Madill 3000/4000 Log Loader Operation & Maintenance Manual PDF

105365G 3000/4000 LOG LOADER OPERATION & MAINTENANCE MANUAL ME001-MANU-A0002 105365G Contents 1. SAFETY INDICATORS........................................................................................ 1 2. FOREWORD.......................................................................

105365G 3000/4000 LOG LOADER OPERATION & MAINTENANCE MANUAL ME001-MANU-A0002 105365G Contents 1. SAFETY INDICATORS........................................................................................ 1 2. FOREWORD........................................................................................................ 2 3. MACHINE OVERVIEW......................................................................................... 3 4. GENERAL LAYOUT............................................................................................. 4 5. EMERGENCY EXIT............................................................................................. 5 5.1 Emergency Exit Operation.............................................................................................5 5.2 Emergency Roof Exit....................................................................................................5 Outside Release:..................................................................................................................6 5.3 Alternative Side Window Exits......................................................................................6 6. SAFETY PRECAUTIONS..................................................................................... 7 6.1 Before you start.............................................................................................................7 6.2 Tilting Engine House and Cab.......................................................................................7 6.3 After Transporting.........................................................................................................9 6.4 Starting Up....................................................................................................................9 6.5 Before Performing Service.............................................................................................9 6.6 While Operating.......................................................................................................... 10 6.7 Travelling.................................................................................................................... 10 6.8 Night Switch................................................................................................................ 10 6.9 Overloading................................................................................................................. 11 6.10 Fire prevention........................................................................................................... 11 6.11 Welding Precautions.................................................................................................. 12 6.12 High Voltage Contact................................................................................................ 14 6.13 Fuse Panel and Ratings.............................................................................................. 14 7. TRANSPORTATION.......................................................................................... 16 7.1 Disassembly................................................................................................................ 16 7.2 Machine Dimensions................................................................................................... 17 8. MACHINE FUNCTIONS..................................................................................... 18 8.1 Heeler Joystick Controls.............................................................................................. 18 8.2 Butt N’ Top Joystick Controls..................................................................................... 19 8.3 Keypad Controls.......................................................................................................... 20 8.4 Key Switch.................................................................................................................. 21 8.5 Pilot isolator................................................................................................................ 21 8.6 Air Conditioning Unit.................................................................................................. 21 8.7 Travel - Left & Right Pedals........................................................................................ 21 8.8 Seat Controls................................................................................................................ 22 8.9 Secondary House Tilt Location.................................................................................... 23 9. INTERFACE & WARNING LIGHTS.................................................................... 24 9.1 Main Display............................................................................................................... 24 9.2 Warning Lights and Buzzers........................................................................................ 25.......................................................................................................................................... 26 105365G 9.3 Climate Control........................................................................................................... 26 9.4 Joystick Set-up............................................................................................................ 27 Engine Coolant/ Hydraulic Oil Temperature...................................................................... 31 Engine Oil Pressure........................................................................................................... 31 Voltmeter.......................................................................................................................... 31 Fuel/ DEF Level Gauge...................................................................................................... 32 Low Fuel/ DEF.................................................................................................................. 32 Hour Meter........................................................................................................................ 33 Hydraulic Filter.................................................................................................................. 33 10. SERVICE & LUBRICATION............................................................................... 34 10.1 Lubrication................................................................................................................ 34 10.2 Fuel Tank................................................................................................................... 35 10.3 Hydraulic Oil Tank.................................................................................................... 35 10.4 Urea (DEF) Tank....................................................................................................... 35 10.5 Engine Crankcase...................................................................................................... 35 10.6 Radiator..................................................................................................................... 35 10.7 Batteries..................................................................................................................... 35 10.8 Engine Oil Filter........................................................................................................ 36 10.9 Hydraulic Return Filter.............................................................................................. 36 10.10 Primary Fuel Filter/Water Separator........................................................................... 36 10.11 Secondary Fuel Filter (4000 ONLY)......................................................................... 36 10.12 Engine Air Cleaner Filter.......................................................................................... 36 10.13 Swing Drive Gearbox............................................................................................... 36 10.14 Track Drive Gearbox............................................................................................... 36 10.15 Tracks, Rollers & Rails............................................................................................ 37 10.16 Third Party/Second-Hand Attachments.................................................................... 37 10.17 3000 Log Loader Service & Lubrication Chart......................................................... 39 10.18 4000 Log Loader Service & Lubrication Charts....................................................... 40 11. GENERAL INFORMATION................................................................................ 41 Appendicies Attached Fault Code Table Hydraulic Schematic, BNT, 3000 Hydraulic Schematic, Heeler, 4000 Wiring Harness, Deck, 3000 Wiring Harness, Deck, 4000 Wiring Harness, Riser Wiring Harness, Cab Wiring Harness, Seat Pinout Table 105365G 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. 1 105365G 2. FOREWORD The operation and maintenance manual is designed to familiarize the operator with the machine and all the necessary information so they may take full advantage of the built- in capabilities. If the machine is operated and maintained properly, it will 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. Between boom pins Note: Madill reserves the right to make technical changes on the machine without notice. 2 105365G 3. MACHINE OVERVIEW When the machine is first delivered, it is important to go through a series of inspections and checks before placing the machine in service. When checking for leaks in the Checking the positions of the shipping blocks hydraulic system, use a piece of supporting the machine can indicate damage that may have occurred during shipping. All cardboard or wood. A small blocking should be tightly in place and all cables stream of high pressure oil can should be properly tensioned. Loose cables and penetrate the skin and cause blocks may mean the machine has been jarred serious injury. or subjected to unusual vibration; this could mean loose parts and bolts. Inspect the machine DO NOT USE YOUR HAND OR surface for damage. Walk around the machine and perform a visual inspection. FINGERS TO SEARCH FOR LEAKS. 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 If you are struck by pressurized concentration in the radiator. Hydraulic fluid in hydraulic fluid, seek medical the reservoir should be in the proper range attention immediately. 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 all gearboxes. Consult the Service & Lubrication Section for correct service procedures. Lubricate all fittings to be sure they will accept grease. Read Section 6.3, ‘Starting Up’, before running the engine. Start and run the engine until it warms up. Cycle the various functions and monitor the system for unexpected behavior such as stalling or pressure loss. Normally the first hours of operation or break in period During break in period (first are the most crucial to the machine. It is at this time that bolts loosen due to wearing-in process and metal 100-200 hours of operation) contact is greatest in the hydraulic system. Open the higher oil consumption is doors of the machine and look over the wiring, hoses, normal. For this reason, clamps and piping. Verify the fluid levels of the engine, check the oil level more radiator and hydraulic reservoir are still sufficient. frequently than the normal Inspect the side frames for oil on the rollers and the recommendation. drive gear boxes. 3 105365G 4. GENERAL LAYOUT 4 105365G 5. EMERGENCY EXIT The Madill Log Loader is equipped with an emergency exit. To ensure the proper operation of this exit, regular inspection and proper maintenance is essential. The latch and knobs should be checked for proper operation regularly and lubricated as required. This exit should be tested / opened monthly. 5.1 Emergency Exit Operation The window located in the roof of the cab serves as the secondary emergency exit for this machine. 5.2 Emergency Roof Exit Inside Release: 1. Pull down on rubber latches. 2. Move seated ball out of retaining clips. 3. Swing the window up. 5 105365G Outside Release: 1. Unscrew the two outside star knobs and remove them. 2. Push threaded rods through emergency exit housing. 3. Swing window open. 5.3 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. 6 105365G 6. SAFETY PRECAUTIONS 6.1 Before you start Know your machine; become familiar with the machine’s work envelope/area. Adhere to proper cleaning and maintenance schedules. Do not operate the machine without Do not walk on any wearing PPE as per your worksite and/or local regulations. surface not designated as Ensure protective guards are in place. Check height, weight part of the access system. and width restrictions for your work area. Be sure you know Never walk on the rear about any hazards, such as power lines. Be familiar with the portion of the house or hand signals used in your workplace. along the top of the boom. 6.2 Tilting Engine House and Cab 6.2.1 Engine House Tilting Always be aware of your surroundings when tilting the engine house. Never tilt the engine house unless the machine is on level ground and any objects on or in the engine house have been removed or properly secured. The cooler door, on the rear of the machine, Do not enter the engine bay until must be closed before opening the engine house. the engine house is fully open Ensure all personnel and objects are clear of the engine house as it is being raised or lowered. 6.2.2 Cab Tilting Always be aware of your surroundings when tilting the cab. Never tilt the cab unless the machine is on level ground. Ensure no people or objects are in the shaded hazard area of the cab when it is being raised or lowered. When raising the cab keep hands clear of the area where the cab meets the riser. Always check for any objects that could contact the cab prior to raising or lowering. Also, check for any objects on the engine house or cab that could fall off prior to lowering the cab. Inspect the cab restraint cable before tilting cab back up to operating position. Operating Instructions for Tilting the Cab 1. Park the machine on level ground 2. Shut off the engine before tilting the cab 3. Check that the cab will clear any obstructions 7 105365G 4. Remove or secure all loose objects from cab to prevent damage when cab is tilted 5. Make sure all access hatches are closed and latched 6. Remove the cab-to-riser bolts along the back edge of the cab 7. The cab door must be closed before the cab can be tilted 8. Make sure all personnel are clear of the area in front of the cab 9. Tilt the cab down using the tilt cab switch, extend the cylinder until the cab restraint cable is tight. Never leave the cab in a position where it is not supported by either the safety cable or riser bolts 10. Inspect the cab restraint cable, hydraulic cylinder and anchor pins for damage while the cab is tilted down 11. To return the cab to the operating position, retract the cylinder until the cab is reseated 12. Secure cab into position by installing the cab-to-riser bolts. Torque the bolts as per section 6.3 Make sure all personnel are clear of the caution areas when tilting the cab or engine house 8 105365G Make sure all personnel are clear of pinch areas 6.3 After Transporting Always ensure all six cab-to-riser mounting bolts are installed and properly torqued. Under no circumstance Cab to Riser bolts to be shall the machine be operated without all handrails torqued to 1100 Ft.-lb. per bolt installed and affixed. See transportation section for with Loctite C5-A applied. disassembly and re-assembly of machine access system. 6.4 Starting Up Make sure all controls are in proper position for starting. Check for warning tags. Start the machine only from the operator’s cab with the wand switch in the downward position and do not leave the cab while the engine is Starting spray of any kind is running. Warm the machine up gradually. Operate the never permitted machine to confirm correct functions. Report any unusual noises or conditions for immediate repair. If an attachment NEVER start the engine has been installed, ensure operator is aware of proper without an air filter in place and safe operation of said attachment. 6.5 Before Performing Service Place attachment on ground, shut off engine and remove keys from ignition. Attach a “DO NOT OPERATE” tag in an obvious place in operator’s cab. 9 105365G 6.6 While Operating PAY ATTENTION! Know the working range of your machine. Know where any obstructions might be. Be sure everyone is in the clear before moving any part of the machine. Never swing or position any attachment or load over ground crew or vehicles. Never allow anyone to ride on any attachment or load. Never attempt to operate the machine from any position outside the operator’s cab. Never operate in a location where the machine or load may contact electric power lines. If the machine comes into contact with high voltage lines refer to section 6.11 before determining if it is safe to return to operation. ALWAYS operate with seat belt fastened. Do not walk on any surface not designated as part of the access system. Never walk on the rear portion of the house or along the top of the boom. 6.7 Travelling Always ensure that the working area is free of persons before swinging or travelling the machine. Never get on or off the machine while it is in motion. Lock the swing brake when you travel. Cross obstacles at an angle and at low speed. Watch to see that your boom clears all obstacles. Hydraulically released travel brakes are automatically released when any travel control is engaged. Loss of system pressure will cause the brake to apply automatically. When traveling downgrade and loading/unloading the machine, it is highly recommended to lock the travel mode selector into the low gear setting. To avoid unnecessary wear or track skipping/ falling off, it is crucial to travel the machine such that the drive sprockets are at the ‘rear’ of the travel direction. Neglecting to do so may lead to premature failures. 6.8 Night Switch The night switch is 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 Before performing any this switch to the OFF position every day service on this machine, after use and during shipping. the Night switch must be turned to the OFF position, unless otherwise specified for testing procedures. 10 105365G The orange light beside the cab tilt rocker switch will flash if the engine shut down sequence is in progress. DO NOT turn the night switch to the OFF position while the The courtesy lights on the light is flashing, doing so will cause engine machine can be activated code and check engine light to illuminate. Once the orange for 3 minutes by cycling the light stops flashing, the night switch may be safely turned to night switch off, then on. the OFF position. 6.9 Overloading Overloading is hazardous. Make certain you are within the safe load and work radius limits of your machine for prevailing conditions. Uneven or sloping terrain will Overloading the machine reduce the load and working radius of your machine. may result in rollover which Overloading the machine can result in rollover which may cause serious injury may cause serious injury or death. or death. 6.10 Fire prevention Due to the operating conditions found in mechanized logging there are significant fire hazards that can arise over time if the equipment is not kept clean and well maintained on a continual basis. In order to minimize the fire hazards present on the machine it is important to reduce or eliminate both potential sources of fuel for a fire and potential sources of ignition. The following precautions must be taken for the safe operation of the machine: Accumulation of needles, leaves, bark, wood chips, sawdust or other debris must be removed daily Hydraulic leaks, accumulations of grease, diesel fuel or oil must be repaired and cleaned up immediately Electrical wires, battery cables, hydraulic hoses and fuel lines must be inspected daily and replaced immediately if damaged or worn The radiator and engine cooling system 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. Refer to section 6.10, ‘Welding Precautions’, before beginning any welding operations 11 105365G Refuel the machine only after the engine has been stopped and allowed to cool down For machines with an automatic fire suppression system the following precautions are required to ensure maximum effectiveness: The house must be kept down with all access doors closed while the machine is running except when required for service, maintenance and inspections If a fire is detected before the system has discharged, activate the system manually DO NOT wait for the system to automatically activate In the event of a fire while the house is open, immediately close the house after ensuring that all personnel are clear of the area. Once closed, manually activate fire suppression system 6.11 Welding Precautions When welding, the following must be done to avoid damage to the machine electrical systems. 1. Turn the night switch to the OFF position as per the Night Switch procedure (section 6.7) in this manual. Welding on engine or 2. Both the positive (+) and the negative (-) battery engine mounted leads must be disconnected before welding. components is NEVER recommended. 12 105365G 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 connections. 13 105365G 6.12 High Voltage Contact If the machine has been subjected to high voltage contact, it must be removed from service until a qualified person has conducted an inspection of and undertaken If the fuse blows a second time, any necessary repairs to the machine. the circuit must be inspected and tested for shorts or 6.13 Fuse Panel and Ratings malfunctioning parts. Failure to Every circuit on the machine is protected by a fuse do so can harm other equipment located in either MVEC #1 or MVEC #2 on the wall in the or result in a fire. It is never cab riser. If a fuse blows it MUST be replaced with one of recommended to bypass a fuse. the correct value (see Chart). MVEC #1 MVEC #2 14 105365G Note: Fuse table and diagrams also provided in attached 17” x 22” schematics 15 105365G 7. TRANSPORTATION To facilitate the transportation of the machine, several parts of the machine access system are commonly removed. It is mandatory that all parts of this access system are replaced before the machine is operated. 7.1 Disassembly 1. Once the machine is located on suitable transport platform and secured, remove the six cab-to-riser bolts and place in a clean and secure location. 2. Remove all house handrails. To remove the handrails, the locking pin located at the base of the handrail must be removed. The handrail can then be lifted vertically off its mount. 3. Once removed, the handrails should be stowed and secured on a suitable platform. Ensure the handrails are secured using suitable straps. 4. The cab upper structure can now be tilted into its transport position. This is done using the rocker switch found in the cab riser, located above the night switch. Hold the rocker switch until the cab upper structure rotates into its lowest position. 5. With the cab upper structure in the transport position, rotate the night switch to the “OFF” position to remove all power to the machine. 6. Always perform a final walk-around to ensure machine has been properly secured to the transport device. Confirm all railings and access system components are properly secured. 16 105365G 7.2 Machine Dimensions Cab down: Cab up: Note: Machine shown above is a 4000, refer to table below for correlating dimensions for 4000 and 3000 machines. Dimensions are intended as reference dimensions, it is recommended that a machine is measured if accurate dimensions are required. 3000 4000 DIM METRIC (M) IMPERIAL METRIC (M) IMPERIAL A 3.72 12’ 2 ¾” 3.95 12 ’11” B 7.97 26’ 2” 8.21 26’ 11 ⅓” C 13.96 45’ 9 ¾” 15.14 49’ 8 ¼” D 3.44 11’ 3 ½” 3.56 11’ 8” E 3.51 11’ 6 ½” 3.67 12’ ½” F 4.11 13’ 5 ½” 4.25 13’ 11 ½” G 5.25 17’ 2 ¾” 5.36 17’ 7 ¼” 17 105365G 8. MACHINE FUNCTIONS 8.1 Heeler Joystick Controls Note: Operator can customize joystick function through touch screen display 18 105365G 8.2 Butt N’ Top Joystick Controls Note: Operator can customize joystick function through touch screen display 19 105365G Park Function Press Sequence - Activates pilot pressure and hydraulic function 8.3 Keypad Controls - Deactivates pilot pressure and hydraulic function Travel Mode Press Sequence - Allows automatic gear selection of HIGH/LOW - Locks travel drives in low gear Engine Fan Reverse - Press to reverse fan direction - Press and hold button will activate max fan override Swing Brake Press Sequence - Locks swing function - Unlocks and allows 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 1800 rpm for 3000 or 1500 rpm for 4000 - Brings idle to 2000 rpm for 3000 or 1650 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 delay/ 3 second delay/ Continuous /OFF Left Window UP - Press and hold Right Window UP - Press and hold House down - Press and hold Washer Fluid - Press and hold Left Window Down - Press and hold Right Window Down - Press and hold 20 105365G 8.4 Key Switch OFF – Disconnects all electrical power, Turn to OFF position to shut down engine. Leave key in this position when machine is not operating. RUN – Battery is connected and electrical function is regained, Key will stay in this position while engine is running. START – This will start the engine by connecting the battery to the start relay, hold here until engine starts. Once released the key will return to RUN position. 8.5 Pilot isolator This safety feature is provided to prevent accidental and improper use of the hydraulic controls. The pilot isolator requires the wand The pilot isolator must not be to be in the down position to unlock hydraulic tampered with or deactivated in any functions. way. Never operate the machine from anywhere but the operators seat. 8.6 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 has not been run on a regular basis. 8.7 Travel - Left & Right Pedals To maximize undercarriage component life keep the drive sprockets to the rear of the machine. This orientation is assumed for travel direction descriptions. FORWARD Depress front of both pedals REVERSE Depress rear for both pedals STEER LEFT Depress front of right pedal and rear of left pedal to steer left STEER RIGHT Depress front of left pedal and rear of right pedal to steer right 21 105365G 8.8 Seat Controls Seat MAX load is 400lb; overloading the operator’s seat may result in premature failures and voided warranty 1. Handle for seat depth adjustment. 2. Handle for seat angle adjustment. 3. Handle for height adjustment and for weight adjustment. 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. 22 105365G 8.9 Secondary House Tilt Location The Madill Log Loader is equipped with the standard house tilt controls located on the keypad. In the unlikely event where cab power/control is lost the machine is equipped with 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 switched, the rocker switch will now control the house tilt function. In order to regain Cab tilt control you must switch the connector back to its original configuration. It is imperative to keep the The plug must always be radiator door shut as this returned to its original position. switch configuration will If the connector is left joined to bypass the open door safety the override connector, the feature and can cause house will not be operable from damage to the house and the cab door. 23 105365G 9. INTERFACE & WARNING LIGHTS 9.1 Main Display 24 105365G 9.2 Warning Lights and Buzzers SIGNAL LIGHT BUZZER DERATE Check Engine Yes No Pilot locked No No Pilot Unlocked No No Oil Filter No No Hydraulic Filter Yes No Low Hydraulic Oil Yes No High Hydraulic Oil Yes No Temperature No No Fan Reverse No No Rad Door No No Cab Door No No Rear Light No No Work Lights No No Wand Indicator No No Preheat No Yes Exhaust After Treatment System 25 105365G 9.3 Climate Control - 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 26  105365G 9.4 Joystick Set-up Use the button to scroll the red marker through to the control you wish to change Once 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 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 27 105365G 9.5 Display Icons Warm Up Mode 1. Once selected a dialogue box (shown right) will appear outlining Warm Up Mode Parameters. Press any button on the screen to close the dialogue box. Pressing the button again once Warm Up Mode is activated will toggle the mode off. Functionality o 1000 RPM for 1 minute o Then 1400 RPM for remainder of Warm Up Mode o Warm Up Mode will persist until engine coolant reaches 55 C, or until 15 minutes is reached Information Press once to display all software versions loaded on machine Auto Fan Purge Press once to activate auto fan purge (highlighted green). Fan will purge once every hour for 15s Attachment Selection Press through the sequence of attachments (Heeler, BNT, Power Clam) select the appropriate attachment your machine is equipped with Counter 28 105365G Press once to reset counter display on screen Back Up Camera Press once to activate rear view camera on screen Note: camera will automatically be displayed when traveling Auto Idle Mode 1. With Auto idle active computer will control 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 1800 RPM for 3000 1500 RPM for 4000 o Second press sets 2000 RPM for 3000 1650 RPM for 4000 o Third Press sets 1200 RPM for 3000 900 RPM for 4000 29 105365G Live Engine Monitoring Display This screen displays live operating information for the engine 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. MVEC Status Monitoring This page allows you to monitor the status of fuses and relays. Proper operation is displayed with a green dot, an issue or uninstalled component is displayed with a red dot Scroll Arrows Use the up and down arrows to navigate through the displayed fault codes Delete Button Use this button to erase fault codes (Note: not all fault codes can be erased) 30 105365G Engine Coolant/ Hydraulic Oil Temperature A gauge is provided to monitor engine coolant temperature (Red inside needle). Normal operating range for coolant is 180-200°F (82-93°C). An alarm will sound if engine coolant approaches 221°F (105°C). Engine derate will occur at 225°F (107°C). A gauge is provided to monitor Hydraulic oil temperature (outside orange needle). Normal operating range for hydraulic oil is 140-160ºF. (60-70ºC.). In event of values outside this range: 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 after engine has started. At operating temperature oil pressure should be between 300-650kPa (44-94 psi). If pressure is not sufficient alarm will sound followed by total engine shut down. In this event: Check Engine oil level and fill to an adequate level. Voltmeter Gauge provided to monitor electrical system voltage. Normal range is 24-30V. 31 105365G Fuel/ DEF Level Gauge Gauges are provided to monitor the level of Fuel and DEF on board the machine. The Fuel level is shown with the inside green needle and the DEF level is shown with the outside blue needle. Low Fuel/ DEF Low level indicators will appear when approximately 100L (26.4gal) of fuel or 15L (4gal) of DEF remain in the tanks. Low DEF levels will 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 32 105365G 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-up conditions due to high viscosity. If the light indicates when the hydraulic oil has reached operating temperature the filter element should be replaced. 33 105365G 10. SERVICE & LUBRICATION In order to properly protect your machine and get the best performance with the longest life; schedules of preventive maintenance and lubrication must be adhered to. All maintenance and lubrication schedules are guidelines based upon normal cycles under average working conditions. When unusually severe working conditions or operations are encountered, maintenance and lubrication frequencies must be increased. Operating in extreme temperatures (hot or cold), under constant heavy load, operating intermittently, or operating in very dusty conditions constitute severe conditions and operation. Machine surfaces get extremely hot 10.1 Lubrication during operation and can cause severe Keeping your machine properly lubricated is the burns. most effective way to prevent failures. The lubrication chart (pg. 39 & 40) provides reference Before performing any service on the to all points requiring lubrication, and to the machine allow all surfaces to cool recommended frequency of lubrication. down to below 100F (38C) A. Keep all lubricants and lubricating equipment clean and free of contamination both while in storage and while in use. B. Clean all grease fittings and surfaces before applying a grease gun. Dirt on fittings will be forced through along with the clean grease and may cause accelerated wear and premature bearing failure. C. Wipe off excess grease and other lubricants. Oily and greasy surfaces collect dirt which may work its way into moving parts and cause wear. D. When greasing fittings under normal Under no circumstances may the working conditions, apply grease until recommended lubrication intervals it appears. Under extremely dirty or be exceeded. Avoiding service dusty conditions, apply grease to intervals will be constituted as fittings until old grease has been negligence and will void the flushed. warranty on the machine. 34 105365G 10.2 Fuel Tank Fill the tank daily or as required with diesel fuel. Location of the filler cap is on the top of the tank at the rear of the upper grated platform. Ensure adequate fuel level is maintained. 10.3 Hydraulic Oil Tank Check this daily for oil level. A sight glass is provided and located on the side of the hydraulic tank. Clean hydraulic oil should be added via the hand pump and wand assembly on the side of the hydraulic tank. Never overfill the system. Never run the machine with low oil because this may damage the pumps. 10.4 Urea (DEF) Tank Top up the DEF tank with every fuel fill; only use AdBlue/DEF meeting ISO-22241 specification. Store DEF out of direct sunlight where temperatures DO NOT exceed 35 deg. C. DEF is very corrosive, contact with the solution can cause irritation. When handling wear gloves, change gloves and clothes if spillage occurs. Note: Upon engine shut down DEF pump will evacuate fluid out of system to prevent freezing Allow machine to cool before adding DEF and solution spoiling. DO NOT disconnect solution. Do not re-fill DEF tank with the power before the completion of this process machine running or at operating which can take up to 2 minutes (see Night Switch Operation). If draining the DEF tank is temperature. Allow all surfaces to cool to required there is a drainage port on the bottom 100F (38C) before adding solution. of the DEF tank. 10.5 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 change. 10.6 Radiator Check the coolant level daily. Be sure to use the appropriate coolant mixture in cold weather. Consult the engine manufacturer’s recommendations. Change the coolant and flush the system as per lubrication & maintenance chart. Keep the radiator and oil cooler fins clean so that the cooling system may operate efficiently. Refer to the engine manufacturer’s manual for specific information on engine coolant and service. 10.7 Batteries Check the water level of both batteries weekly. If it is necessary to fill the battery, use distilled water only. DO NOT USE TAP WATER as it may contain minerals which will contaminate the electrolyte. Batteries are located on the floor in the cab riser. 35 105365G 10.8 Engine Oil Filter For oil filter locations refer to the D8 or D13 owner’s manual. Refer to section 10.17 or 10.18 for service intervals. 10.9 Hydraulic Return Filter The Hydraulic return filter is equipped with a gauge displaying OK or CHANGE. Look at the gauge while the machine is running, change return filter when the needle enters the CHANGE zone. 10.10 Primary Fuel Filter/Water Separator Drain water off daily. The filter is remote mounted on the side of the engine. Service as per lubrication and maintenance chart. 10.11 Secondary Fuel Filter (4000 ONLY) The secondary fuel filter is mounted on the side of the engine to the rear of the machine. Service as per lubrication and maintenance chart. 10.12 Engine Air Cleaner 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. 10.13 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. DO NOT operate the machine with improper lubricant level. Service as per lubrication and maintenance chart. 10.14 Track Drive Gearbox Check the level of the lubricant in both track drive gearboxes daily. The level should be checked at the level plug on the outside cover of the gearbox. Housing should be half filled with lubricant. Track may require rotation to put level plug in correct location as cover rotates with drive sprocket. DO NOT operate the machine with improper lubricant level. Service as per lubrication and maintenance chart (pg. 39 & 40). 36 105365G 10.15 Tracks, Rollers & Rails Check track tension regularly and perform a regular inspection of the rollers, by raising each track off the ground with the boom. We suggest a good regular inspection of the rollers, by raising each track off the ground with the boom. Once track is off the ground, measure the gap between the center roller and the top of the track chain. The gap should measure between 2.5” and 3.5” for 3000, and 3.5” and 5” for the 4000. Adjust accordingly; repeat procedure on the opposite side. Consider a program of switching 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. 10.16 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 filter be installed in-line such that the end tool is isolated from all other hydraulic components. Operating unfiltered used attachments can cause severe damage to other hydraulic components on the machine. Ensure operator has proper instruction and understanding of safe operation of attachment. Running a Madill log loader with an unfiltered used attachment will void the warranty 37 105365G 38 105365G 10.17 3000 Log Loader Service & Lubrication Chart 39 105365G 10.18 4000 Log Loader Service & Lubrication Charts 40 105365G 11. GENERAL INFORMATION 3000 MADILL LOG LOADER MACHINE INFORMATION Deck Width - ft. (m) 11’2” (3.40) Tail Swing - ft. (m) 11’2” (3.40) Undercarriage Width - ft. (m) 11’11” (3.63) Travel Speed – mph (kph) 2.8 (4.5) Swing Torque - ft. lbs. (Nm) 102,000 (138,293) Swing Speed - RPM 7.5 Max Reach - ft. (m) 40’6” (12.34) 20' (6.1m) 35’ (10.7m) Lift. @ Reach - lb. (kg) 33,460 (15,117) 14,910 (6,763) Machine Weight - lb. (kg) 95,000 (43,091) ENGINE Manufacturer Volvo Penta Model TAD873VE Cylinders 6 Power - HP (kW) 320 (235) @ 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 Gallons (Liters) Diesel 240 (908) Engine Oil 7.1 (27) Hydraulic Oil 96 (363) Coolant 13.5 (51) DEF 18 (68) 41 105365G 4000 MADILL LOG LOADER MACHINE INFORMATION Deck Width - ft. (m) 12'4" (3.76) Tail Swing - ft. (m) 11'10" (3.50) Undercarriage Width - ft. (m) 12'6" (3.81) Travel Speed – mph (kph) 2.9 (4.7) Swing Torque - ft. lbs. (Nm) 139,000 (188,459) Swing Speed - RPM 7.5 Max Reach - ft. (m) 44 (13.4) 20' (6.1m) 40' (12.2m) Lift. @ Reach - lb. (kg) 46,930 (21,287) 19,300 (8,754) Machine Weight - lb. (kg) 106,000 (48,081) 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 35° Firing Order 1-5-3-6-2-4 3 Displacement - in (cc) 780 (12782) Compression Ratio 17.8:1 System Voltage 24V FLUID CAPACITIES – US Gallons (Liters) Diesel 280 (1060) Engine Oil 13 (49) Hydraulic Oil 108 (408) Coolant 24 (91) DEF 18 (68) 42 105365G 43  Madill 3000 log loader fault codes (rev-) ISO DTC Description (J2012 WWH) System SPN FMI Failure Type (FTB Description) P0016 Crankshaft Position - Camshaft Position Correlation Bank 1 Sensor A CAM Speed sensor 636 7 Wrong Mounting Position P001676 Crankshaft Position - Camshaft Position Correlation CAM Speed sensor 636 7 Wrong Mounting Position P0045 Turbocharger/Supercharger Boost Control "A" VGT Actuator on CAN 641 0 Commanded Position Not Reachable P0045 Turbocharger/Supercharger Boost Control "A" VGT Actuator on CAN 641 5 Circuit Open P0045 Turbocharger/Supercharger Boost Control "A" VGT Actuator on CAN 641 6 Circuit Current Above Threshold P0045 Turbocharger/Supercharger Boost Control "A" VGT Actuator on CAN 641 11 Performance or Incorrect Operation P004A Turbocharger/Supercharger Boost Control "B" Intake supercharger actuator 520566 4 Circuit Short To Ground P004A Turbocharger/Supercharger Boost Control "B" Intake supercharger actuator 520566 5 Circuit Open P004A Turbocharger/Supercharger Boost Control "B" Intake supercharger actuator 520566 7 Slow Response P006E Turbocharger/Supercharger Boost Control "A" Supply Voltage Circuit VGT Actuator on CAN 641 3 Circuit Voltage Above Threshold P0087 Fuel Rail/System Pressure - Too Low Bank 1 Rail Pressure 157 1 No Sub Type Information P0088 Fuel Rail/System Pressure - Too High Bank 1 Rail Pressure 157 0 No Sub Type Information P008A Low Pressure Fuel System Pressure - Too Low Fuel pressure 94 18 No Sub Type Information P008A00 Low-Pressure Fuel System Pressure - Too Low Fuel System 94 18 N/A P008B Low Pressure Fuel System Pressure - Too High Fuel pressure 94 0 Component or System Operation Obstructed or Blocked P0090 Fuel Pressure Regulator 1 Control High Pressure Circuit - Fuel Pressure Regulator 679 3 Circuit Short To Battery P0090 Fuel Pressure Regulator 1 Control High Pressure Circuit - Fuel Pressure Regulator 679 4 Circuit Short To Ground P0090 Fuel Pressure Regulator 1 Control High Pressure Circuit - Fuel Pressure Regulator 679 5 Circuit Open P0094 Fuel System Leak Detected - Small Leak Rail pressure system 1239 14 No Sub Type Information P009B Fuel Pressure Relief Control High Pressure Circuit - Fuel Pressure Electrical Relief Valve (EPRV) 520244 3 Circuit Short To Battery P009B Fuel Pressure Relief Control High Pressure Circuit - Fuel Pressure Electrical Relief Valve (EPRV) 520244 4 Circuit Short To Ground P009B Fuel Pressure Relief Control High Pressure Circuit - Fuel Pressure Electrical Relief Valve (EPRV) 520244 5 Circuit Open P009B Fuel Pressure Relief Control High Pressure Circuit - Fuel Pressure Electrical Relief Valve (EPRV) 520244 7 Actuator Stuck Closed P00C6 Fuel Rail Pressure Too Low - Engine Cranking Bank 1 Rail Pressure 157 14 No Sub Type Information P00D9 Ambient Air Temperature Sensor "B" Air Inlet Temperature /(Ambient Air Temp) 172 4 Circuit Short To Ground P00D9 Ambient Air Temperature Sensor "B" Air Inlet Temperature /(Ambient Air Temp) 172 5 Circuit Open P00D911 Ambient Air Temperature Sensor “B” Intake air system 172 4 CIRCUIT SHORT TO GROUND P00D913 Ambient Air Temperature Sensor “B” Intake air system 172 5 CIRCUIT OPEN P0105 Manifold Absolute Pressure/Barometric Pressure Sensor Boost Pressure 102 3 Circuit Short To Battery P0105 Manifold Absolute Pressure/Barometric Pressure Sensor Boost Pressure 102 4 Circuit Short To Ground P0105 Manifold Absolute Pressure/Barometric Pressure Sensor Boost Pressure 102 5 Circuit Open P010512 Manifold Absolute Pressure/Barometric Pressure Sensor Intake air system 102 3 CIRCUIT SHORT TO BATTERY P010513 Manifold Absolute Pressure/Barometric Pressure Sensor Intake air system 102 5 CIRCUIT OPEN P0110 Intake Air Temperature Sensor 1 Bank 1 Boost Temperature 105 4 Circuit Short To Ground P0110 Intake Air Temperature Sensor 1 Bank 1 Boost Temperature 105 5 Circuit Open P011011 Intake Air Temperature Sensor 1 Bank 1 Intake air system 105 4 CIRCUIT SHORT TO GROUND P011013 Intake Air Temperature Sensor 1 Bank 1 Intake air system 105 5 CIRCUIT OPEN P0115 Engine Coolant Temperature Sensor 1 Coolant Temperature 110 4 Circuit Short To Ground P0115 Engine Coolant Temperature Sensor 1 Coolant Temperature 110 5 Circuit Open P011511 Engine Coolant Temperature Sensor 1 Coolant System 110 4 CIRCUIT SHORT TO GROUND P011513 Engine Coolant Temperature Sensor 1 Coolant System 110 5 CIRCUIT OPEN P0120 Throttle/Pedal Position Sensor "A" Acceleration pedal (PENTA) 91 0 Signal Above Allowable Range P0120 Throttle/Pedal Position Sensor "A" Acceleration pedal (PENTA) 91 9 Alive / Sequence Counter Incorrect / Not Updated P0120 Throttle/Pedal Position Sensor "A" Acceleration pedal (PENTA) 91 19 Value of Signal Protection Calculation Incorrect P012082 Throttle/Pedal Position Sensor “A”. 91 9 Alive / Sequence Counter Incorrect / Not Updated P012083 Throttle/Pedal Position Sensor “A”. 91 19 Value of Signal Protection Calculation Incorrect P012085 Throttle/Pedal Position Sensor “A”. 91 0 Signal Above Allowable Range P0168 Fuel Temperature Too High Rail Fuel Temp 3468 16 No Sub Type Information P016E Closed Loop Fuel Pressure Control At Limit - Pressure Too High Rail pressure system 520245 0 No Sub Type Information P016F Closed Loop Fuel Pressure Control At Limit - Pressure Too Low Rail pressure system 520245 1 No Sub Type Information P0185 Fuel Temperature Sensor "B" Rail Fuel Temp 3468 2 Signal Plausibility Failure P0185 Fuel Temperature Sensor "B" Rail Fuel Temp 3468 4 Circuit Short To Ground P0185 Fuel Temperature Sensor "B" Rail Fuel Temp 3468 5 Circuit Open P0185 Fuel Temperature Sensor "B" Rail Fuel Temp 3468 12 General Electrical Failure P018F Fuel System Over Pressure Relief Valve Frequent Activation High Pressure Circuit - Fuel Pressure mechanical Relief Valve (PRV) 520244 12 No Sub Type Information P0190 Fuel Rail Pressure Sensor Bank 1 Rail Pressure 157 5 Circuit Open P0190 Fuel Rail Pressure Sensor Bank 1 Rail Pressure 157 7 Signal Compare Failure P0190 Fuel Rail Pressure Sensor Bank 1 Rail Pressure 157 12 General Electrical Failure P0195 Engine Oil Temperature Sensor "A" Oil Temperature 175 3 Circuit Short To Battery P0195 Engine Oil Temperature Sensor "A" Oil Temperature 175 4 Circuit Short To Ground P0195 Engine Oil Temperature Sensor "A" Oil Temperature 175 5 Circuit Open P019511 Engine Oil temperature Sensor “A” Oil system 175 4 CIRCUIT SHORT TO GROUND P019513 Engine Oil temperature Sensor “A” Oil system 175 5 CIRCUIT OPEN P0201 Cylinder 1 Injector "A" Injector 1 651 3 Circuit Short To Battery P0201 Cylinder 1 Injector "A" Injector 1 651 4 Circuit Short To Ground P0201 Cylinder 1 Injector "A" Injector 1 651 5 Circuit Open P020112 Cylinder 1 Injector “A” Fuel System 651 3 CIRCUIT SHORT TO BATTERY P020113 Cylinder 1 Injector “A” Fuel System 651 5 CIRCUIT OPEN P0202 Cylinder 2 Injector "A" Injector 2 652 3 Circuit Short To Battery P0202 Cylinder 2 Injector "A" Injector 2 652 4 Circuit Short To Ground P0202 Cylinder 2 Injector "A" Injector 2 652 5 Circuit Open P020212 Cylinder 2 Injector "A" Fuel System 652 3 CIRCUIT SHORT TO BATTERY P020213 Cylinder 2 Injector "A" Fuel System 652 5 CIRCUIT OPEN P0203 Cylinder 3 Injector "A" Injector 3 653 3 Circuit Short To Battery P0203 Cylinder 3 Injector "A" Injector 3 653 4 Circuit Short To Ground P0203 Cylinder 3 Injector "A" Injector 3 653 5 Circuit Open P020312 Cylinder 3 Injector "A" Fuel System 653 3 CIRCUIT SHORT TO BATTERY P020313 Cylinder 3 Injector "A" Fuel System 653 5 CIRCUIT OPEN P0204 Cylinder 4 Injector "A" Injector 4 654 3 Circuit Short To Battery P0204 Cylinder 4 Injector "A" Injector 4 654 4 Circuit Short To Ground P0204 Cylinder 4 Injector "A" Injector 4 654 5 Circuit Open P020412 Cylinder 4 Injector "A" Fuel System 654 3 CIRCUIT SHORT TO BATTERY P020413 Cylinder 4 Injector "A" Fuel System 654 5 CIRCUIT OPEN P0205 Cylinder 5 Injector "A" Injector 5 655 3 Circuit Short To Battery P0205 Cylinder 5 Injector "A" Injector 5 655 4 Circuit Short To Ground P0205 Cylinder 5 Injector "A" Injector 5 655 5 Circuit Open P020512 Cylinder 5 Injector "A" Fuel System 655 3 CIRCUIT SHORT TO BATTERY P020513 Cylinder 5 Injector "A" Fuel System 655 5 CIRCUIT OPEN P0206 Cylinder 6 Injector "A" Injector 6 656 3 Circuit Short To Battery P0206 Cylinder 6 Injector "A" Injector 6 656 4 Circuit Short To Ground P0206 Cylinder 6 Injector "A" Injector 6 656 5 Circuit Open P020612 Cylinder 6 Injector "A" Fuel System 656 3 CIRCUIT SHORT TO BATTERY P020613 Cylinder 6 Injector "A" Fuel System 656 5 CIRCUIT OPEN P0217 Engine Coolant Over Temperature Condition Coolant Temperature 110 0 No Sub Type Information P021700 Engine Coolant Over Temperature Condition Coolant System 110 0 No Sub Type Information P0219 Engine Overspeed Condition Engine Speed 190 0 No Sub Type Information P021900 Engine Overspeed Condition 190 0 No Sub Type Information P0243 Turbocharger/Supercharger Wastegate Solenoid "A" Wastegate 1188 3 Circuit Short To Battery P0243 Turbocharger/Supercharger Wastegate Solenoid "A" Wastegate 1188 4 Circuit Short To Ground P0243 Turbocharger/Supercharger Wastegate Solenoid "A" Wastegate 1188 5 Circuit Open P024311 Turbocharger/Supercharger Wastegate Solenoid “A” Exhaust System 1188 4 CIRCUIT SHORT TO GROUND P024312 Turbocharger/Supercharger Wastegate Solenoid “A” Exhaust System 1188 3 CIRCUIT SHORT TO BATTERY P024313 Turbocharger/Supercharger Wastegate Solenoid “A” Exhaust System 1188 5 CIRCUIT OPEN P0298 Engine Oil Over Temperature Condition Oil Temperature 175 0 No Sub Type Information P029800 Engine Oil Over Temperature Oil system 175 0 No Sub Type Information P02E0 Diesel Intake Air Flow Control Engine throttle actuator (cold) 3464 3 Circuit Short To Battery P02E0 Diesel Intake Air Flow Control Engine throttle actuator (cold) 3464 4 Circuit Short To Ground P02E0 Diesel Intake Air Flow Control Engine throttle actuator (cold) 3464 5 Circuit Open P02E0 Diesel Intake Air Flow Control Engine throttle actuator (cold) 3464 7 Low/Insufficient Flow P02E0 Diesel Intake Air Flow Control Engine throttle actuator (cold) 3464 10 Slow Response P02E0 Diesel Intake Air Flow Control Engine throttle actuator (cold) 3464 12 High/Excessive Flow P02E011 Diesel Intake Air Flow Control Intake air system 3464 4 CIRCUIT SHORT TO GROUND P02E012 Diesel Intake Air Flow Control Intake air system 3464 3 CIRCUIT SHORT TO BATTERY P02E013 Diesel Intake Air Flow Control Intake air system 3464 5 CIRCUIT OPEN P02E07C Diesel Intake Air Flow Control Intake air system 3464 10 Slow Response P02E09B Diesel Intake Air Flow Control Intake air system 3464 12 High/Excessive Flow P02E09C Diesel Intake Air Flow Control Intake air system 3464 7 Low/Insufficient Flow P02E6 Diesel Intake Air Flow Position Sensor Engine throttle position (cold) 51 3 Circuit Short To Battery P02E6 Diesel Intake Air Flow Position Sensor Engine throttle position (cold) 51 5 Circuit Open P02E6 Diesel Intake Air Flow Position Sensor Engine throttle position (cold) 51 7 Exceeded Learning Limit P02E6 Diesel Intake Air Flow Position Sensor Engine throttle position (cold) 51 12 General Electrical Failure P02E6 Diesel Intake Air Flow Position Sensor Engine throttle position (cold) 51 13 Component or System Operation Obstructed or Blocked P02E612 Diesel Intake Air Flow Position Sensor Intake air system 51 3 CIRCUIT SHORT TO BATTERY P02E613 Diesel Intake Air Flow Position Sensor Intake air system 51 5 CIRCUIT OPEN P02E697 Diesel Intake Air Flow Position Sensor Intake air system 51 13 Component or System Operation Obstructed or Blocked P02E699 Diesel Intake Air Flow Position Sensor Intake air system 51 7 Exceeded Learning Limit P0335 Crankshaft Position Sensor "A" Crank Speed sensor 637 2 Circuit Intermittent P0335 Crankshaft Position Sensor "A" Crank Speed sensor 637 8 Signal Frequency Incorrect P0335 Crankshaft Position Sensor "A" Crank Speed sensor 637 9 No Signal P03351F Crankshaft Position Sensor “A”. 637 2 Circuit Intermittent P033531 Crankshaft Position Sensor “A”. 637 9 No Signal P033538 Crankshaft Position Sensor “A”. 637 8 Signal Frequency Incorrect P0340 Camshaft Position Sensor "A" Bank 1 or Single Sensor CAM Speed sensor 636 8 Signal Frequency Incorrect P0340 Camshaft Position Sensor "A" Bank 1 or Single Sensor CAM Speed sensor 636 9 No Signal P034031 Camshaft Position Sensor “A” Bank 1 or Single Sensor. 636 9 No Signal P034038 Camshaft Position Sensor “A” Bank 1 or Single Sensor. 636 8 Signal Frequency Incorrect P0400 EGR "A" Flow EGR Mass Flow 2659 10 Slow Response P0400 EGR "A" Flow EGR Mass Flow 2659 18 Low/Insufficient Flow P04009C EGR “A” Flow EGR system 2659 18 Low/Insufficient Flow P0403 EGR "A" Control EGR Valve 1 (CAN) 2791 5 Circuit Open P0403 EGR "A" Control EGR Valve 1 (CAN) 2791 6 Circuit Short To Battery P0403 EGR "A" Control EGR Valve 1 (CAN) 2791 7 Actuator Stuck P0403 EGR "A" Control EGR Valve 1 (CAN) 2791 11 Performance or Incorrect Operation P0403 EGR "A" Control EGR Valve 1 (CAN) 2791 12 General Checksum Failure P0403 EGR "A" Control EGR Valve 1 (LISK) 2791 3 Circuit Short To Ground P0403 EGR "A" Control EGR Valve 1 (LISK) 2791 5 Circuit Open P0403 EGR "A" Control Internal EGR 2791 7 Component or System Operation Obstructed or Blocked P040397 EGR “A” Control EGR system 2791 7 Component or System Operation Obstructed or Blocked P0409 EGR Sensor "A" EGR Diff Pressure 411 3 Circuit Short To Battery P0409 EGR Sensor "A" EGR Diff Pressure 411 5 Circuit Open P0409 EGR Sensor "A" EGR Diff Pressure 411 12 General Electrical Failure P040A EGR Temperature Sensor "A" EGR Temperature After Cooler 412 4 Circuit Short To Ground P040A EGR Temperature Sensor "A" EGR Temperature After Cooler 412 5 Circuit Open P040A EGR Temperature Sensor "A" EGR Temperature After Cooler 412 12 General Electrical Failure P041A EGR Temperature Sensor "B" EGR Valve 1 (CAN) 2791 3 Circuit Short To Battery P041A EGR Temperature Sensor "B" EGR Valve 1 (CAN) 2791 4 Circuit Short To Ground P041A EGR Temperature Sensor "B" EGR Valve 1 (CAN) 5765 10 Signal Stuck In Range P0480 Fan 1 Control Circuit Cooling Fan control 647 3 Circuit Short To Battery P0480 Fan 1 Control Circuit Cooling Fan control 647 4 Circuit Short To Ground P0480 Fan 1 Control Circuit Cooling Fan control 647 5 Circuit Open P048011 Fan 1 Control Circuit Coolant System 647 4 CIRCUIT SHORT TO GROUND P048012 Fan 1 Control Circuit Coolant System 647 3 CIRCUIT SHORT TO BATTERY P048013 Fan 1 Control Circuit Coolant System 647 5 CIRCUIT OPEN P0486 EGR Sensor "B" Circuit / EGR Sensor "B" EGR Valve 1 (CAN) 2791 2 Circuit Open P051A Crankcase Pressure Sensor Crankcase Pressure /(Crankhouse Pressure) 101 3 Circuit Short To Battery P051A Crankcase Pressure Sensor Crankcase Pressure /(Crankhouse Pressure) 101 5 Circuit Open P051A12 Crankcase Pressure Sensor. 101 3 CIRCUIT SHORT TO BATTERY P051A13 Crankcase Pressure Sensor. 101 5 CIRCUIT OPEN P0520 Engine Oil Pressure Sensor/Switch "A" Oil Pressure 100 3 Circuit Short To Battery P0520 Engine Oil Pressure Sensor/Switch "A" Oil Pressure 100 4 Circuit Short To Ground P0520 Engine Oil Pressure Sensor/Switch "A" Oil Pressure 100 5 Circuit Open P052012 Engine Oil Pressure Sensor/Switch “A” Oil system 100 3 CIRCUIT SHORT TO BATTERY P052013 Engine Oil Pressure Sensor/Switch “A” Oil system 100 5 CIRCUIT OPEN P0524 Engine Oil Pressure Too Low Oil Pressure 100 1 No Sub Type Information P052400 Engine Oil Pressure Too Low Oil system 100 1 No Sub Type Information P0526 Fan Speed Sensor Circuit Fan speed 1639 3 Circuit Short To Battery P052612 Fan Speed Sensor Circuit Coolant System 1639 3 CIRCUIT SHORT TO BATTERY P053E Crankcase Pressure Too High Crankcase Pressure /(Crankhouse Pressure) 101 0 No Sub Type Information P053E00 Crankcase Pressure Sensor 101 0 No Sub Type Information P0540 Intake Air Heater "A" Control Preheat sense 1 729 5 Circuit Open P0540 Intake Air Heater "A" Control Preheat sense 1 729 6 Actuator Stuck On P0540 Intake Air Heater "A" Control Preheat sense 1 729 7 Actuator Stuck Off P0540 Intake Air Heater "A" Control Preheat sense 1 729 12 General Electrical Failure P054001 Intake Air Heater “A” Control Intake air system 729 12 General Electrical Failure P054013 Intake Air Heater “A” Control Intake air system 729 5 CIRCUIT OPEN P054070 Intake Air Heater “A” Control Intake air system 729 6 Actuator Stuck On P05407F Intake Air Heater “A” Control Intake air system 729 7 Actuator Stuck Off P0544 Exhaust Gas Temperature Sensor Bank 1 Sensor 1 Exhaust Gas Temperature 3241 19 Signal Invalid P0544 Aftertreatment 1 Exhaust Gas Temperature 1 Exhaust gas temperature #1 3241 5 Circuit Short To Battery or Open P0544 Aftertreatment 1 Exhaust Gas Temperature 1 Exhaust gas temperature #1 3241 4 Circuit Short To Ground P0544 Aftertreatment 1 Exhaust Gas Temperature 1 Exhaust gas temperature #1 3241 12 General Electrical Failure P054486 Exhaust Gas Temperature Sensor Bank 1 Sensor 1 EATS 3241 19 Signal Invalid P055A Engine Oil Pressure Sensor/Switch "B" Oil Filter Pressure 520570 3 Circuit Short To Battery P055A Engine Oil Pressure Sensor/Switch "B" Oil Filter Pressure 520570 4 Circuit Short To Ground P055A Engine Oil Pressure Sensor/Switch "B" Oil Filter Pressure 520570 5 Circuit Open P055A Engine Oil Pressure Sensor/Switch "B" Oil Filter Pressure 520570 11 Component Failure P055A Engine Oil Pressure Sensor/Switch "B" Oil Filter Pressure 520570 12 General Electrical Failure P0560 System Voltage ECU battery potential 158 0 Signal Above Allowable Range P0560 System Voltage ECU battery potential 158 1 Signal Below Allowable Range P056084 System Voltage Unstable Electrical 158 1 Signal Below Allowable Range P056085 System Voltage Unstable Electrical 158 0 Signal Above Allowable Range P0561 System Voltage Unstable ECU battery potential 158 2 Circuit Intermittent P05611F System Voltage Unstable Electrical 158 2 Circuit Intermittent P05C2 Engine Coolant Pressure Sensor Fresh Water Coolant Pressure 20 3 Circuit Short To Battery P05C2 Engine Coolant Pressure Sensor Fresh Water Coolant Pressure 20 4 Circuit Short To Ground P05C2 Engine Coolant Pressure Sensor Fresh Water Coolant Pressure 20 5 Circuit Open P0607 Control Module Performance Programme memory 628 2 General Checksum Failure P060741 Electronic Control Unit Programming 628 2 General Checksum Failure P0615 Starter Relay Starter Output 677 3 Circuit Short To Battery P0615 Starter Relay Starter Output 677 4 Circuit Short To Ground P061511 Starter Relay Electrical 677 4 CIRCUIT SHORT TO GROUND P061512 Starter Relay Electrical 677 3 CIRCUIT SHORT TO BATTERY P061513 Starter Relay Electrical 677 5 CIRCUIT OPEN P061519 Starter Relay Electrical 677 6 Circuit Current Above Threshold P0627 Fuel Pump "A" Control Fuel Pump Pressurizing Assembly #1 1347 7 Low/Insufficient Flow P0657 ECU Power Output Supply Voltage #1 ACM Actuator high supply 1 3597 4 Circuit Short To Ground P0657 ECU Power Output Supply Voltage #1 ACM Actuator high supply 1 3597 3 Circuit Short To Battery P0685 ECM/PCM Power Relay Control ECM Main Relay 1485 7 Actuator Stuck Closed P06B0 Sensor supply voltage 1 Aftertreatment Sensor Supply Voltage #1 (+5V DC) 3509 3 Circuit Voltage Above Threshold P06B0 Sensor supply voltage 1 Aftertreatment Sensor Supply Voltage #1 (+5V DC) 3509 4 Circuit Voltage Below Threshold P06B0 Sensor Power Supply "A" Sensor Supply Voltage #1 (+5V DC) 3509 3 Circuit Voltage Above Threshold P06B0 Sensor Power Supply "A" Sensor Supply Voltage #1 (+5V DC) 3509 4 Circuit Voltage Below Threshold P06B016 Sensor Power Supply “A” Electrical 3509 4 Circuit Voltage Below Threshold P06B017 Sensor Power Supply “A” Electrical 3509 3 Circuit Voltage Above Threshold P06B3 Sensor supply voltage 2 Aftertreatment Sensor Supply Voltage #2 (+5V DC) 3510 3 Circuit Voltage Above Threshold P06B3 Sensor supply voltage 2 Aftertreatment Sensor Supply Voltage #2 (+5V DC) 3510 4 Circuit Voltage Below Threshold P06B3 Sensor Power Supply "B" Circuit Sensor Supply Voltage #2 (+5V DC) 3510 3 Circuit Voltage Above Threshold P06B3 Sensor Power Supply "B" Circuit Sensor Supply Voltage #2 (+5V DC) 3510 4