MAFI Trac T225 User manual

Maintenance manual
MAFI - Trac
T225/T230
Terminal Trac
...get it rolling
Production no. 326xxxx

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: serv[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.

TABLE OF CONTENTS
Maintenance manual T225/T230 1
Vehicle identification ................................................. 3
Vehicle identification plate ................................................... 4
Production number ............................................................... 5
User instructions ....................................................... 7
About 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 .................................................................... 19
Qualifications of the operating personnel ........................... 22
Personal 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 conditioner ................................................................... 92
Electrical system ................................................................ 95
Air suspension ................................................................. 100
Operating materials ............................................... 101
General information ......................................................... 102
Fuels ................................................................................ 103
Oils .................................................................................. 105
Coolant ............................................................................. 107
Lubricating greases .......................................................... 108
Filling quantities ............................................................... 109
ENVIRONMENTAL NOTES .................................... 111

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

VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION PLATE
4Maintenance manual T225/T230
Vehicle identification 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:
zvehicle type
zproduction number
zweights
zcargo
zbattery
11-C26-003-007A-5
11-C00-017-001A-2

VEHICLE IDENTIFICATION
PRODUCTION NUMBER
Maintenance manual T225/T230 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
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:
3260xxx
Door key Ignition key
............................. .............................

6Maintenance manual T225/T230

USER INSTRUCTIONS
ABOUT THIS MAINTENANCE MANUAL
8Maintenance manual T225/T230
About this Maintenance manual
General information
This maintenance manual (MM) is a part of the MAFI Trac. In
the following the MAFI Trac is abbreviated to MT.
It informs you of the correct maintenance and intended use of
the MT. The more familiar you are with the MT, the better you
can work with it and drive in traffic.
Therefore it is important:
zYou are familiar with and understand the contents of this
Maintenance manual,
zThat, after familiarising yourself theoretically with the
operating 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
warnings,
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).
11-C26-000-012-2

USER INSTRUCTIONS
CONTENT OVERVIEW
Maintenance manual T225/T230 9
Content overview
This maintenance manual contains tips and advice on the
following:
zWorking safely with the MT,
zMaintaining the operability and efficiencyof the MT,
zTroubleshooting in the event of problems.
Vehicle identification
In this chapter, you will find 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
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 operating materials that
are used in the MT.
Environmental notes
In this chapter, you will find information on environmentally
safe disposal of operating materials.
Maintenance certificates
In this chapter, you will find certification boxes to certify the
maintenance tasks that have been performed on the MT.

USER INSTRUCTIONS
WARRANTY/LIABILITY
10 Maintenance manual T225/T230
Warranty/Liability
The “General sales terms and delivery conditions” of MAFI-
Transport-Systeme GmbH always apply. MAFI rules out
warranty and liability claims for personal injury and material
damage if they result from one or more of the following:
zUnintended 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 T225/T230 11
MAFI Service
The MT belongs to the class of industrial trucks.
According to the Sections 37, 38, 39 Accident Prevention
regulations “Industrial Trucks” (BGV 27D), industrial trucks
have to 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 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 “Industrial Trucks” (BGV 27 D).
Our trained personnel provide fast and competent
maintenance and repairs.

USER INSTRUCTIONS
SAFETY INSTRUCTIONS
12 Maintenance manual T225/T230
Safety instructions
The safety signs in this maintenance manual are in a
systematic order depending on the severity of the danger and
the probability of their occurring.
DANGER!
Life threatening!
A symbol together 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 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.
XBe sure to observe the measures described to avoid
these dangers.
CAUTION!
Material damage!
A symbol together 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 T225/T230 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
performed.
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
bullet 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 further information.

USER INSTRUCTIONS
SYMBOLS
14 Maintenance manual T225/T230
Symbols
Important and especially useful information is emphasised
with the following symbols so that it 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 23.
Note, tip
This symbol marks general notes.

SAFETY
GENERAL INFORMATION
16 Maintenance manual T225/T230
General information
The Chapter “Safety” contains basic safety instructions and
worker's protection regulations for handling the MT.
Observing all instructions given in this 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 those safety
instructions as well.

SAFETY
INTENDED USE
Maintenance manual T225/T230 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.
ausgelegt und abgestimmt.
The MT may only be driven on the traffic routes permitted by
the company.
The MT is designed and built for carrying the following loads:
T 225
T 230
Only for training and instruction purposes is another person
allowed to be seated 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 consultation with MAFI.
Spare parts, ancillary attachments, extra installations, and
accessory parts have to be authorised by MAFI before use.
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
INTENDED USE
18 Maintenance manual T225/T230
Inappropriate use
zTransporting extra persons on the MT or in the driver's
cab.
zMoving or carrying loads that exceed the maximum
permissible load.
zTransporting loads at speeds greater than the permitted
maximum.
zMoving or transporting loads that cannot be safely secured
by the available MT couplings.
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