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Mauldin 1560 Operation Manual

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Operation Manual
Model: 1560
Covers Serial Number Range:
848-S-56TCG9Y2*03848 through ______________________
Sold & Serviced By:

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Summary of Contents for Mauldin 1560

  • Page 1 Operation Manual Model: 1560 Covers Serial Number Range: 848-S-56TCG9Y2*03848 through ______________________ Sold & Serviced By:...

  • Page 2: Table Of Contents

    Contents 1. Introduction ..................... 4 1.1 Machine Components ..................4 1.2 Serial Number Plate ..................5 2. Safety ....................... 5 2.1 General Safety Information ................5 2.1.1 Safety Alert And Signal Words ................5 2.2 Operation Hazards .................... 6 2.2.1 ⚠Pressurized Fluids ...................8 2.2.2 ⚠...
  • Page 3 4 Screed Setup..................19 4.1 Initial Screed Setup ..................19 4.2 Extension Bottom Setup ................21 5 Fluid Capacities and Recommendations ..........24 5.1 Engine Coolant....................24 5.2 Lubrication and Service Procedures ............24 5.2.1 Air Filters ......................24 5.3 Battery ......................24 5.3.1 Removal ......................25 5.3.2 Cleaning ......................25 5.3.3 Installation ......................25...

  • Page 4: Introduction

    Calder Brothers Corp Serial Number Range: Page 4 Model: 1560 Paver V2.0 848-S-56TCG9Y2*03848 to ________________ 1. Introduction 1.1 Machine Components Dash 1. Sight Gauge Rod (both sides) Machine Steering Levers 2. Front Tie Down (both sides) Operator Display 3. Rear D-ring Tie Down (both sides) Engine Compartment 4.

  • Page 5: Serial Number Plate

    Calder Brothers Corp Serial Number Range: Page 5 V2.0 Model: 1560 Paver 848-S-56TCG9Y2*03848 to _____________ 1.2 Serial Number Plate Serial number plate is located on the left side of the engine enclosure. record serial number and date in spaces below.

  • Page 6: Operation Hazards

    Calder Brothers Corp Serial Number Range: Page 6 Model: 1560 Paver V2.0 848-S-56TCG9Y2*03848 to ________________ ⚠ CAUTION Indicates a hazardous condition that could result in serious injury if not performed appropriately. NOTICE Indicates a situation that could result in damage to the machine or other property.
  • Page 7 Calder Brothers Corp Serial Number Range: Page 7 V2.0 Model: 1560 Paver 848-S-56TCG9Y2*03848 to _____________ Long hair must be tied back or netted. Keep clear of moving components. Never operate machine with open or missing guards or shields. ⚠ WARNING Fire, burns or property damage hazard.

  • Page 8: Pressurized Fluids

    Calder Brothers Corp Serial Number Range: Page 8 Model: 1560 Paver V2.0 848-S-56TCG9Y2*03848 to ________________ ⚠ WARNING Crush hazard. A raised screed or partially open hopper will fall if a hydraulic line or fitting is opened, or manual override button on hydraulic valve is pressed.

  • Page 9: Hazards From Modifying Equipment

    Do not make any alterations to your paver. Altering may cause your equipment to be unsafe and may void the manufacturers’ warranty. Always use Mauldin replacement parts. 2.3 Maintenance Hazards The following maintenance hazards are in additional to those found while operating the paver. All maintenance and service personal must be familiar with all hazards before working on the machine.

  • Page 10: Fire Or Explosion Prevention

    Calder Brothers Corp Serial Number Range: Page 10 Model: 1560 Paver V2.0 848-S-56TCG9Y2*03848 to ________________ If you must troubleshoot machine with engine running, have someone in constant visual contact who can shut off the engine or engage an Emergency Stop.
  • Page 11 Calder Brothers Corp Serial Number Range: Page 11 V2.0 Model: 1560 Paver 848-S-56TCG9Y2*03848 to _____________ 3 - Danger Stand Back. There are moving objects that could result in harm. Stand back a safe distance to avoid harm. Failure to keep back may result in serious injury or death.

  • Page 12: Safety Decals On Machine

    Calder Brothers Corp Serial Number Range: Page 12 Model: 1560 Paver V2.0 848-S-56TCG9Y2*03848 to ________________ 2.4.2 Safety Decals on Machine...

  • Page 13: Paver Operation

    Calder Brothers Corp Serial Number Range: Page 13 V2.0 Model: 1560 Paver 848-S-56TCG9Y2*03848 to _____________ 3 Paver Operation 3.1 Machine Functions Explained 1. Hopper Open and Close. Left or Both Hoppers 2. Hopper Open and Close Right Hopper (optional) 3. Forward Hopper Lights On/off 4.
  • Page 14 Calder Brothers Corp Serial Number Range: Page 14 Model: 1560 Paver V2.0 848-S-56TCG9Y2*03848 to ________________ 17. Left Auger Direction In/Out 18. Left Conveyor Feed AUTO/Manual 19. Right Conveyor Feed AUTO/Manual 20. Right Auger Direction In/Out 21. Auger Control AUTO/Manual. Auto uses the sonic sensors to determine when to turn on the feed system (augers and conveyors).

  • Page 15: Digital Display

    Calder Brothers Corp Serial Number Range: Page 15 V2.0 Model: 1560 Paver 848-S-56TCG9Y2*03848 to _____________ 24. Left Extension Lever. This extends and retracts the left hand screed extension 3.2 Digital Display This digital display indicates engine oil pressure, engine coolant temperature, battery voltage, engine speed, engine torque being used, diesel exhaust fluid tank level, diesel fuel tank level and engine hours.

  • Page 16: Material Feed Screen

    9. Day/night mode. 10. Press to display engine code(s) if present. 11. Regen inhibit. Press to inhit exhaust regen. 12. DEF tank level. (not available on 1560) 13. Machine hour meter. 3.2.3 Material Feed Screen Note: Material feed screen can be viewed at the right hand station, but that the material height change and the dual/single can only be changed from the left hand station.

  • Page 17: Password Screen

    11. Selected screed heat setpoint. Default temperature is 230°F. 3.2.5 Password Screen Password screen should only be accessed while being directed by a Mauldin Paving Products service technician. 1. Selected station indicator. This symbol will be displayed on operators station screen with active travel controls.

  • Page 18: Driving

    Calder Brothers Corp Serial Number Range: Page 18 Model: 1560 Paver V2.0 848-S-56TCG9Y2*03848 to ________________ Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Always start and operate the engine in a well-ventilated area.

  • Page 19: Screed Setup

    Calder Brothers Corp Serial Number Range: Page 19 V2.0 Model: 1560 Paver 848-S-56TCG9Y2*03848 to _____________ 4 Screed Setup Model: Freedom 14 Main Screed Setup MAULDIN PAVING PRODUCTS Date: 08-01-19 4.1 Initial Screed Setup Calder Brothers Corporation Page: 1 of 2...
  • Page 20 Calder Brothers Corp Serial Number Range: Page 20 Model: Freedom 14 Main Screed Setup MAULDIN Model: 1560 Paver PAVING PRODUCTS V2.0 848-S-56TCG9Y2*03848 to ________________ Date: 08-01-19 Calder Brothers Corporation Page: 2 of 2 Initial Screed Adjustment Settings EXTENSION SLOPE TURNBUCKLE...

  • Page 21: Extension Bottom Setup

    Calder Brothers Corp Serial Number Range: Page 21 MAULDIN Model: Freedom 14 Extension Setup V2.0 Model: 1560 Paver 848-S-56TCG9Y2*03848 to _____________ PAVING PRODUCTS Date: 11-21-13 Calder Brothers Corporation 4.2 Extension Bottom Setup Page: 1 of 3 Extension Adjustable Bottom 1/2-13, 1.5" LONG BOLT HINGED EXTENSION SCREEDING WITH LOCK WASHER.
  • Page 22 Calder Brothers Corp Serial Number Range: Page 22 Model: 1560 Paver V2.0 848-S-56TCG9Y2*03848 to ________________ MAULDIN Model: Freedom 14 Extension Setup PAVING PRODUCTS Date: 11-21-13 Calder Brothers Corporation Page: 2 of 3 Extension Adjustable Bottom BOLT NOT SHOWN FOR CLARITY.
  • Page 23 Calder Brothers Corp Serial Number Range: Page 23 V2.0 Model: 1560 Paver 848-S-56TCG9Y2*03848 to _____________ MAULDIN Model: Freedom 14 Extension Setup PAVING PRODUCTS Date: 11-21-13 Calder Brothers Corporation Page: 3 of 3 Extension Adjustable Bottom BOLT NOT SHOWN FOR CLARITY.

  • Page 24: Fluid Capacities And Recommendations

    Calder Brothers Corp Serial Number Range: Page 24 Model: 1560 Paver V2.0 848-S-56TCG9Y2*03848 to ________________ 5 Fluid Capacities and Recommendations Fluid Capacity Recommendation Engine Oil 8.5 Quarts 15w40 Hydraulic Oil 15.5 US Gallons AW46 Hydraulic Oil Grease As required N.G.L.I #2 high Temp Engine Coolant 2.5 US Gallons...

  • Page 25: Removal

    Calder Brothers Corp Serial Number Range: Page 25 V2.0 Model: 1560 Paver 848-S-56TCG9Y2*03848 to _____________ ⚠ WARNING DISCONNECT GROUND CABLE FROM THE NEGATIVE BATTERY POST BEFORE ATTEMPTING TO SERVICE OR REMOVE BATTERY. 5.3.1 Removal a. Open engine compartment and locate battery to your near left side.

  • Page 26: Engine And Engine Filters

    Calder Brothers Corp Serial Number Range: Page 26 Model: 1560 Paver V2.0 848-S-56TCG9Y2*03848 to ________________ 5.4 Engine and Engine Filters 1. Fuel Filter / Water Separator The fuel filter and water separator is a combined unit, PLEASE NOTE it is NOT disposable.

  • Page 27: Hydraulic Fluid Change

    Calder Brothers Corp Serial Number Range: Page 27 V2.0 Model: 1560 Paver 848-S-56TCG9Y2*03848 to _____________ ENERGY, REGULARLY VERIFY DURING THE SERVICE AND MAINTENANCE THAT SUCH ENERGY HAS NOT REACCUMULATED TO HAZARDOUS LEVELS. ⚠ DANGER DO NOT RELEASE OR OPEN ANY HOSE OR HYDRAULIC CIRCUIT WHILE ANY IMPLMENT IS SUSPENDED IN THE AIR.

  • Page 28: Troubleshooting

    Calder Brothers Corp Serial Number Range: Page 28 Model: 1560 Paver V2.0 848-S-56TCG9Y2*03848 to ________________ 6 Troubleshooting 6.1 General Proper troubleshooting begins with an organized approach to the problem at hand. Begin with investigation of the most probable cause, following the guidelines below.

  • Page 29: Engine

    Calder Brothers Corp Serial Number Range: Page 29 V2.0 Model: 1560 Paver 848-S-56TCG9Y2*03848 to _____________ ENERGY, REGULARLY VERIFY DURING THE SERVICE AND MAINTENANCE THAT SUCH ENERGY HAS NOT REACCUMULATED TO HAZARDOUS LEVELS. ⚠ DANGER DO NOT RELEASE OR OPEN ANY HOSE OR HYDRAULIC CIRCUIT WHILE ANY IMPLMENT IS SUSPENDED IN THE AIR.

  • Page 30: Hydraulic System Pressures

    Calder Brothers Corp Serial Number Range: Page 30 Model: 1560 Paver V2.0 848-S-56TCG9Y2*03848 to ________________ If possible, trace malfunction to source; pump, control, motor or cylinder. Determine pressure operating the function as specified: 6.4.1 Hydraulic System Pressures Priority circuit, triple gear pump 2,500 –...

  • Page 31: Recommended Preventive Maintenance Intervals

    Calder Brothers Corp Serial Number Range: Page 31 V2.0 Model: 1560 Paver 848-S-56TCG9Y2*03848 to _____________ 6.5 Recommended Preventive Maintenance Intervals Initial Item Procedure After First 50 Hours: Change all hydraulic filers Check for hydraulic leaks Initial Break in Change engine oil and filters...

  • Page 32: Warranty

    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. This...

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