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Madill 3000, Operation & Maintenance Manual

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Madill 3000 Operation & Maintenance Manual Download Page 4

 
 

1 

SAFETY INDICATORS   

For your safety it is imperative to read and comprehend this 

operator’s manual before 

operating or providing service on the Madill Log Loader. Through this manual these 
symbols will be used to draw your attention to safety information.  

 

  (Red) 

Indicates an imminently hazardous situation which, if not avoided, will result in death or 
serious injury. This signal word is to be limited to the most extreme situations.  

 

  (Orange) 

Indicates a potentially hazardous situation which, if not avoided, could result in death or 
serious injury. 

 

 

  (Yellow) 

Indicates a potentially hazardous situation which, if not avoided, may result in minor or 
moderate injury. It may also be used to alert against unsafe practices. 

 

  (Blue) 

Indicates information pertinent to the operation and maintenance of the machine, which, 
if not heeded, may result in premature component wear or failure.

 

 

 

Summary of Contents for 3000

Page 1: ...3000 4000 LOG LOADER OPERATION MAINTENANCE MANUAL ...

Page 2: ...ransporting 7 Starting Up 7 While Operating 7 Travelling 8 Before Performing Service 7 Night Switch 8 Overloading 8 Fire prevention 9 Welding Precautions 10 Fuse Panel 11 Fuse Ratings 12 MACHINE FUNCTIONS 13 Heeler Joystick Controls 13 Butt N Top Joystick Controls 14 Keypad Controls 15 Key Switch 16 Pilot isolator 16 Air Conditioning Unit 16 Travel Left Right Pedals 16 Diagnostic Plug 16 Stereo 17...

Page 3: ...31 Lubrication 31 Fuel Tank 32 Hydraulic Oil Tank 32 Urea DEF Tank 32 Engine Crankcase 32 Radiator 32 Batteries 32 Engine Oil Filter 33 Hydraulic Return Filter 33 Primary Fuel Filter Water Separator 33 Secondary Fuel Filter 4000 ONLY 33 Engine Air Cleaner Filter 33 Swing Drive Gearbox 33 Track Drive Gearbox 33 Tracks Rollers Rails 34 Third Party Second Hand Attachments 34 3000 Log Loader Service L...

Page 4: ...result in death or serious injury This signal word is to be limited to the most extreme situations Orange Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Yellow Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices Blue Indicates informati...

Page 5: ...ill lessen the need for costly out of warranty repairs and downtime For this reason it is imperative that the basic needs of the machine be satisfied The machine must be lubricated with the specified lubricants at the recommended intervals When ordering parts please include the Madill serial number of the machine and Volvo serial number of the engine Note Madill reserves the right to make technica...

Page 6: ...chine and perform a visual inspection Before the machine is run the oil level in the engine should be checked to ensure it is at the proper level Also check the coolant level and concentration in the radiator Hydraulic fluid in the reservoir should be in the proper range pointed out on the sight glass do not overfill this room must be allowed for fluid expansion due to heat Check the oil level in ...

Page 7: ...4 GENERAL LAYOUT ...

Page 8: ...ch and knobs should be checked for proper operation regularly and lubricated as required This exit should be tested opened monthly Emergency Exit Operation The window located in the roof of the cab serves as the secondary emergency exit for this machine Emergency Roof Exit Inside Release 1 Pull down on rubber latches 2 Move seated ball out of retaining clips 3 Swing the window up ...

Page 9: ...t housing 3 Swing window open Alternative Side Window Exits Inside Release 1 Unscrew the three star knobs that run up the edge of the window 2 Push threaded rod through cab wall 3 Swing window open The Alternate Side Window Exists are only operable from inside the cab There is no outside release for these windows ...

Page 10: ...trols are in proper position for starting Check for warning tags Start the machine only from the operator s cab and do not leave the cab while the engine is running Warm the machine up gradually Operate the machine to confirm correct functions Report any unusual noises or conditions for immediate repair Before Performing Service Place attachment on ground shut off engine and remove keys from ignit...

Page 11: ... lead to premature failures Night Switch The night switch is located in the cab riser on the bottom right hand side This switch is used to completely disconnect all electrical circuits in the machine from the battery It is good practice and highly recommended to turn this switch to the OFF position every day after use and during shipping Note When cycling the night switch on ensure that the igniti...

Page 12: ... should be cleaned and serviced daily to maintain moderate engine temperatures Ensure a fire extinguisher and other required firefighting equipment are on the machine and properly maintained If welding on the machine ensure that the area to be welded has been thoroughly cleaned of any flammable materials and that a fire extinguisher is within close reach Refuel the machine only after the engine ha...

Page 13: ...the OFF position as per the Night Switch procedure in this manual 2 Both the positive and the negative battery leads must be disconnected before welding 3 Unplug the following four computer harnesses located in the cab riser prior to welding 4 Ground cable must be in close proximity to welding location Locate ground near electrode so that no current will flow through bearings bushings or pinned co...

Page 14: ... do so can harm other equipment or result in a fire It is never recommended to bypass a fuse Fuse Panel Every circuit on the machine is protected by a fuse located in either MVEC 1 or MVEC 2 on the wall in the cab riser If a fuse blows it MUST be replaced with one of the correct value see Chart MVEC 1 MVEC 2 MVEC 2 MVEC 1 ...

Page 15: ...8_LP5 10A F8 Pressurizer 15A F9 Ignition Power IGN_PWR 10A F9 RC Card 4000 Only 3A F10 Rear Light LHTS_REAR 10A F10 Not Used 3A F11 Display Power VA_PWR 5A F11 115V Inverter 30A F12 HFX48 Load Power 6 HFX48_LP6 10A F12 RC Card 4000 Only 10A F13 HFX48 ECU Power HFX48_PWR 5A F13 Seat Heat 10A F14 HFX20 Load Power 1 HFX20_LP1 10A F14 24V Sensors 5A F15 HFX20 Load Power 2 HFX20_LP2 10A F15 Not Used 3A...

Page 16: ...13 MACHINE FUNCTIONS Heeler Joystick Controls Note Operator can customize joystick function through touch screen display ...

Page 17: ...14 Butt N Top Joystick Controls Note Operator can customize joystick function through touch screen display ...

Page 18: ...lows swing function Work Light Triple function press sequence LOW HIGH OFF Rear Light Press sequence ON OFF Interior Light Press sequence ON OFF Throttle Control Press Sequence Brings idle to 2000 rpm for 3000 or 1650 rpm for 4000 Brings idle to 1800 rpm for 3000 or 1500 rpm for 4000 Brings idle to 1200 rpm for 3000 or 900 rpm for 4000 House Up Press and hold Window Wiper Press Sequence 10 second ...

Page 19: ...s Air Conditioning Unit The air conditioning unit in your Madill machine must be cycled on a bi weekly basis to ensure that the compressor seals remain lubricated Refrigerant may leak from the compressor if the unit is not run regularly particularly over the fall and winter months The air conditioner warranty does not cover claims for refrigerant loss that are compressor seal related if the unit h...

Page 20: ...er button 1 to display the software version 2 Press the VOL button 3 to display RESET 3 Press the power button to confirm factory default restore After reset the unit will default to FM mode Volume Press the VOL button 3 to increase the volume Press the VOL button 2 to decrease the volume Press and hold either button to change the volume level quickly Mute Press the MUTE button 9 to silence the au...

Page 21: ... Seek Press and hold the l or l button to seek strong radio frequencies Preset Channel Store To manually store a favorite channel to one of the six preset channels perform the following steps 1 Press the l or l button 6 7 to tune to the radio frequency you want to store 2 Press and hold the FOLDER button 4 5 to access the preset channel list 3 Press the l or l button to select the desired preset c...

Page 22: ...n to access the following Bluetooth Menu options o BT ON OFF Press the VOL ON or VOL OFF button to turn the Bluetooth function on or off o BT Pair On the BT Pair screen press the MUTE 9 button to make pairing available for 120 seconds then connect using your Bluetooth enabled device o DEVICE Press the MUTE button to view a list of previously paired mobile phone devices Press the VOL or VOL buttons...

Page 23: ...l be able to listen to audio stored on your Bluetooth enabled device through the radio Answering a Call When answering a call using the connected phone Bluetooth audio play back will pause After hanging up from the call Bluetooth audio will continue on some phones It may be necessary to press the play button to resume Bluetooth audio playback Bluetooth Audio A2DP Selecting Tracks During playback p...

Page 24: ...djustment 4 Handle for fore and aft adjustment 5 Handle for backrest angle adjustment 6 Turn wheel for armrest height adjustment 7 Turn dial for lumbar adjustment For further seat operation information see manufacturer s manual Seat MAX load is 400lb overloading the operator s seat may result in premature failures and voided warranty ...

Page 25: ...ith a house tilt override In standard operating configuration the rocker switch located in the cab riser see picture controls the cab tilt function However there is a manual override to change this rocker switch to the house tilt function The picture below shows the connector that must be switched to change the function of the switch Once this connector located in the riser wiring harness has been...

Page 26: ...23 INTERFACE WARNING LIGHTS Main Display ...

Page 27: ...lot Unlocked Oil Filter Hydraulic Filter Low Hydraulic Oil High Hydraulic Oil Temperature Fan Reverse Rad Door Cab Door Rear Light Work Lights Seat Belt Preheat Exhaust After Treatment System Yes No No No Yes Yes Yes No No No No No No No No No No No No No No No No No No No No No No Yes ...

Page 28: ...ontrol Return to home screen Defrost mode Unit selection Celsius Fahrenheit Air recirculation Max Defrost mode Decrease temperature Increase temperature AC Heat mode selection Decrease fan speed Increase fan speed ...

Page 29: ...e the control you wish to change is highlighted red press the button to scroll through the available options When you have found your new desired control press you wish to set simply press the button until the red highlighting around the symbols disappears The button will bring you back to the main screen ...

Page 30: ...engine RPM o Idle at 1200 RPM for 3000 900 RPM for 4000 o As soon as hydraulic function is applied bump up to 2000 RPM for 3000 1650 RPM for 4000 o After 15 seconds idle time bump down to 1200 RPM for 3000 900 RPM for 4000 2 With Auto idle deactivated engine rpm set from control panel o First press sets 2000 RPM for 3000 1650 RPM for 4000 o Second press sets 1800 RPM for 3000 1500 RPM for 4000 o T...

Page 31: ...ne Live Machine Monitoring Display This screen displays live operating information of the machine Engine Fault Code Display This screen is available in a landscape orientation only Here the engine will display all necessary information for the operator to service or diagnose repairs as required ...

Page 32: ...e Check hydraulic reservoir for low oil level Check oil cooler filter for clogging Check for excessive relief valve operation or hydraulic circuit malfunction Warning lights and buzzer indicate high oil temperature Engine Oil Pressure Gauge provided to monitor engine oil pressure Oil pressure must register immediately aft er engine has started At operating temperature oil pressure should be betwee...

Page 33: ...ill cause engine to de rate DEF is less than 15L 4gal low level indication icon is yellow DEF is less than 5L 1 3gal low level indication icon is red Hour Meter Gauge provided to monitor engine operating hours Hydraulic Filter Warning light indicates that the in tank return filter is nearing by pass operation Light indicates at 15 psi filter by passes at 21 psi Light may indicate under cold start ...

Page 34: ...res hot or cold under constant heavy load operating intermittently or operating in very dusty conditions constitute severe conditions and operation Lubrication Keeping your machine properly lubricated is the most effective way to prevent failures The lubrication chart provides reference to all points requiring lubrication and to the recommended frequency of lubrication A Keep all lubricants and lu...

Page 35: ...ll evacuate fluid out of system to prevent freezing and solution spoiling Do NOT disconnect power before the completion of this process which can take up to 2 minutes see Night Switch Operation Engine Crankcase Check the level of the engine oil daily and add the proper oil as necessary see the manufacturer s recommendations Never operate the engine with low oil Change the oil filter at every oil c...

Page 36: ...r Filter Clean or replace engine air filter element as per lubrication and maintenance chart or as required by conditions Remove the filter element and tap against a clean surface to remove dust and particles DO NOT blow out with compressed air Swing Drive Gearbox Check the level of lubricant in the swing drive gearboxes daily The level should be checked at the level plug on the top of the gearbox...

Page 37: ...rollers to equalize wear Regular roller rotation greatly increases product lifecycle as the front and rear rollers take approximately 80 of the wear on track machines The wear drops off to a minimum on center rollers Third Party Second Hand Attachments In the event a Madill log loader is fitted with an attachment that is third party or second hand it is mandatory that a dual flow hydraulic oil fil...

Page 38: ...35 ...

Page 39: ...36 3000 Log Loader Service Lubrication Chart ...

Page 40: ...37 4000 Log Loader Service Lubrication Chart ...

Page 41: ... 35 10 7m 35 500 16 103 15 800 7 167 Machine Weight lb kg 94 000 42 638 ENGINE Manufacturer Volvo Penta Model TAD873VE Cylinders 6 Power HP kW 315 253 2000 rpm Torque ft lbs Nm 828 1123 2000 rpm Hydraulic Flow GPM L m 151 572 4500 psi Weight lb kg 2088 947 Angularity limits 40 Firing Order 1 4 2 6 3 5 Displacement in3 cc 470 7702 Compression Ratio 17 5 1 System Voltage 24V FLUID CAPACITIES US Gall...

Page 42: ...20457 19 200 8709 Machine Weight lb kg 102 700 46 584 ENGINE Manufacturer Volvo Penta Model TAD1371VE Cylinders 6 Power HP kW 388 285 1650 rpm Torque ft lbs Nm 1338 1814 1650 rpm Hydraulic Flow GPM L m 292 1105 4000 psi Weight lb kg 3946 1790 Angularity limits 11 degree Firing Order 1 5 3 6 2 4 Displacement in3 cc 780 12782 Compression Ratio 17 8 1 System Voltage 24V FLUID CAPACITIES US Gallons Li...

Page 43: ...40 ...

Page 44: ...Madill Equipment 9896 Galaran Road P O Box 2128 Sidney BC Canada V8L 3S6 ...

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