Madill 3000 Manual

3000/4000 LOG LOADER
OPERATION & MAINTENANCE MANUAL

TABLE OF CONTENTS
SAFETY INDICATORS......................................................................................................1
FOREWORD......................................................................................................................2
MACHINE OVERVIEW ......................................................................................................3
GENERAL LAYOUT...........................................................................................................4
EMERGENCY EXIT...........................................................................................................5
Emergency Exit Operation...................................................................................................... 5
Emergency Roof Exit.............................................................................................................. 5
Outside Release:...................................................................................................................... 6
Alternative Side Window Exits .............................................................................................. 6
SAFETY PRECAUTIONS ..................................................................................................7
Before you start....................................................................................................................... 7
After Transporting .................................................................................................................. 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 ConditioningUnit ........................................................................................................... 16
Travel - Left & Right Pedals ................................................................................................. 16
DiagnosticPlug..................................................................................................................... 16
Stereo .................................................................................................................................... 17
Seat Controls ......................................................................................................................... 21
Secondary House Tilt Location ............................................................................................ 22

INTERFACE & WARNING LIGHTS .................................................................................23
Main Display......................................................................................................................... 23
Warning Lights and Buzzers................................................................................................. 24
Climate Control..................................................................................................................... 25
Joystick Set-up...................................................................................................................... 26
Engine Coolant/ Hydraulic Oil Temperature........................................................................ 29
Engine Oil Pressure............................................................................................................... 29
Voltmeter............................................................................................................................... 29
Fuel/ DEF Level Gauge......................................................................................................... 30
Low Fuel/ DEF ..................................................................................................................... 30
Hour Meter............................................................................................................................ 30
Hydraulic Filter ..................................................................................................................... 30
SERVICE & LUBRICATION.............................................................................................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/WaterSeparator....................................................................................... 33
SecondaryFuel 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 & Lubrication Chart.................................................................... 36
4000 Log Loader Service & Lubrication Chart.................................................................... 37
GENERAL INFORMATION..............................................................................................38

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.

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.
Note: Madill reserves the right to make technical changes on the machine without notice.
Between boom pins

3
When checking for leaks in the
hydraulic system, use a piece of
cardboard or wood. A small
stream of high pressure oil can
penetrate the skin and cause
serious injury.
DO NOT USE YOUR HAND OR
FINGERS TO SEARCH FOR
LEAKS.
If you are struck by pressurized
hydraulic fluid, seek medical
attention immediately.
During break in period (first
100-200 hours of operation)
higher oil consumption is
normal. For this reason,
check the oil level more
frequently than the normal
recommendation.
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.
Checking the positions of the shipping blocks
supporting the machine can indicate damage
that may have occurred during shipping. All
blocking should be tightly in place and all
cables should be properly tensioned. Loose
cables and blocks may mean the machine has
been jarred or subjected to unusual vibration;
this could mean loose parts and bolts. Inspect
the machine surface for damage. Walk around
the machine 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 all gearboxes. Consult the Service & Lubrication
Section for correct service procedures. Lubricate all fittings to be sure they will accept
grease.
Read the procedure for machine start-up before running the engine on
assembled machine.
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 are the most crucial to the machine. It is at
this time that bolts loosen due to wearing-in process
and metal contact is greatest in the hydraulic system.
Open the doors of the machine and look over the
wiring, hoses, clamps and piping. Verify the fluid
levels of the engine, radiator and hydraulic reservoir
are still sufficient. Inspect the side frames for oil on
the rollers and the drive gear boxes.

4
GENERAL LAYOUT

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.
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.

6
Outside Release:
1. Unscrew the two outside star knobs and remove them.
2. Push threaded rods through emergency exit 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.

7
Starting spray of any kind is
never permitted
NEVER start the engine
without an air filter in place
Cab to Riser bolts to be
torqued to 1100 Ft.-lb. per bolt
with Loctite C5-A applied.
SAFETY PRECAUTIONS
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
wearing PPE as per your worksite and/or local regulations. Ensure protective guards
are in place. Check height, weight and width restrictions for your work area. Be sure
you know about any hazards, such as power lines. Be familiar with the hand signals
used in your workplace.
After Transporting
Always ensure all six cab to riser mounting bolts
are installed and properly torqued.
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 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 ignition. Attach a “DO NOT
OPERATE” tag in an obvious place in operator’s cab.
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. ALWAYS
operate with seat belt fastened.