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OPERATION & MAINTENANCE MANUAL

PREFACE

The operating and maintenance manual is designed to familiarize the operator of this
machine with all the necessary information so that he 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 main-
tenance of the hydraulic oil filters will help ensure a trouble free and dependable hydrau-
lic system.

The maintenance sections of the manual outline repair and replacement procedures
which may be periodically necessary. This covers both mechanical and hydraulic repairs.

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 attach-
ment, which will have their own Parts & Service manuals.

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OPERATION & MAINTENANCE MANUAL

SAFETY PRECAUTIONS

REMEMBER! SAFETY IS UP TO YOU!

The following are some safety tips that you should follow when operating the 1800 Log
Loader for the protection of the people who work around you and for your own protection.

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.

AFTER TRANSPORTING
Always ensure cab 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. Practice with the function controls. Report any
unusual noises or conditions for immediate repair. STOP ACCIDENTS BEFORE THEY
STOP YOU!

WHILE OPERATING
PAY ATTENTION! Know the working range of your machine. Know where any obstruc-
tions 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 any-
one 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.

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 spring brake when you travel. Cross obstacles
at an angle and at low speed. Watch to see that your boom clears all obstacles.

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OPERATION AND MAINTENANCE MANUAL

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 fire fighting equipment are 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.

- 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.

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WARNING!

ATTACHMENT CAN HIT CAB & TRACKS! USE CAUTION WHEN WORKING IN CLOSE.

THIS WARNING APPLIES TO ALL TYPES OF ATTACHMENTS

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FEATURES

POWER UNIT

The Madill 1800 is powered by a Cummins QSB 5.9L 205 HP diesel engine. The engine
is direct coupled to a tandem 2 x 112cc variable displacement axial piston pump that
provides hydraulic power for all machine functions.

UNDERCARRIAGE
The crawler type undercarriage features two speed hydraulic drive motors “Plugged In”
to 3 stage planetary gearboxes. Track rollers are lifetime lubricated. Track adjustment is
maintained by a combination of spring and grease tensioners.

OPERATOR’S CAB
Forward positioning of the cab provides the operator with excellent visibility while steel
tube and plate construction provide safety. Simple layout and hands on controls facilitate
simultaneous functions. Standard features include air conditioning and an AM/FM/CD
Player.

MACHINE DECK
A clean and simple machine deck features twin frame rails with integrated underdecking
and fuel tank.

HOUSE
Large punched plate doors provide ventilation. Gas spring assist hood and lift out panels
for excellent engine access.

HYDRAULIC SYSTEM
Tandem piston pumps power track, swing, boom and implement functions through a nine
spool excavator style valve featuring twin spools for high speed boom and stick
functions.

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OPERATION

GENERAL NOTES ON OPERATION

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, see a doctor at once.

When a machine is first delivered, it is important to go through a series of inspections

and checks before placing the machine in service. Each machine has been thoroughly
inspected. A comprehensive post-delivery inspection by the distributor will detect any
problems developed in transit, so they may be corrected before the machine reaches its
ultimate user.

Prior to removing the equipment from the carrier, all shortages and damage must be
noted on the shipping papers. Contact Madill Service Department if any questions should
arise.

Checking the positions of the shipping blocks supporting the machine can indicate what
type of damage may have occurred during shipping. All blocking should be tightly in
place and all cables should be properly tensioned. Loose cables and blocks mean the
machine has probably been jarred and moved around, and 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, checking for oil
leaks.

Before the machine is run, the oil level in the engine should be checked to ensure 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 OVER-
FILL THIS, room must be allowed for fluid expansion due to heat. Check the oil level in
all gearboxes, add if too low, drain if over filled. Consult the lubrication instructions for
correct service procedures. Lubricate all fittings to be sure they will accept grease.
Re-torque bolts if necessary.

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 examine the
machine for hydraulic oil leaks.

Normally the first hours of operation are the most crucial to the machine because this is
when the parts are breaking in. Frequent visual inspections to bolts should be performed
during this time.

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TRAVEL RESTRICTIONS & PRECAUTIONS
1. Switch travel speed selector to low when travelling down grades or when loading/
unloading machine onto a trailer.
2. ** IMPORTANT** RE-TORQUE THE TRACK PAD BOLTS AFTER THEIR FIRST 40
HOURS OF OPERATION.
3. Keep the driving sprockets to the rear while travelling.

TRAVEL BRAKE FUNCTION

The multi-disc spring applied, hydraulically released travel brakes are automatically
released when any travel control is engaged. Loss of system pressure will cause the
brake to apply automatically.

ROLLERS & RAILS

Rollers and rails, and related component life can be increased by the following
preventative maintenance steps:

1. Make daily visual inspections of your equipment.. Check for loose bolts, leaking seals
and abnormal wear.
2. Consider a program of switching rollers to equalize wear. It takes time, but the
expense saved in equalizing wear usually justifies the effort.

The front and rear rollers take approximately 80% of the wear on track machines. The
wear drops off to a minimum on center rollers. We suggest a good regular inspection of
the rollers, by raising each track off the ground with the boom.

AIR CONDITIONING UNIT

The air conditioning unit in your Madill equipment 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
refigerant loss that are compressor seal related if the unit has not been run on a regular
basis.

INSPECTION
A proper pre-start visual inspection each day of operation will help spot problems or
potential problems in their early stages and save on expensive repairs and down time.
This daily inspection should be done in conjunction with any and all necessary daily
lubrication requirements. All lubrication procedures along with their locations are
explained in the lubrication section of this manual.

Open the doors of the machine and look over the hoses, clamps and piping. Check the
fluid levels of the engine and radiator. Check the oil level in the hydraulic oil reservoir.
Inspect the side frames for oil on the rollers and the drive gear boxes. The regular
inspection of this machine is the first step in a good maintenance program. Following our
recommended procedures will assure you efficient and profitable operation.

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JOYSTICK CONTROL FUNCTIONS - HEELER, B&T, CLAM

STANDARD HANDLES

OPTIONAL “SURE-GRIP HANDLES

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TRAVEL LEFT AND RIGHT PEDALS WITH LEVERS
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 of 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

INSTRUMENT PANEL CONTROLS

WORK LIGHTS

ROCKER SWITCH Depress up to switch on work lights

Depress down to switch off work lights

REAR LIGHT

ROCKER SWITCH Depress up to switch on rear light

Depress down to switch off rear light

SWING BRAKE

ROCKER SWITCH Depress up to apply swing brake (brake on)

Depress down to release swing brake (brake off)

The swing brake is hydraulically released. The engine must be running to release the
swing brake. Always have swing brake switch “on” before starting engine.

TRAVEL MODE

ROCKER SWITCH Depress down to lock in low speed travel (low)

Depress up to lock in high speed travel (high)

Track drive motors have two speeds. Low speed provides high drive torque. High speed
provides low drive torque.

Lock in low speed when descending grades or loading/unloading machine onto a trailer
or while harvesting or operating in rough terrain to improve control.

BUZZER OVERRIDE
MOMENTARY Depress down to silence warning buzzer
ROCKER SWITCH Buzzer will come on again only if a second warning signal is
received
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ENGINE THROTTLE

ROCKER SWITCH Depress up for high idle

Centre for medium idle
Depress down for low idle

AUTO IDLE

ROCKER SWITCH Depress up to activate auto idle

Depress down to deactivate auto idle

ENGINE DIAGNOSTIC

ROCKER SWITCH Depress up to activate diagnostic flash out of fault codes

Depress down to deactivate

A/C

ROCKER SWITCH Depress up to activate air conditioner

Depress down to deactivate air conditioner

FAN

ROTARY SWITCH 4 POSITION - Used to select OFF-LOW-MED-HIGH

SPARE

ROCKER SWITCH A spare rocker switch may be present to instrument panel

depending on original equipment and options

POWER

3 POSITION OFF - Shuts off all electrical power via relay operated battery
KEY SWITCH switch
RUN - Switches on electrical power
START - Energizes engine starter solenoid and warning light
bulb test circuit
WIPER/WASHER (If equipped)

ROTARY SWITCH Intermittent plus two-speed wiper

Push to activate washer

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CIRCUIT BREAKERS

PUSH BUTTON Circuit breakers provide individual protection to electric circuits.

TO RESET Overloading will cause circuit breaker to trip and button to pop
out. To re-set, push button in.

ADDITIONAL CAB CONTROLS

PILOT CONTROL ISOLATOR - Lever on Arm Rest

Pilot control circuit must be isolated when entering cab to prevent accidental control
actuation. Lift pilot control isolator lever to isolate pilot control circuit and gain access to
operator’s seat. Once seated, lower lever to activate pilot control circuit. Lift lever to exit
cab. An electric micro switch located in the arm rest activates a solenoid valve to isolate
the pilot control unit.

DOME LIGHTS

Aircraft style dome lights are individually controlled by switches incorporated into each
light.

DEFROSTER FAN
Swivelling fan controlled by switch on fan.

SEAT CONTROLS - SEATS INC. SEAT

All adjustment knobs/levers are designated with orange marking.

1. Individual weight adjustment. Control knob is situated on the right side of the lower
front portion of the seat pan.

2. Seat with control pods fore and aft adjustment, 5” of total movement. Lever is located
at very bottom of seat suspension and is operated by being pushed over to the left.

3. Infinite back rest angle adjustment using control knob on lower left side of seat back
rest.

4. Seat height adjustment, 3” total movement. Lever is located on the lower left side of
the seat pan and is operated by being pulled up. The adjustment operates using the
“knee-action” suspension, which simultaneously moves the seat vertically and
horizontally. The fore and aft position may need to be adjusted to compensate.

5. Control pod fore and aft adjustment, 4” of total movement. Control pods slide along a
slot under the armrest, and lock in place using a rotary knob.

6. Side armrest vertical adjustment, 1-1/2” of total movement. Armrests slide along a slot
under the armrest and lock in place using two rotary knobs.

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7. Head rest adjustment, 2-3/4” of total movement. Operated by lifting up or pushing
down on headrest.

8. Lumbar support adjustment, 4 positions. Operated by rotating lever on lower right side
of back rest in either direction.

AM/FM RADIO/CD PLAYER

Refer to Instruction Manual for detailed operation.

REPLACEMENT OF LEXAN AND MARGUARD WINDOWS

It is important that damaged Lexan or Marguard windows be replaced with the equivalent
product. Sustitution with an inferior product may greatly reduce the level of protection to
the operator and WCB requirements may not be met. For example, the impact strength
of Lexan is 200 times that of glass and 30 times that of acrylic.

PROTECT THE OPERATOR - DO NOT SUBSTITUTE AN INFERIOR PRODUCT!

LEXAN & MARGUARD WINDOWS - CLEANING INSTRUCTIONS

When Lexan sheet is first installed, glazing compound and masking paper adhesive can
be easily removed by applying naphtha (VM&P) or kerosene with a soft cloth, followed
immediately with a thorough soap and water cleaning. DO NOT USE GASOLINE!
Adherence to regular and proper cleaning procedures is recommended to preserve
appearance.

WASHING TO MINIMIZE SCRATCHING

Wash Lexan XL sheet and Lexan Thermoclear sheet with a mild soap or detergent (e.g.
Joy Dishwashing Liquid) and lukewarm water, using a clean sponge or a soft cloth. Rinse
well with clean water. Dry thoroughly with a chamois or moist cellulose sponge to prevent
water spots. Do not scrub or use brushes on these products; their coating is
UV-resistant, not mar-resistant.

Fresh paint splashes, grease and smeared glazing compounds can be removed easily
before drying by rubbing lightly with a good grade of VM&P naphtha or isopropyl alcohol.
Afterward, a warm final wash should be made, using a mild soap or detergent solution
and ending with a thorough rinsing with clean water.

MINIMIZE HAIRLINE SCRATCHES

Scratches and minor abrasions can be minimized by using a mild automobile polish.
Three such products that tend to polish and fill scratches are Johnson Paste Wax, Novus
Plastic Polish No.1 and No.2, Novus Inc. Minneapolis, MN and Mirro Glaze plastic polish
(M.G.M.10), Mirror Bright Polish Co., Pasadena, CA. It is suggested that a test be made
on a sample of Lexan sheet with the product selected and that the polish manufacturer’s
instructions be followed.

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SOME IMPORTANT “DON’T’S”
- DO NOT use abrasive or highly alkaline cleaners on Lexan sheet products.
- Never scrape Lexan sheet products with squeegees, razor blades or other sharp instru-
ments.
- Benzene, gasoline, acetone or carbon tetrachloride should never be used on Lexan
sheet products.
- DO NOT clean Lexan sheet products in hot sun or at elevated temperatures.
- DO NOT use butyl cellosolve on XL-1 or TC-2.

COMPATIBLE CLEANERS FOR LEXAN SHEET PRODUCTS

The following cleaning agents have been found compatible with Lexan sheet, Lexan XL
sheet and Lexan Thermoclear sheet. The manufacturer’s recommendations and
instructions shoud be followed.

* JOY * TOP JOB

* Freon T.F. * VM&P grade naphtha
* Palmolive Liquid * Windex with Ammonia D

LEXAN MR5 SHEET CLEANING INSTRUCTIONS

Because of this material’s highly mar-and UV resistant coating, avoid the use of abrasive
cleaners and/or cleaning implements that may mar or gouge the coating.

GRAFFITTI REMOVAL FOR LEXAN MR5 SHEET

- Butyl cellosolve works well for removal of paints, marking pen inks, lipstick, etc.
- Masking tape, adhesive tape or lint removal tools work well for lifting off old, weathered
paints.
- To remove labels, stickers, etc., the use of kerosene or VM&P naphtha is generally
effective. When the solvent will not penetrate sticker material, apply heat (hair dryer) to
soften the adhesive and promote removal. GASOLINE SHOULD NOT BE USED!

JOB SITE PRECAUTIONS

New construction and renovations frequently require that the glazing and surrounding
sash and wall finish can be cleaned of any excess mortar, paint, sealant, primers or other
construction compounds. Only recommended cleaners should be used to clean Lexan
sheet. Contact with harsh solvents such as methyl ethyl ketone (MEK) or muriatic acid
can result in surface degradation and possible crazing of LEXAN sheet.

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GAUGES AND WARNING LIGHTS

ENGINE COOLANT TEMPERATURE

Gauge provided to monitor engine coolant temperature. Normal operating range is 180-
190 deg.F. (82-88 deg.C.)

ENGINE OIL PRESSURE

Gauge provided to monitor engine oil pressure. Oil pressure must register immediately
after engine has started. At low idle minimum oil pressure should be 10-15 psi. At high
idle minimum oil pressure should be 30 psi. Check the engine oil level if pressure is not
sufficient.

HYDRAULIC OIL TEMPERATURE & LEVEL

Gauge is provided to monitor hydraulic reservoir temperature. Normal operating range is
140-160 deg.F. (60-70 deg.C.). DO NOT operate machine if temperature exceeds 200
deg.F. (94 deg.C.). Check hydraulic reservoir for low oil level. Next check oil cooler for
clogging. If high temperature persists check for excessive relief valve operation or
hydraulic circuit malfunction. Warning light indicates low hydraulic reservoir oil level.

BATTERY VOLTAGE GAUGE

Monitors system voltage.

HYDRAULIC FILTER
Warning light indicates that the in-tank 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 temperatures the filter element should be replaced.

LOW FUEL
Warning light indicates when approximately 130 litres (34 U.s.Gallons) of fuel remain in
the fuel tank, when parked on level ground.

ENGINE WARNING LIGHT

The warning light provides critical operator messages. These messages require timely,
operator attention. The warning light is also used to delineate diagnostics fault codes.

STOP ENGINE

The stop engine light provides critical operator messages. These messages require
immediate and decisive operator response. The stop engine light is also used to flash out
diagnostic fault codes.
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WAIT-TO-START
The wait-to-start light indicates that the pre-start intake manifold heater warm-up
sequence is active. Grid heater will automatically heat the intake manifold when needed
prior to engine starting. Intake manifold heating improves engine starting in cold
temperatures and reduces white smoke.

WATER-IN-FUEL
The water-in-fuel light indicates there is water in the fuel. When the light is illuminated the
vehicle driver/operator should release the water from the fuel filter.

MAINTENANCE
Upon ECM power up the engine maintenance light will flash when it is time to change the
oil. It also will illuminate during engine operation when certain lower priority faults are
present.

HOUR METER
Gauge provided to monitor engine operating hours. Circuit senses engine oil pressure.

COUNTER
Counter provided is activated by a button on left armrest plaque. Press reset button on
readout to zero (0).

WARNING SYSTEM
SIGNAL LIGHT BUZZER SHUTDOWN
Engine Yes No No
Warning
Stop Engine Yes No Yes
Low Yes Yes No
Hydraulic
Oil Level
Hydraulic Yes No No
Filter
(Restricted)
Low Fuel Yes No No
Level
High Yes Yes No
Hydraulic
Oil Temp.
Wait to Start Yes No No
Eng.Mainte- Yes No No
nance
Water in Yes No No
Fuel

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CUMMINS ENGINE DIAGNOSTICS

The electronically controlled QSB engine in the Madill 1800 has been selected for its per-
formance and reliability. One of the benefits of modern electronic engine control sys-
tems is that abnormal operating parameters can be detected early, before loss of
performance or engine damage results.

The Madill 1800 control panel is equipped with indicator lights connected to the Cum-
mins Quantum electronic engine control system. The functions of the “Engine Warning”,
“Stop Engine”, “Wait to Start”, “Water in Fuel” and “Maintenance” (or “Check Engine”)
lights are described earlier in this manual. On models with rear-entry cabs, the lights are
located in the overhead panel on the operator’s left. Side-entry cabs have the lights in
the control panel to the right of the seat. The “Stop Engine” light is red, the others are
yellow or amber.

On startup, all five lights will be illuminated, then go out one at a time if the engine is
operating normally. If the engine Electronic Control Module (ECM) has detected a fault
with the operation of the engine, the “Engine Warning” light or the “Stop Engine” light, or
both, will come on and remain illuminated.

“STOP ENGINE” LIGHT ILLUMINATION

If the “Stop Engine” light comes on while the engine is running, the engine must be shut
down as soon as the machine is in a safe parking position and as soon as the load can
be safely lowered. Certain engine parameters (high coolant temperature, high intake
manifold temperature, low oil pressure) will trigger the “Stop Engine” light and cause the
ECM to automatically shut the engine down within 30 seconds of the fault being estab-
lished. Low coolant level will also do this, but the time delay is longer. The cause of the
“Stop Engine” light illumination must be determined immediately, by reading the fault
codes stored in the ECM.

“ENGINE WARNING” LIGHT ILLUMINATION

Operating faults that are less likely to result in catastrophic engine failure will cause the
ECM to light up the “Engine Warning” light, indicating that fault codes are stored in the
ECM. It is important to read these codes as soon as convenient because, among other
things, they sometimes indicate faults with the sensors that would otherwise be able to
detect more serious operating problems.

DIAGNOSTIC PROCEDURE
The active fault codes will appear as a series of flashes on the red “Stop Engine” light
when the procedure is initiated. These flashes designate 3-digit codes, to be read off the
table that follows. To start the code sequence:
Turn the key to the “on” or “run” position, but do not start the engine.
Press the “Engine Diagnostic” switch to the “on” position.
Prepare to read and record the number of times that the “Stop Engine” light flashes.

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FLASH SEQUENCE
The “Engine Warning” (yellow) light will flash once, then there will be three groups of
flashes on the “Stop Engine” (red) light, followed by another single flash of the “Engine
Warning” light to indicate the end of that particular code. For example:

(yellow) “flash” - start of code

(red) “flash” “flash” “flash” “flash” - 4
“pause”
(red) “flash” “flash” - 2
“pause”
(red) “flash” “flash” - 2
(yellow) “flash” - end of code

The code is therefore “422”, which in the table is “Engine Coolant Level Sensor Circuit –
data incorrect”. This particular code can be generated if, for example, the Coolant Level
Sensor in the top of the radiator is disconnected. If the disconnection exists prior to the
start of the diagnostic procedure, the “Engine Warning” light will be “on” when the key is
“on”, indicating that a fault exists, but that it is not likely to cause immediate engine dam-
age.

If the “Stop Engine” light is on prior to the start of the diagnostic procedure, do not start
the engine again until the fault causing “Stop Engine” light illumination is identified and
corrected.

MULTIPLE CODES AND NO CODES

Codes always flash on the RED light. The flash of the YELLOW light indicates a separa-
tion between codes. Each code will flash twice in a row (with a yellow light flash in
between), then the yellow light will flash, followed by the next active code (twice). When
all codes have been flashed, the code sequence will repeat, until the key is shut off. If no
codes are present, pressing the diagnostic switch will cause the “Stop Engine” and
“Engine Warning” lights to come on together, without flashing.

FAULT CODE INTERPRETATION

The following chart provides a description of the Cummins Quantum system fault codes
applicable to the QSB and QSC engines (the 1800 has the QSB engine). This chart may
help to identify problems with disconnected or shorted wiring, low fluid levels and similar
easily correctable problems. Extended diagnostic and evaluation capability is provided
by the dealers’ field service “INSITE” PC-based diagnostic tool. This offboard analyzer is
connected by means of the circular connector located at the rear of the overhead panel
in rear-entry cabs, and in the middle of the control panel to the right of the seat in side-
entry cabs. In addition to accessing fault data, this tool can provide details of engine
operating history and performance.

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CAUTION
Do not operate the engine when a “Stop Engine” code is active. Operation under this
condition may result in serious engine damage or complete failure. If the cause of the
code cannot be identified, contact the dealer and arrange to have a diagnosis made with
the INSITE tool.

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FAULT INDICATOR QSB QSC

DESCRIPTION
CODE LAMP ENGINE ENGINE
111 RED Engine Control Module-Critical X X
Internal Failure

115 RED Engine Speed/Position Sensor-lost both of X X

two signals from the magnetic pickup sen-
sor

116 RED Fuel Timing Pressure Sensor Circuit - X

shorted high

117 RED Fuel Timing Pressure Sensor Circuit - X

shorted low

118 YELLOW Fuel Pump Delivery Pressure Sensor X

Circuit - shorted high

119 YELLOW Fuel Pump Delivery Pressure Sensor X

Circuit - shorted low

121 YELLOW Engine Speed/Position Sensor-lost one of X

two signals from the magnetic pickup sen-
sor

122 YELLOW Intake Manifold Pressure Sensor #1 X X

Circuit - shorted high

123 YELLOW Intake Manifold Pressure Sensor #1 X X

Circuit - shorted low

131 RED Accelerator Pedal Position Sensor X X

Circuit - shorted high

132 RED Accelerator Pedal Position Sensor X X

Circuit - shorted low

133 RED Remote Accelerator Pedal Position X X

Sensor Circuit - shorted high

134 RED Remote Accelerator Pedal Position X X

Sensor Circuit - shorted low

135 YELLOW Engine Oil Pressure Sensor Circuit- X X

shorted high

141 YELLOW Engine Oil Pressure Sensor Circuit- X X

shorted low

143 YELLOW Engine Oil Pressure Low-Warning X X

144 YELLOW Engine Coolant Temperature Sensor X X

Circuit - shorted high

145 YELLOW Engine Coolant Temperature Sensor X X

Circuit - shorted low

146 YELLOW Engine Coolant Temperature High - X X

Warning

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FAULT INDICATOR QSB QSC
DESCRIPTION
CODE LAMP ENGINE ENGINE
147 RED Accelerator Pedal Position Sensor Circuit- X X
low frequency

148 RED Accelerator Pedal Position Sensor Circuit- X X

high frequency

151 RED Engine Coolant Temperature High-Critical X X

153 YELLOW Intake Manifold Temperature Sensor #1 X X

Circuit - shorted high

154 YELLOW Intake Manifold Temperature Sensor #1 X X

Circuit - shorted low

155 RED Intake Manifold Temperature #1 High - X X

Critical

184 YELLOW Engine Control Module Identification Input X X

State Error

221 YELLOW Ambient Air Pressure Sensor Circuit- X

shorted high

222 YELLOW Ambient Air Pressure Sensor Circuit- X

shorted low

234 RED Engine Speed High - Critical X X

235 RED Engine Coolant Level Low - Critical X X

241 YELLOW Vehicle Speed Sensor Circuit-data X X

incorrect

242 YELLOW Vehicle Speed Sensor Circuit-tampering X X

has been detected

243 YELLOW Engine Brake Driver #1 Circuit-shorted X X

low

245 YELLOW Fan Clutch Circuit-shorted low X X

261 YELLOW Fuel Temperature High-Warning X

263 YELLOW Fuel Temperature Sensor Circuit-shorted X

high

264 YELLOW Fuel Temperature sensor Circuit-data out- X

of-range

265 YELLOW Fuel Temperature Sensor Circuit-shorted X

low

268 YELLOW Fuel Pressure Sensor Circuit-data X

incorrect

271 YELLOW High Fuel Pressure Solenoid Valve #1 X

Circuit-shorted low

272 YELLOW High Fuel Pressure Solenoid Valve #1 X

Circuit-shorted high

Section One Page 7e

 1800
FAULT INDICATOR QSB QSC
DESCRIPTION
CODE LAMP ENGINE ENGINE
273 YELLOW High Fuel Pressure Solenoid Valve #2 X
Circuit-shorted low

274 YELLOW High Fuel Pressure Solenoid Valve #2 X

Circuit-shorted high

275 YELLOW Fuel Pumping Element #1 (Front)- X

mechanically stuck

276 YELLOW Fuel Injection Control Valve Circuit- X

shorted high

277 YELLOW Fuel Injection Control Valve - X

mechanically stuck

278 YELLOW Fuel Priming Pump Control Circuit- X X

shorted high/low

279 YELLOW Fuel Injection Control Valve Circuit- X

shorted low

281 YELLOW High Fuel Pressure Solenoid Valve #1 - X

mechanically stuck

282 YELLOW High Fuel Pressure Solenoid Valve #2 - X

mechanically stuck

283 YELLOW Engine Speed/Position Sensor #1 X X

(Crankshaft) Supply Voltage Circuit-
shorted high

284 YELLOW Engine Speed/Position Sensor #1 X X

(Crankshaft) Supply Voltage Circuit-
shorted low

285 YELLOW SAE J1939 Multiplexing PGN Timeout X X

Error

286 YELLOW SAE J1939 Multiplexing Configuration X X

Error

287 RED SAE J1939 Multiplexing Accelerator Pedal X X

Sensor System Error

288 RED SAE J1939 Multiplexing Remote Throttle X X

Data Error

296 RED Auxiliary Pressure Sensor Input #2 Engine X X

Protection - Critical

297 YELLOW Auxiliary Pressure Sensor Input #2 Circuit X X

- shorted high

298 YELLOW Auxiliary Pressure Sensor Input #2 Circuit X X

- shorted low

319 MAINT.(CHECK) Real Time Clock - Power Interrupt X X

349 YELLOW Transmission Output Shaft (Tailshaft) X X

Speed High - Warning

Page 7f Section One

 1800
FAULT INDICATOR QSB QSC
DESCRIPTION
CODE LAMP ENGINE ENGINE
352 YELLOW Sensor Supply Voltage #1 Circuit-shorted X X
low

361 RED Fuel Pump Control Module,Fuel Control X

Valve Circuit - shorted high

362 YELLOW Fuel Pump Control Module,Fuel Control X

Valve Circuit - shorted low

363 YELLOW Fuel Pump Control Module,Fuel Control X

Valve Circuit - mechanically stuck

364 YELLOW Fuel Pump Control Module, CAN Commu- X

nication Error-abnormal update rate

365 YELLOW Fuel Pump Control Module, Supply Volt- X

age Circuit - shorted low

366 YELLOW Fuel Pump Control Module, Supply Volt- X

age Circuit - data incorrect

367 YELLOW Fuel Pump Control Module, Increment X

Angle Time Sensor Error

368 YELLOW Fuel Pump Control Module, Timing Error X

369 YELLOW Fuel Pump Control Module, Engine X

Synchronization Error

372 YELLOW Fuel Pump Control Module, Idle Validation X

Error

373 RED Fuel Pump Control Module, Fuel Shutoff X

Error

374 YELLOW Fuel Pump Control Module, Self-Test X

Error

375 YELLOW Fuel Pump Control Module, Electronic X

Calibration Code Error

376 YELLOW Fuel Pump Control Module, Fueling or X

Engine Speed Mismatch

377 YELLOW Fuel Pump Control Module, Stuck Relay X

Error

381 YELLOW Intake Air Heater(Relay Enable) #1 Circuit X X

-data incorrect

382 YELLOW Intake Air Heater(Relay Enable) #2 Circuit X X

-data incorrect

385 YELLOW OEM Sensor Supply Voltage Circuit - X X

shorted high

386 YELLOW Sensor Supply Voltage #1 Circuit - X X

shorted high

Section One Page 7g

 1800
FAULT INDICATOR QSB QSC
DESCRIPTION
CODE LAMP ENGINE ENGINE
387 YELLOW Accelerator Pedal Position Sensor Supply X X
Voltage Circuit - shorted high

389 YELLOW Fan Clutch Circuit Error X X

391 YELLOW Fuel Shutoff Valve Supply Voltage Error X

415 RED Engine Oil Pressure Low - Critical X X

418 WIF/Maint. Water In Fuel Indicator High-Maintenance X X

422 YELLOW Engine Coolant Level Sensor Circuit-data X X

incorrect

429 YELLOW Water in Fuel Sensor Circuit-shorted low X X

431 YELLOW Accelerator Pedal Idle Validation Circuit- X X

data incorrect

432 RED Accelerator Pedal Idle Validation Circuit- X X

out of calibration

433 YELLOW Intake Manifold Pressure Sensor Circuit- X X

data incorrect

434 YELLOW Power Lost Without Ignition Off X X

441 YELLOW Battery #1 Voltage Low-Warning X X

442 YELLOW Battery #1 Voltage High-Warning X X

443 YELLOW Accelerator Pedal Position Sensor Supply X X

Voltage Circuit-shorted low

444 YELLOW OEM Sensor Supply Voltage Low-Warn- X X

ing

449 YELLOW Fuel Pressure High-Warning X

451 YELLOW Injector Metering Rail #1 Pressure Sensor X

Circuit-shorted high

452 YELLOW Injector Metering Rail #1 Pressure Sensor X

Circuit-shorted low

488 YELLOW Intake Manifold Temperature High- X X

Warning

489 YELLOW Transmission Output Shaft(Tailshaft) X X

Speed Low-Warning

493 - Fuel Pump Calibration Trim Circuit Error X

497 YELLOW Multiple Unit Sychronization Switch Circuit X X

-data incorrect

515 YELLOW Accelerator Pedal Frequency Position X X

Sensor Supply Circuit-shorted high

516 YELLOW Accelerator Pedal Frequency Position X X

Sensor Supply Circuit-shorted low

Page 7h Section One

 1800
FAULT INDICATOR QSB QSC
DESCRIPTION
CODE LAMP ENGINE ENGINE
517 YELLOW Fuel Metering Solenoid-bad device X

524 YELLOW OEM Alternate Droop Switch Validation- X X

data incorrect

527 YELLOW Auxiliary Input/Output #2 Circuit-shorted X X

high

528 YELLOW OEM Alternate Torque Switch Validation- X X

data incorrect

529 YELLOW Auxiliary Input/Output #3 Circuit-shorted X X

high

539 YELLOW Injector Control Valve Electronic Filter X

(Transorb) Error

551 YELLOW Accelerator Pedal Idle Validation Circuit - X X

shorted low

599 RED OEM Commanded Dual Output Shutdown X X

611 NONE Engine Hot Shutdown X X

768 YELLOW Output Device Driver (VGT or Transmis- X X

sion Shift PWM Signal)

779 YELLOW Auxiliary Equipment Sensor Input #3 X X

(OEM Switch)

Section One Page 7i

RETURN TO INDEX
 1800 RETURN TO INDEX

TILTING THE CAB - REAR ENTRY CAB ONLY

TILTING THE CAB (REAR ENTRY CAB ONLY):

THE CAB MAY BE TILTED FOR TRANSPORT OR SERVICE
- SWING THE UPPER INTO POSITION, TO WHERE THE CAB HAS AN OPEN
PATH TO TILT TO THE EXTENT SHOWN.
- LOWER THE LOADER FRONT SO IT IS SUPPORTED (ON THE GROUND
OR BY THE TRANSPORTER BLOCKING).
- FLIP UP THE ARMREST TO DISABLE THE OPERATOR'S CONTROLS.
- SHUT THE MACHINE DOWN. CAB HOLD-DOWN BOLTS:
- SECURE OR REMOVE ALL LOOSE ITEMS IN THE CAB. REMOVE THESE 2 BOLTS TO
- SHUT THE WINDOW AND CLOSE THE DOOR SECURELY WHEN TILT THE CAB.
LEAVING THE CAB. THESE BOLTS MUST BE
- REMOVE THE TWO HOLD-DOWN BOLTS AT CAB FLOOR LEVEL REINSTALLED WHEN THE CAB
OUTSIDE THE DOOR. IS TILTED BACK UP FOR
- OPEN THE RISER DOOR AND, FROM A SAFE POSITION MACHINE OPERATION.
WITH SOLID FOOTING, ACTIVATE THE CAB-TILT SWITCH AT THE
LOWER CORNER OF THE BREAKER BOX INSIDE THE RISER.
(NOTE: CHECK THE FLUID LEVEL IN THE POWER-PACK BEFORE
TILTING THE CAB. IT SHOULD BE FULL WITH THE CAB "UP".)
- USE CAUTION WHEN TILTING THE CAB. MAKE SURE THAT THE CREW
IS IN THE CLEAR. CHECK TO SEE THAT THE CYLINDER HOSES AND
THE SAFETY CABLE ARE FREE TO MOVE AND THAT NO PINCH-POINT
HAZARDS EXIST.
- WHEN THE CAB IS COMPLETELY TILTED, THE SAFETY CABLE MUST
SUPPORT THE WEIGHT AND THE CYLINDER MUST HAVE SOME 60

RESERVE STROKE.

15
15
RAISING THE CAB:
- CHECK THAT THE WINDOW GUARDS ARE SECURE AND THAT THERE
ARE NO LOOSE OBJECTS ON THE CAB THAT MAY FALL OFF AS
THE CAB COMES UP.
- ACTIVATE THE CAB TILT SWITCH AT THE BREAKER BOX TO RAISE
THE CAB.
- WATCH FOR PINCH-POINT HAZARDS AND MAKE SURE THE SAFETY HYDRAULIC POWER-PACK
CABLE ROLLS UP WITHOUT FOULING.
- WHEN THE CAB IS ALL THE WAY UP, INSTALL AND TIGHTEN THE CAB TILT SWITCH (ON BREAKER BOX)
HOLD-DOWN BOLTS. -INSIDE THE RISER
NOTE: LOCATION OF
- WHENEVER IT IS NECESSARY TO INSPECT THE AREA BETWEEN THE HOLD-DOWN BOLTS
UNDERSIDE OF THE CAB AND THE RISER, THE TILT SWITCH MUST
BE RELEASED AND THE CAB MOTION STOPPED. INSTALL SAFETY
STRAPS OR BLOCKING BEFORE REACHING INTO THE GAP.
- THE TILT MECHANISM IS DESIGNED TO SUPPORT THE CAB ONLY.
NEVER ATTACH WEIGHTS TO, OR RIDE ON OR IN THE TILTING CAB.
- DO NOT LEAVE THE CAB PARTIALLY TILTED WITH THE MACHINE
UNATTENDED. THE CAB MUST BE UP (WITH THE HOLD-DOWN BOLTS
INSTALLED) OR DOWN (SUPPORTED BY THE SAFETY CABLE).

CAB RISER - TOP VIEW

SAFETY CABLE - PART NO. P8208

CYLINDER - PART NO. 7904

(SEE CAB TILT ASS'Y IN PARTS BOOK)

60
15
15

Section One Page 9a

 1800
EMERGENCY ESCAPE-SIDE ENTRY CAB
PRIMARY EMERGENCY ESCAPE - REAR WINDOW

HINGES
REAR
WINDOW
EMERGENCY
ESCAPE
CAB DOOR LATCH

IP
GR
RE
SU

REAR WINDOW ESCAPE:

WHEN RELEASED BY MEANS
OF THE KNOB OR QUICK RELEASE PIN, MAINTENANCE:
THE WINDOW CAN BE SWUNG OUT PAST CHECK THE HINGES, QUICK RELEASE PIN
THE STOP AND SLID OFF THE HINGES AND RELEASE KNOB THREADS REGULARLY.
TO ALLOW EXIT FROM THE CAB. LUBRICATE AS NECESSARY.

QUICK-RELEASE PIN RELEASE KNOB

- FOR EMERGENCY RELEASE - FOR RELEASE FROM
FROM INSIDE THE CAB. OUTSIDE THE CAB.
PULL THE PIN TO ALLOW UNSCREW THE KNOB
THE LINK BAR TO SWING UNTIL IT COMPLETELY
OUT WITH THE WINDOW. RELEASES FROM THE
LINK BAR, THEN SWING
THE WINDOW OPEN.

OVER-CENTER LATCH
- FOR NORMAL WINDOW OPERATION.

REAR WINDOW LATCH DETAIL

Section One Page 10a

 1800 RETURN TO INDEX

EMERGENCY ESCAPE - REAR ENTRY CAB

PRIMARY EMERGENCY ESCAPE-L.H.SIDE WINDOW
(Secondary Escape-R.H.Side Window,Openable From Inside Only)

HINGES
RELEASE KNOB
LOCATIONS
(INSIDE THE
CAB)
-UNSCREW
THESE KNOBS
TO ALLOW THE
WINDOW TO SWING STOP
OPEN ON THE
HINGES.

HINGES
PI

GRIP
RG
ER

E
SUR
U
S

LATCH
CAUTION:
DURING NORMAL
OPERATION THE
RIGHT SIDE
WINDOW MUST BE
CLOSED AND THE
LEFT SIDE (REAR)
WINDOW OPENED LEFT SIDE WINDOW:
ONLY TO THE WHEN RELEASED BY
EXTENT ALLOWED BY MEANS OF THE KNOB
THE OVER-CENTER OR QUICK RELEASE PIN,
LATCH. FAILURE TO THE WINDOW FRAME CAN
DO SO MAY VIOLATE BE SWUNG OUT PAST THE
OSHA REGULATIONS STOP AND SLID OFF THE
FOR OPERATOR HINGES TO ALLOW EXIT
WINDOW PROTECTION. FROM THE CAB. QUICK-RELEASE PIN
WINDOW FRAME
- FOR EMERGENCY
RELEASE FROM INSIDE
MAINTENANCE: RELEASE KNOB - FOR RELEASE THE CAB. PULL THE
CAB WALL CHECK HINGES, QUICK FROM OUTSIDE THE CAB. PIN TO ALLOW THE
RELEASE KNOB - FOR RELEASE RELEASE PIN AND UNSCREW THE KNOB UNTIL IT LINK BAR TO SWING
FROM INSIDE THE CAB ONLY. KNOB THREADS COMPLETELY RELEASES FROM OUT WITH THE WINDOW.
UNSCREW ALL 4 KNOBS UNTIL THEY REGULARLY. THE LINK BAR, THEN SWING
COMPLETELY RELEASE FROM LUBRICATE AS THE WINDOW OPEN. OVER-CENTER LATCH
THE WINDOW FRAME, THEN SWING NECESSARY. -FOR NORMAL WINDOW
THE WINDOW OPEN. OPERATION.

RIGHT SIDE HINGED ESCAPE WINDOW DETAIL LEFT SIDE HINGED ESCAPE WINDOW LATCH DETAIL

Page 10b Section One

 1800 RETURN TO INDEX

GENERAL LAYOUT - REAR ENTRY CAB

Section One Page 11a

 1800
GENERAL LAYOUT - SIDE ENTRY CAB

Page 11b Section One

 1800 RETURN TO INDEX

CIRCUIT BREAKERS AND FUSES

BREAKER BOX

Section One Page 12a

 1800
CIRCUIT BREAKERS AND FUSES...CONT’D.

FUSE BLOCK LOCATED IN OPERATOR’S CAB

- REAR ENTRY CABS - INSIDE LEFT OVERHEAD PANEL (LOWER THE
PANEL FOR ACCESS)
- SIDE ENTRY CABS - INSIDE RIGHT FRONT CORNER (GAUGE)
PANEL

TYPE ATO FUSE

Page 12b Section One

 1800 RETURN TO INDEX

WELDING ON THE MACHINE

To prevent damage to the electronic control systems on the machine, some basic steps
must be taken before welding:

- Disconnect the batteries.

- Disconnect the 31-pin and 50-pin harness connectors at the engine, as well as the
J1939 3-way datalink connector (see diagram).

- Shut off or disconnect any power circuits to the electronic control systems on any of the
logging attachments (e.g., Waratah processors, shut off the key switch in the power sup-
ply module). Consult the manufacturer’s manuals for information on this requirement.

- DO NOT weld on the engine, or on any components bolted directly to the engine. Dis-
mount the components before welding if any engine-mounted items require modification.

-Attach the ground clamp no more than two feet from the part being welded, no matter
where on the machine or attachment the weld is being made. NEVER attach the ground
clamp to the engine ECM.

Section One Page 13a