124 Interlock Yarder Operation Manual 1 Preface .................................................................................................................... 2 2 Safety Precautions ................................................................................................... 3 3 General Description ............................................................................................... 10 4 Operation ............................................................................................................... 12 5 Joystick Control Functions ..................................................................................... 15 6 Control Panel Switches .......................................................................................... 17 7 Control Panel Indicators ......................................................................................... 20 8 Additional Cab Controls ......................................................................................... 22 9 Control Stand ......................................................................................................... 24 10 Emergency Escape ................................................................................................ 25 11 Self-Propelled Travelling ........................................................................................ 27 12 Transport and Servicing ......................................................................................... 28 13 Winch Operation .................................................................................................... 35 14 Guylines ................................................................................................................. 38 15 Lubrication and Maintenance ................................................................................. 42 16 Horn (Whistle) ........................................................................................................ 53 17 Machine Rigging .................................................................................................... 56 18 Trouble Shooting.................................................................................................... 60 19 Onboard Diagnostics - DDEC V ............................................................................. 63 20 Transmission Codes .............................................................................................. 66 21 Lexan & Marguard Windows .................................................................................. 71 22 Quick Reference Parts List .................................................................................... 73 1 Preface The operating and maintenance manual is designed to familiarize the operator of this machine with all the necessary information so that they may take full advantage of the capabilities built into the machine. If the machine is operated and maintained properly, it will yield profitable results. For this reason, it is imperative that the basic needs of the machine be satisfied. When the machine is lubricated with the recommended lubricants at the recommended intervals, abnormal part wear and failures will be avoided. Using the correct hydraulic oil for the prevailing temperatures and conditions, and careful maintenance of the hydraulic oil filters will help ensure a trouble free and dependable hydraulic system. When ordering parts, please include the serial number of the machine. Also serviceable parts will be covered in the parts manual with the exception of the engine and the transmission, which will have their own Parts & Service manuals. Note: Madill Equipment reserves the right to make technical changes on the machine without notice or incurring any liability where it simplifies or improves efficiency and productivity. 124 Operator's Manual 097214A Page 2 of 74 2 Safety Precautions The following are some safety tips that you should follow when operating the 124 interlock yarder for the protection of the people who work around you and for your own protection. 2.1 Before you start Know your machine. Inspect it thoroughly. Keep it clean. Wear close fitting clothing and protective items. Make sure protective guards are in place. Check height, weight and width restrictions for your work area. Be sure you know about any hazards. Make sure you agree with your signal person on hand signals. NOTE: This machine is designed to operate on prepared landings with slopes not more than 20%. 2.2 Safety Warning Labels and Decals The Madill Yarder is delivered equipped with numerous safety and warning labels and decals, to better inform operators of the potential safety hazards. It is very important that these labels be read and understood, and that they are in place and legible at all times. If you notice that any of these are missing or unreadable due to painting, tearing, abuse, or any other cause, report it immediately to your supervisor. Attempting to operate your yarder with warning labels missing or unreadable may be a violation of WCB, or local regulations. 2.3 Starting Up Make sure all controls are in proper position for starting and that the transmission is in neutral. 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. Practice with the function controls. Report any unusual noises or conditions for immediate repair. Stop accidents before they stop you! NOTE: Allow air pressure to reach 120 Psi before operating the winch. 2.4 While Operating PAY ATTENTION! Know the working range of your machine. Know where any obstructions might be. Do not move the machine unnecessarily fast. 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 truck cab. 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. 2.5 While Travelling Make sure that no one is endangered before you make your move. Never get on or off the machine while it is in motion. Lock the swing brake when you travel. Cross 124 Operator's Manual 097214A Page 3 of 74 obstacles at an angle and at low speed. Watch to see that your boom clears all obstacles. Shift the transmission and yarding control to neutral. This machine is designed to operate on prepared landings with slopes not more than 20%. 2.6 Before Performing Service Slack yarder working lines, shut off engine and remove keys from ignition. Attach a “DO NOT OPERATE” tag in an obvious place in operator’s cab. Ensure that the battery lockout master switch located inside the front left access door is locked out. 2.7 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 reduce the load and working radius of your machine. Overloading the machine can result in rollover which may cause serious injury or death, damage or an increased rate of wear that will not be covered by warranty. 2.8 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. Sources of fuel can accumulate due to normal operation, service or component failure. These include such materials as needles, leaves, bark, wood chips, sawdust, hydraulic oil, grease and fuel. Sources of ignition include overheating engine and hydraulic components, exhaust components, and sparks due to damage to the electrical system. 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, 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 is on the machine and properly maintained. • When 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. 124 Operator's Manual 097214A Page 4 of 74 • 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. 2.9 Safe Winch Operation