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Mauldin M415XT MAINTAINER Manual

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M415XT MAINTAINER
OWNER / OPERATOR
M415XT Maintainer Serial Number:
M415XT Maintainer Specification Number:
Sold & Serviced by:

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Summary of Contents for Mauldin M415XT MAINTAINER

  • Page 1 M415XT MAINTAINER OWNER / OPERATOR M415XT Maintainer Serial Number: M415XT Maintainer Specification Number: Sold & Serviced by:...

  • Page 3: Table Of Contents

    Section I – Storage: ..................Pages 49 Section J – Computer Diagnostic: ..............Pages 50 Section K – Warranty Statement: ..............Pages 69 Section L – Axle Service: ................Pages 70 Calder Brothers Corporation 2/3/2020 Page 3 of 78 Model: M415XT Maintainer...

  • Page 4: Section A - Safety

    ALWAYS keep this manual in a convenient place for instant reference and NEVER make repairs or adjustments that you do not fully understand. If you require additional information or service, contact you authorized MAULDIN Dealer. REMEMBER! It is the owner’s responsibility to communicate information on the safe use and proper maintenance of this machine! This includes providing understandable interpretation of these instructions for operators who are not fluent in reading English.
  • Page 5 ALWAYS maintain a safe distance from electric power lines or buried cables, and avoid any electrically charged conductor! Contact can result in electrocution. Call your proper local authorities for utility line locations BEFORE starting a job! Calder Brothers Corporation 2/3/2020 Page 5 of 78 Model: M415XT Maintainer...
  • Page 6 Where such authorization is granted, tags or decals shall be changed accordingly. All attachments MUST be marked to identify the Attachment(s) and show the approximate weight of the machine and Attachment combination. Calder Brothers Corporation 2/3/2020 Page 6 of 78 Model: M415XT Maintainer...
  • Page 7 (alarms, extra mirrors, blinking lights, etc.). The operator/user is responsible for providing and maintaining such devices. Calder Brothers Corporation 2/3/2020 Page 7 of 78 Model: M415XT Maintainer...
  • Page 8 Part #100A3706-A - Located on either side of platform Part #165924 - Located either side of the radiator. Part #065927 - Located at various places on the machine. Part #A1002504 - Located on fuel tank. Calder Brothers Corporation 2/3/2020 Page 8 of 78 Model: M415XT Maintainer...
  • Page 9 M415XT Section A - Safety Part #108787 - Located beside operator’s seat on seat deck. Part #108785-Located at each wheel. Calder Brothers Corporation 2/3/2020 Page 9 of 78 Model: M415XT Maintainer...

  • Page 10: Section B - Specifications

    Bucket Capacity ..........1/2 cubic yd/2,000 lbs (.38m 3 /.91 kg) Dump Height (E) ..........120” (3.05m) Minimum Turning Radius: Inside Wheel ............ 96” (2.44m) Inside Moldboard ..........60” (1.525m) Calder Brothers Corporation 2/3/2020 Page 10 of 78 Model: M415XT Maintainer...

  • Page 11: Section C - Controls & Accessories

    If this reads toward the far left during normal operation with the Engine running, STOP the Engine immediately. After allowing the oil to drain down for a few minutes, check the Engine oil level. Maintain oil level at the FULL mark on the dipstick. Calder Brothers Corporation 2/3/2020 Page 11 of 78 Model: M415XT Maintainer...
  • Page 12 When provided, these are used to operate the Windshield Wiper, Heater and Air Conditioning. Other Optional Dash Switches When provided, these are used to operate lights and turn signals. Calder Brothers Corporation 2/3/2020 Page 12 of 78 Model: M415XT Maintainer...
  • Page 13 4 wheels are centered straight forward. The icon will stop flashing when the wheels are centered and the machine will be in the desired steering mode. Calder Brothers Corporation 2/3/2020 Page 13 of 78 Model: M415XT Maintainer...
  • Page 14 TRAVEL should only be used for transporting and not for working. Park Brake The machine cannot be started unless the Park Brake is set. To operate the machine, you must have Park Brake off. Calder Brothers Corporation 2/3/2020 Page 14 of 78 Model: M415XT Maintainer...
  • Page 15 Blade Functions. Grader Mode is indicated on the display with a small grader. You can toggle between the modes using the button on the Display. You can also double click button (B) on the joystick to switch between the modes. Calder Brothers Corporation 2/3/2020 Page 15 of 78 Model: M415XT Maintainer...
  • Page 16 Blade Angle Move Slider (D) FORWARD on the Joystick to pivot the Moldboard counter-clockwise (left angle position). Pull Slider (D) BACK to extend the Moldboard clockwise (right angle position). Calder Brothers Corporation 2/3/2020 Page 16 of 78 Model: M415XT Maintainer...

  • Page 17: Section D - Operations

    BEFORE starting to grade. Before operating the machine on roads or highways, check local laws regarding the use of lights, flags, licensing, slow moving vehicle emblems (SMV), etc. Calder Brothers Corporation 2/3/2020 Page 17 of 78 Model: M415XT Maintainer...
  • Page 18 If the engine fails to start on the first try or it dies out after only running a short time, turn the Key Switch to OFF, wait at least two minutes and repeat above steps. Calder Brothers Corporation 2/3/2020 Page 18 of 78 Model: M415XT Maintainer...
  • Page 19 Bring the machine to full parking stop on a level surface. NEVER park on a slope or hill side. With all personnel clear of the machine, slowly lower hydraulic equipment flat to the ground Calder Brothers Corporation 2/3/2020 Page 19 of 78 Model: M415XT Maintainer...
  • Page 20 Side shift the Moldboard to cast material outside of the tires’ path by using the BLADE SHIFT Control. Side shifting the Moldboard also allows continued grading in a straight path while avoiding obstructions or obstacles at the end of the Moldboard. Calder Brothers Corporation 2/3/2020 Page 20 of 78 Model: M415XT Maintainer...
  • Page 21 When the Bucket clears the sideboard of the truck, tilt the Bucket completely forward. When the Bucket is empty, tilt it back completely and back the Maintainer away from the truck. Calder Brothers Corporation 2/3/2020 Page 21 of 78 Model: M415XT Maintainer...
  • Page 22 Check all Cylinders for signs of leaks. Secure the machine. NOTE Always fill the Fuel Reservoir completely at the end of the working day to prevent moisture condensation from occurring overnight. Calder Brothers Corporation 2/3/2020 Page 22 of 78 Model: M415XT Maintainer...

  • Page 23: Section E - Fuels & Lubrication

    Hydraulic Suction Strainer Use AW 46 Hydraulic Oil NOTE Refer to Operator Services in Section H - Service, of this manual, for detailed information regarding periodic checking and replenishing of lubricants. Calder Brothers Corporation 2/3/2020 Page 23 of 78 Model: M415XT Maintainer...
  • Page 24 Replace any missing or damaged fittings when necessary. To minimize dirt build- up, avoid excessive greasing. The following illustrations show the location of all grease fittings. Boom & Bucket Assembly 10 Grease Zerks (Z) Calder Brothers Corporation 2/3/2020 Page 24 of 78 Model: M415XT Maintainer...
  • Page 25 M415XT Section E – Fuels & Lubrication Tool Bar Assembly 6 Grease Zerks (Z) Calder Brothers Corporation 2/3/2020 Page 25 of 78 Model: M415XT Maintainer...
  • Page 26 M415XT Section E – Fuels & Lubrication Front Axle & Frame Assembly 3 Grease Zerks (Z) Calder Brothers Corporation 2/3/2020 Page 26 of 78 Model: M415XT Maintainer...
  • Page 27 M415XT Section E – Fuels & Lubrication Moldboard Assembly 25 Grease Zerks (Z) Calder Brothers Corporation 2/3/2020 Page 27 of 78 Model: M415XT Maintainer...
  • Page 28 Moldboard is centered on the trailer when it is in the full down position. Lower the Scarifier and Blade to full down position. Stop the Engine according to Mandatory Safety Shutdown Procedures in Section A - Safety, of this manual. Calder Brothers Corporation 2/3/2020 Page 28 of 78 Model: M415XT Maintainer...
  • Page 29 If necessary, adjust the machine so that the wheels are in line and centered with the ramps. Slowly (at the lowest Engine speed possible) and carefully drive the machine down the ramps. NOTE All loading and unloading should be done in Low (4-wheel) drive. Calder Brothers Corporation 2/3/2020 Page 29 of 78 Model: M415XT Maintainer...
  • Page 30 Report the theft to the dealer and insurance company. Provide all the model and serial numbers. Request that your dealer forward this same information to Calder Brothers Corporation. Calder Brothers Corporation 2/3/2020 Page 30 of 78 Model: M415XT Maintainer...
  • Page 31 This Troubleshooting guide presents problems, causes, and remedies beyond the extent of loose, worn, or missing parts and is developed in consideration of the machine being in otherwise good operating condition. Repairs to hydraulic components, electronic systems, engine or transmission should ONLY be done by your MAULDIN Dealer or authorized Service Dealer.
  • Page 32 Replace if clogged. NEVER to exceed 225°F.) Bad gauge. Replace. Bad gauge. Replace. Hydraulic Oil Temperature Low Or Not Indicating Extreme low ambient temperature. Consult an authorized Service Dealer. Calder Brothers Corporation 2/3/2020 Page 32 of 78 Model: M415XT Maintainer...
  • Page 33 Engine fan v-belt loose. Adjust. Temperature Engine thermostat inoperative. Refer to Engine Manual. Water pump not working properly. Refer to Engine Manual. Internal engine malfunctions. Refer to Engine Manual. Calder Brothers Corporation 2/3/2020 Page 33 of 78 Model: M415XT Maintainer...
  • Page 34 Cylinder leaking internally Repair or replace. Hydraulic Cylinders Leaking Down or Will Not Hold Their Position Control valve leaking internally. Repair or replace. Hydraulic Cylinders/Control Valves Seals/O-Rings worn. Replace. Leaking Externally Calder Brothers Corporation 2/3/2020 Page 34 of 78 Model: M415XT Maintainer...
  • Page 35 Consult an authorized Service Dealer. Dealer. Plugged pump orifice. Consult an authorized Service Dealer. Drive System Not Responsive When Changing Directions Transmission pump problems. Consult an authorized Service Dealer. Calder Brothers Corporation 2/3/2020 Page 35 of 78 Model: M415XT Maintainer...
  • Page 36 Consult an authorized Service Dealer. loss of charge pressure. Brakes Engaging Prematurely or Consult an authorized Service Dealer. When Slowing Machine Down Excessive worn drive pump. Consult an authorized Service Dealer. Brake malfunction. Calder Brothers Corporation 2/3/2020 Page 36 of 78 Model: M415XT Maintainer...
  • Page 37 In addition, WARRANTY repairs can only be done by a MAULDIN Dealer. They will know what portions of the machine are covered under the terms of the MAULDIN warranty and what portions are covered by other vendor OEM warranties.
  • Page 38 Having the hydraulic cylinders extended will cause the level in the hydraulic tank to be below the sight gauge window. When all hydraulic cylinders are retracted there should be a “line” level of fluid in the sight gauge window. Calder Brothers Corporation 2/3/2020 Page 38 of 78 Model: M415XT Maintainer...
  • Page 39 Whenever Battery is removed from the unit, BE SURE to disconnect the negative (-) Battery terminal connection cable first. NOTE The Battery in the machine is warranted by the supplier. Calder Brothers Corporation 2/3/2020 Page 39 of 78 Model: M415XT Maintainer...
  • Page 40 70°F (21°C) for a minimum of 48 hours before reusing. CAUTION NEVER use an Element that is damaged. Severe Engine wear and eventual failure can result if dirt gets through a hole in the Element. Calder Brothers Corporation 2/3/2020 Page 40 of 78 Model: M415XT Maintainer...
  • Page 41 Whenever the Fuel Filter is removed and replaced, or the Engine runs out of fuel, air MUST be bled from the system. Refer to the Engine manual for instructions in proper bleeding procedures. Calder Brothers Corporation 2/3/2020 Page 41 of 78 Model: M415XT Maintainer...
  • Page 42 Whenever faulty or plugged injectors are indicated, see your nearest authorized Engine dealer. Injection Pump Timing (As Required) Whenever Injection Pump timing or other pump service is indicated by abnormal Engine operation, contact your nearest Engine dealer. Calder Brothers Corporation 2/3/2020 Page 42 of 78 Model: M415XT Maintainer...
  • Page 43 Engine Block, NOT to the Battery Negative Post. When making the connection to the Engine, keep the clamp away from the Battery, Fuel Lines, Tubing, or Moving Parts. Calder Brothers Corporation 2/3/2020 Page 43 of 78 Model: M415XT Maintainer...
  • Page 44 NOTE If the Battery frequently becomes discharged, have the Battery checked for possible dead cell(s) or troubleshoot the entire electrical system for possible short circuits or damaged wire insulation. Calder Brothers Corporation 2/3/2020 Page 44 of 78 Model: M415XT Maintainer...
  • Page 45 Refer to Section H – Service Check/Clean Air Pre-Cleaner Refer to Section H – Service Check All Decals Refer to Section A - Safety for Decal Locations DATE SERVICE IS COMPLETED Calder Brothers Corporation 2/3/2020 Page 45 of 78 Model: M415XT Maintainer...
  • Page 46 Check Fan Belt Tension & Wear Refer to Section H – Service Check Tire pressure Refer to Section H – Service Check Wheel Nuts Refer to Section H - Service DATE SERVICE IS COMPLETED Calder Brothers Corporation 2/3/2020 Page 46 of 78 Model: M415XT Maintainer...
  • Page 47 Refer to Section H – Service Check Fluid in Power Wheel Hubs Refer to Section H – Service Refer to Section H - Service Check Cylinder Attach Bolts/Pin Setscrews DATE SERVICE IS COMPLETED Calder Brothers Corporation 2/3/2020 Page 47 of 78 Model: M415XT Maintainer...
  • Page 48 Refer to Section H – Service & OEM Engine Man. Check/Replace Cutting Edges or Ripper Points Refer to Section H – Service Clean (Wash or Steam) Exterior Surfaces Refer to Section H - Service DATE SERVICE IS COMPLETED Calder Brothers Corporation 2/3/2020 Page 48 of 78 Model: M415XT Maintainer...

  • Page 49: Section I - Storage

    Review and re-familiarize yourself with all safety precautions as outlined in Section A - Safety, in this manual. Follow the starting and warm-up procedures as outlined in Section D - Operation, in this manual. Calder Brothers Corporation 2/3/2020 Page 49 of 78 Model: M415XT Maintainer...
  • Page 50 Check coil parameters in BODAS service • coil currents incorrect • Check wiring / connector • function Blade Lift Right DSD 0x8006 Error • disabled • Replace coil(s) coil faults Calder Brothers Corporation 2/3/2020 Page 50 of 78 Model: M415XT Maintainer...
  • Page 51 Parameters incorrect Service • • Check wiring / connector coil disconnected • function Blade Shift A Coil 0x800D Error • disabled • Replace coil Wiring issues / loose connection Calder Brothers Corporation 2/3/2020 Page 51 of 78 Model: M415XT Maintainer...
  • Page 52 Boom A Coil Error 0x8012 temperatures) disabled • Coil damaged • Check coil parameters in BODAS service • • Check wiring / connector Boom B Coil Error 0x8013 coil disconnected Calder Brothers Corporation 2/3/2020 Page 52 of 78 Model: M415XT Maintainer...
  • Page 53 • Not Used • NA • NA 57344 Error CAN Engine Rx PGN • No effect on • • Check wire harness 0x801B Error from Engine 64892 Error functionality Calder Brothers Corporation 2/3/2020 Page 53 of 78 Model: M415XT Maintainer...
  • Page 54 Can Rx Data HMI 4 0x8021 Error • Will not be • Make sure termination resistors • Error between Display and Controller. able to change are used. boom speed Calder Brothers Corporation 2/3/2020 Page 54 of 78 Model: M415XT Maintainer...
  • Page 55 Regen on demand • Will not be able to skip intro screens. Can Rx Data HMI 6 0x8023 • Not used • NA • NA Error Calder Brothers Corporation 2/3/2020 Page 55 of 78 Model: M415XT Maintainer...
  • Page 56 • Engine oil pressure warning • Engine def Can Tx Data HMI 5 0x8028 Error level low warning • Neutral position front axle • Neutral position rear axle • Emergency stop Calder Brothers Corporation 2/3/2020 Page 56 of 78 Model: M415XT Maintainer...
  • Page 57 Can Tx Data HMI 6 • • NA • NA 0x8029 Not Used Error • Machine • • Check battery voltage. Low Battery 0x802A Low battery could stop if Calder Brothers Corporation 2/3/2020 Page 57 of 78 Model: M415XT Maintainer...
  • Page 58 • Check wiring harness, Joystick 1 Axis 2 Wiring harness damaged implement 0x8034 Error functionality • Ensure termination resistors used disabled in wiring harness • • Check joystick 0x8035 Joystick damaged Calder Brothers Corporation 2/3/2020 Page 58 of 78 Model: M415XT Maintainer...
  • Page 59 • Pedal disconnected Pressure Sensor • • NA • NA 0x803F Not Used Blade 1A Error Pressure Sensor • • NA • NA 0x8040 Not Used Blade 1B Error Calder Brothers Corporation 2/3/2020 Page 59 of 78 Model: M415XT Maintainer...
  • Page 60 • Replace coil Wiring issues / loose connection • Current draw too high as a coil with a different resistance is used (possible at lower temperatures) • Coil damaged Calder Brothers Corporation 2/3/2020 Page 60 of 78 Model: M415XT Maintainer...
  • Page 61 • NA • NA Error • • Check wiring / connector coil disconnected • Drive Pump 2B Out Error 0x8059 • Disabled • Replace coil Wiring issues / loose connection Calder Brothers Corporation 2/3/2020 Page 61 of 78 Model: M415XT Maintainer...
  • Page 62 Coil damaged • • Check wiring / connector coil disconnected • Unable to Steering Mode 2 0x8061 Coil Error change • • Replace coil Wiring issues / loose connection Calder Brothers Corporation 2/3/2020 Page 62 of 78 Model: M415XT Maintainer...
  • Page 63 • check wiring harness • check connector to angle sensor • ensure sensors are connected to • angle sensor disconnected correct sockets • ensure solenoids are connected • wiring harness issue Calder Brothers Corporation 2/3/2020 Page 63 of 78 Model: M415XT Maintainer...
  • Page 64 • pump goes • • check wiring harness incorrect parameters Left Pres input out intp ET mode 0x8073 of range • • check pump sensor damaged • sensor disconnected Calder Brothers Corporation 2/3/2020 Page 64 of 78 Model: M415XT Maintainer...
  • Page 65 (possible at lower temperatures) • Coil damaged • • Check wiring / connector Wiring error • Functionality Beacon Output 0x807D Error disabled • • Replace sensor Sensor disconnected Calder Brothers Corporation 2/3/2020 Page 65 of 78 Model: M415XT Maintainer...
  • Page 66 0x8086 Error Pin 2 • Sensor disconnected displayed on • Check wiring the display • Wiring fault • • Check wiring / connector Front Motor HS 0x8087 coil disconnected Calder Brothers Corporation 2/3/2020 Page 66 of 78 Model: M415XT Maintainer...
  • Page 67 • Check sensor Rear speed sensor fault • Speed will Rear Speed Sensor • • Check connection 0x808E Wiring error Error Pin 2 be incorrectly • • Check wiring Sensor damaged Calder Brothers Corporation 2/3/2020 Page 67 of 78 Model: M415XT Maintainer...
  • Page 68 Coil damaged into ET mode • • Check wiring harness Pump damaged • Wiring fault • Machine Emergency Stop • • Disengage e-stop 0x8094 E-stop is pressed functionality Pressed disabled Calder Brothers Corporation 2/3/2020 Page 68 of 78 Model: M415XT Maintainer...
  • Page 69 Mauldin or an Authorized Service Representative. EXCLUSIONS: This warranty does not apply to routine wearable parts of the Mauldin machine such as seals, points, plugs, hoses or similar items. This warranty does not extend to any machine or part replaced or repaired under this warranty.
  • Page 70 Hence, this manual must be read by persons authorized to make repairs before they start any such work in order to guarantee the best result. 1.2. ID PLATE Axle identification plate PART NUMBER SERIAL NUMBER Calder Brothers Corporation 2/3/2020 Page 70 of 78 Model: M415XT Maintainer...

  • Page 71: Section L - Axle Service

    - Scrupulously observe the indications given on the warning and indication plates that are on the vehicle. All auxiliary means and tools must be in perfect condition for use and absolutely safe. Calder Brothers Corporation 2/3/2020 Page 71 of 78 Model: M415XT Maintainer...
  • Page 72 Greasing (where envisaged) 200 hours (2) weekly / every 200 hours (1)(2) (1) which of the two conditions occurs first (2) 50 hours in the case of hard work Calder Brothers Corporation 2/3/2020 Page 72 of 78 Model: M415XT Maintainer...
  • Page 73 For the filling oil instruction see the first time installation card of the 128 axle series. Filling the steering axle: For the filling oil instruction see the first time installation card of the 128 axle series. Calder Brothers Corporation 2/3/2020 Page 73 of 78 Model: M415XT Maintainer...
  • Page 74 Bevel gear: 1. Excessive use Replace the bevel gear. Breakage due to fatigue of the 2. Continuous overload pinion tooth (check for characteristic fracture lines) Calder Brothers Corporation 2/3/2020 Page 74 of 78 Model: M415XT Maintainer...
  • Page 75 4. Lubricant is dirty recommended. Shaft: Extremely intense use of the Replace the shaft Shaft deformed or fracture- vehicle, overloaded split Calder Brothers Corporation 2/3/2020 Page 75 of 78 Model: M415XT Maintainer...
  • Page 76 6. Adjust 4. Pinion bearings with 7. Replace clearance 8. Top up 5. Differential bearings are 9. Replace worn 10. Replace 6. Differential bearings with 11. Replace 12. Replace clearance Calder Brothers Corporation 2/3/2020 Page 76 of 78 Model: M415XT Maintainer...
  • Page 77 1. Differential planet gears worn 2. Replace Noise on a curve 2. Differential housing and/or 3. Replace differential pins worn 4. Replace 3. Differential washers worn 4. Grooving on the shaft worn Calder Brothers Corporation 2/3/2020 Page 77 of 78 Model: M415XT Maintainer...
  • Page 78 NOTE: When reassembling it is essential to replace all the seals. Take care NOT to pinch the oil retainers during assembly. Calder Brothers Corporation 2/3/2020 Page 78 of 78 Model: M415XT Maintainer...
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