MAFI MT 25 User manual
Maintenance manual
MAFI - Trac
MT 25 / 30 YT
Terminal Trac
...get it rolling
Production no.: 3280798
Maintenance manual MT 25 / 30 YT
Publisher MAFI-Transport-Systeme GmbH
Hochhäuser Strasse 18
D-97941 Tauberbischofsheim
Telephone: +49 9341/899-0
Fax: +49 9341/899-108
E-mail: serv[email protected]
Document type Maintenance manual
Translation of the original maintenance manual
Production number 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, translations, microfilm-
ing, and the storage and processing in electronic systems.
TABLE OF CONTENTS
Maintenance manual MT 25 / 30 YT 1
Vehicle identification ................................................. 3
Vehicle identification plate ................................................... 4
Production number ............................................................... 5
User instructions ....................................................... 7
On this Maintenance manual ............................................... 8
Content overview ................................................................. 9
Warranty / Liability ............................................................. 10
MAFI Service ..................................................................... 11
Safety instructions .............................................................. 12
Graphical aids .................................................................... 13
Symbols ............................................................................. 14
Safety ........................................................................ 15
General information ........................................................... 16
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 ........................................................................ 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 conditioner .................................................................... 79
Electrical system ................................................................ 80
Air suspension ................................................................... 86
Operating materials ................................................. 87
General information ........................................................... 88
Fuels .................................................................................. 89
Oils ..................................................................................... 91
Coolant ............................................................................... 94
Lubricating greases ............................................................ 95
Filling quantities ................................................................. 96
ENVIRONMENTAL NOTES ...................................... 97
2Maintenance manual MT 25 / 30 YT
Disposing of operating materials ........................................ 98
MAINTENANCE CERTIFICATES ............................103
General ............................................................................ 104
Maintenance certificate .................................................... 105
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION PLATE
4Maintenance manual MT 25 / 30 YT
Vehicle identification 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:
zvehicle type
zproduction number
zweights
zcargo
zbattery
11-C25-003-007A-3
VEHICLE IDENTIFICATION
PRODUCTION NUMBER
Maintenance manual MT 25 / 30 YT 5
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:
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 key
……………………….. ………………………..
6Maintenance manual MT 25 / 30 YT
USER INSTRUCTIONS
ON THIS MAINTENANCE MANUAL
8Maintenance manual MT 25 / 30 YT
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.
The more you are familiar with the MT, the better you can work
with it and drive in traffic.
The following is therefore important:
zYou are familiar with and understand the contents of this
Maintenance manual.
zThat, after familiarising yourself theoretically with the oper-
ating elements and maintenance procedures of the MT, you
practice these before actually using the MT.
zYou do not activate any switches or try out any operating
procedures with which you are unfamiliar.
zInform other users about all safety instructions and warn-
ings.
zAdhere to the generally applicable regulations for the area
(company or public roads) in which you operate the MT.
Directional and positional specifications
Fig. 3: Main travel direction
The positional specifications “front”, “rear”, “left”, and “right”
always refer to those positions when you look in the main travel
direction (arrow).
USER INSTRUCTIONS
CONTENT OVERVIEW
Maintenance manual MT 25 / 30 YT 9
Content overview
This Maintenance manual contains tips and advice on the fol-
lowing:
zWorking safely with the MT
zMaintaining the use and efficiency of the MT
zTroubleshooting in the event of problems.
Vehicle identification
In this chapter you will find information on the location of
mounting and on the contents of the vehicle identification
plate.
User instructions
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.
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.
USER INSTRUCTIONS
WARRANTY / LIABILITY
10 Maintenance manual MT 25 / 30 YT
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:
zInappropriate use of the MT (see “Intended use” on
page 17)
zIgnoring the notes, regulations, and prohibitions of the
Maintenance manual
zArbitrary constructional modifications on the MT
zPoor monitoring of parts that are subject to wear
zImproper and late maintenance.
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.
USER INSTRUCTIONS
SAFETY INSTRUCTIONS
12 Maintenance manual MT 25 / 30 YT
Safety instructions
The safety signs in this Maintenance manual are in a system-
atic order depending on the severity of the danger and the
probability of their occurring.
DANGER!
Life threatening!
A symbol in connection with the word “Danger” warns
about an immediate risk that endangers the health and
life of persons. Ignoring these safety instructions results
in serious injury; possibly even death.
XBe sure to observe the measures described to avoid
these dangers.
WARNING!
Danger of injury!
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.
XBe sure to observe the measures described to avoid
these dangers.
CAUTION!
Material damages!
A symbol in connection with the word “Caution” warns
about a possibly dangerous situation that endangers the
health of persons or about material or environmental
damage. Ignoring these safety instructions can result in
injuries or material or environmental damage.
XBe sure to observe the measures described to avoid
these dangers.
USER INSTRUCTIONS
GRAPHICAL AIDS
Maintenance manual MT 25 / 30 YT 13
Graphical aids
You will find the following graphical aids in this Maintenance
manual.
Instructions / Activities
XThe preceding symbol draws your attention to a task to be
preformed.
XSeveral symbols draw your attention to a sequence of tasks.
3The 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.
zEntry 1,
zEntry 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 with advice or information that can
guide you on.
USER INSTRUCTIONS
SYMBOLS
14 Maintenance manual MT 25 / 30 YT
Symbols
Important and especially useful information are emphasised
with the following symbols so that they can be noticed easily.
Warning
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.
SAFETY
GENERAL INFORMATION
16 Maintenance manual MT 25 / 30 YT
General information
The “Safety” chapter contains basic safety instructions and
worker's protection regulation for handling the MT.
Observing all instructions given in this 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 those safety
instructions as well.
SAFETY
INTENDED USE
Maintenance manual MT 25 / 30 YT 17
Intended use
The MT may be employed only as a tractor. It is designed and
adapted for the special usage requirements in
zterminal traffic in ports,
zshipping, postal, and railway terminals,
zloading cargo cars from semi-trailers,
zindustrial use with the Cargotrailer system, lift trucks, and
semi-trailers.
The MT may only be driven on the traffic routes authorised by
the company.
The MT is designed and built for carrying the following loads:
MT 25
MT 30
A second person may be seated on the foldaway seat only for
the purpose of instructing and training the driver.
Please observe the engineering shop directive (VDMA)
“Guideline for the intended and proper use of industrial trucks”
and the accident prevention regulation “Industrial Trucks”
(BGV D27).
If your MT is to be used for work not specified in these direc-
tives, please consult your nearest MAFI representative.
Refittings, 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
zTransporting extra persons on the MT or in the driver's cab.
zMoving or carrying loads which exceed the maximum per-
missible load.
zTransporting loads at speeds greater than the permitted
maximum.
zMoving or transporting loads that cannot be safely secured
by the available MT couplings.
System load (GCW) 80,000 kg
Coupled load at 6 km/h 25,000 kg
System load (GCW) 90,000 kg
Coupled load at 6 km/h 32,000 kg
SAFETY
OTHER DANGERS
18 Maintenance manual MT 25 / 30 YT
Other dangers
The MT has been constructed according to state-of-the-art
technology and acknowledged safety regulations. Neverthe-
less when it is used there may be danger for life and limb of the
user or other persons or damage to the MT or other property.
Therefore operate the MT only:
zwhen it is in faultless condition,
zwith concern for safety and dangers.
This is under the prerequisite that the MT has been serviced
and maintained properly. Have any deviations on the MT
repaired immediately by qualified technicians. This concerns
especially changes that can become a danger to persons and
property.
Parking
WARNING!
Danger of injury!
A parked MT can roll away on steep inclines and injure
persons.
XAdditionally secure the MT with blocks.
Driving with towed loads
DANGER!
Danger of injury!
Inappropriate driving behaviour in difficult operating
conditions or driving with heavy loads can cause the MT
to lose control, causing considerable personal injury
and property damage.
XHitch up cargo only if is can be braked by the MT.
XAdapt the driving speed to the conditions of the road
and the cargo.
XAdjust the towed load accordingly to suit operating
conditions.
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