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Warning beacon Fig. 62: Warning beacon Unscrew and take off the warning beacon glass. Replace the bulb with a bulb of the same type. Replace the glass and screw it tight. Maintenance manual MT 25 / 30 YT...
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Fig. 63: Central electric box 1 Crew-on key 2 lock 3 unlock 11-C25-019-008-3 Fig. 64: Central electric box The electrical vehicle fuses are located to the right of the oper- ator in a compartment. 11-C25-019-008A-4 Maintenance manual MT 25 / 30 YT...
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MAINTENANCE WORK ELECTRICAL SYSTEM 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 Maintenance manual MT 25 / 30 YT...
After releasing the button the air suspen- sion bellows are inflated again. Check the air suspension bellows for signs of wear. Check and dewater the compressed air tank, see “Com- pressed air system” on page Maintenance manual MT 25 / 30 YT...
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Special diesel fuels can be employed for arctic climate zones down to -44 °C. Normal or super petrol may under no circumstances be added to the diesel fuel. There is a risk of serious motor damages. Maintenance manual MT 25 / 30 YT...
T h e M T m o t o r h a s b e e n f i l l e d a t o u r p l a n t w i t h a n o i l o f v is c o s it y c l a s s S A E - 1 5 W / 4 0 . Maintenance manual MT 25 / 30 YT...
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We r e c o m m e n d u s i n g s y n t h e t i c l u b r i c a n t s o n l y a t t e m - p e ra t u r e s b e l ow - 2 5 °C. Maintenance manual MT 25 / 30 YT...
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A hy d ra u l i c o il h a s b e e n f i l l e d i n t h e p l a n t w i t h t h e v is c o s i t y c la s s I S O VG 4 6 . Maintenance manual MT 25 / 30 YT...
For lubricating the lubricating points, use a lithium multi-pur- pose grease according to DIN 51 502. The battery poles are to be lubricated with acid-resistant grease, e.g. Bosch 5700 102025. Maintenance manual MT 25 / 30 YT...
240 l Oils Motor See manufacturer specifications Transmission approx. 35 l Axle gears 18 l (differential transmission) Planetary gears 2x 1.5 l (wheel hub gears) Hydraulic approx. 85 l Coolant approx. 40 l Maintenance manual MT 25 / 30 YT...
Collect the used oil exclusively in used oil collecting con- tainers. Do not mix with other operating materials. Deposit the used oil collecting containers at a collection point for used oil processing. Observe the regulations of the local authorities. Maintenance manual MT 25 / 30...
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The paper filter inserts need to be taken care of during main- tenance work of the dry air filter in the air filter system of the motor. Dispose of the paper filter inserts according to regulations of the responsible local authorities. Maintenance manual MT 25 / 30...
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You can also drop off the old batteries at a collection point for old batteries. Observe the regulations of the responsible local and the national authorities. Maintenance manual MT 25 / 30...
Don't forget that if the maintenance certifications are not re- corded, the guaranty and liability claims towards MAFI be- come void. T h e m a i n t e n a n c e s c h e d u l e ( s e e “...
MAINTENANCE CERTIFICATES Maintenance certificate Maintenance certificate Fig. 1: Certification boxes, maintenance work Space for entries and additional work Maintenance manual MT 25 / 30 YT...
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MAINTENANCE CERTIFICATES Maintenance certificate Fig. 2: Certification boxes, maintenance work Space for entries and additional work Maintenance manual MT 25 / 30 YT...
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MAINTENANCE CERTIFICATES Maintenance certificate Fig. 3: Certification boxes, maintenance work Space for entries and additional work Maintenance manual MT 25 / 30 YT...
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MAINTENANCE CERTIFICATES Maintenance certificate Fig. 4: Certification boxes, maintenance work Space for entries and additional work Maintenance manual MT 25 / 30 YT...
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MAINTENANCE CERTIFICATES Maintenance certificate Fig. 5: Certification boxes, maintenance work Space for entries and additional work Maintenance manual MT 25 / 30 YT...
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MAINTENANCE CERTIFICATES Maintenance certificate Fig. 6: Certification boxes, maintenance work Space for entries and additional work Maintenance manual MT 25 / 30 YT...
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MAINTENANCE CERTIFICATES Maintenance certificate Fig. 7: Certification boxes, maintenance work Space for entries and additional work Maintenance manual MT 25 / 30 YT...
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MAINTENANCE CERTIFICATES Maintenance certificate Fig. 8: Certification boxes, maintenance work Space for entries and additional work Maintenance manual MT 25 / 30 YT...
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MAINTENANCE CERTIFICATES Maintenance certificate Fig. 9: Certification boxes, maintenance work Space for entries and additional work Maintenance manual MT 25 / 30 YT...
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MAINTENANCE CERTIFICATES Maintenance certificate Fig. 10: Certification boxes, maintenance work Space for entries and additional work Maintenance manual MT 25 / 30 YT...
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MAINTENANCE CERTIFICATES Maintenance certificate Fig. 11: Certification boxes, maintenance work Space for entries and additional work Maintenance manual MT 25 / 30 YT...
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MAINTENANCE CERTIFICATES Maintenance certificate Fig. 12: Certification boxes, maintenance work Space for entries and additional work Maintenance manual MT 25 / 30 YT...
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MAINTENANCE CERTIFICATES Maintenance certificate Fig. 13: Certification boxes, maintenance work Space for entries and additional work Maintenance manual MT 25 / 30 YT...
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MAINTENANCE CERTIFICATES Maintenance certificate Fig. 14: Certification boxes, maintenance work Space for entries and additional work Maintenance manual MT 25 / 30 YT...
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MAINTENANCE CERTIFICATES Maintenance certificate Fig. 15: Certification boxes, maintenance work Space for entries and additional work Maintenance manual MT 25 / 30 YT...
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MAINTENANCE CERTIFICATES Maintenance certificate Fig. 16: Certification boxes, maintenance work Space for entries and additional work Maintenance manual MT 25 / 30 YT...
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MAINTENANCE CERTIFICATES Maintenance certificate Fig. 17: Certification boxes, maintenance work Space for entries and additional work Maintenance manual MT 25 / 30 YT...
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MAINTENANCE CERTIFICATES Maintenance certificate Fig. 18: Certification boxes, maintenance work Space for entries and additional work Maintenance manual MT 25 / 30 YT...
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MAINTENANCE CERTIFICATES Maintenance certificate Fig. 19: Certification boxes, maintenance work Space for entries and additional work Maintenance manual MT 25 / 30 YT...
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MAINTENANCE CERTIFICATES Maintenance certificate Fig. 20: Certification boxes, maintenance work Space for entries and additional work Maintenance manual MT 25 / 30 YT...
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Coolant Motor oil Drain oil dip stick Fill 57, 58, 59, 62 transmission oil Cooler, air conditioner Oil filler neck Cooling system Motor oil Oil viewing window Dewater Operating media Compressed air tank Maintenance manual MT 25 / 30 YT...
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