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Mauldin 1860B Operation Manual

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Operation Manual
Model: 1860B
Covers Serial Number Range:
874-S-86TCX5Y2*03874 through ______________________
Sold & Serviced By:

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Troubleshooting

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Summary of Contents for Mauldin 1860B

  • Page 1 Operation Manual Model: 1860B Covers Serial Number Range: 874-S-86TCX5Y2*03874 through ______________________ Sold & Serviced By:...
  • Page 2 California Proposition 65 Warnings ^ WARNING 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. If in an enclosed area, vent the exhaust to the outside.

  • Page 3: Table Of Contents

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 Contents 1. Introduction ..................... 1 1.1 Machine Components ..................1 1.2 Serial Number Plate ..................2 1.3 Operator Orientation ..................2 2. Safety ....................... 3 2.1 General Safety Information ................3 2.1.1 Safety Alert And Signal Words ................3...
  • Page 4 Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 3.9 Pause/Resume ....................17 3.10 Travel Speed ....................17 3.11 Tow Points ..................... 18 3.13 Screed Heat ....................19 3.14 Match Height ....................19 3.15 Hopper ......................19 3.16 Prime Fuel System ..................
  • Page 5 Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 6.3.5 Verify Lights Are Operable ................36 6.3.6 Check Horn And Signal Devices ..............36 6.3.7 Check Safety Decals ..................36 6.3.8 Check Engine Radiator Intake Screen ............. 36 6.3.9 Drain Fuel/Water Separator ................37...
  • Page 6 Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 8.3.4 Changing Hand Held Out Put ................47 8.3.5 Changing from Metric to English Measurements: .......... 47 8.4 Single Grade Setup ..................47 8.5 Error Codes ..................... 48 8.6 Daily Automation Setup .................

  • Page 7: Introduction

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 1. Introduction 1.1 Machine Components 1. Hopper 17. Left Hand Control Panel 2. Push Beam 18. Engine Enclosure 3. Shipping Front Tie Down (Both Sides) 4. Tow Point Cylinder 5.

  • Page 8: Serial Number Plate

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 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. Serial Number:____________________________ Date Of Purchase:_________________________ 1.3 Operator Orientation...

  • Page 9: Safety

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 2. Safety 2.1 General Safety Information Operating personnel must perform service checks regularly to be sure systems are in good operating condition. If abnormal conditions are detected, inform maintenance personnel immediately.
  • Page 10 Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 ^ WARNING Explosion, fire, or property damage hazard. Do not use starting fluid with this engine. Use of starting fluid can cause an explosion, fire, personal injury or damage to the engine and other property.

  • Page 11: Pressurized Fluids

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 ^ WARNING Explosion, fire, or personal injury. This engine is equipped with an air intake heater. Do not use starting fluid with this engine. Use of starting fluid can cause an explosion, fire, personal injury or damage to the engine and other property.

  • Page 12: Hazardous Chemicals

    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 13: Maintenance And Service

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 ^ WARNING Improper operation, lubrication or maintenance of this paver can be dangerous and could result in injury or death. ^ WARNING Do not perform any lubrication and maintenance on this paver until you read and understand the instructions in the maintenance section of this manual.
  • Page 14 Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 1 - Danger High Voltage. The generator provides 500V AC for screed heater operation. Avoid working on any electrical components while the engine is on. ONLY factory trained personnel should ever work on the high voltage system.
  • Page 15 Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 9 - Danger. Keep clear. Moving parts can result in harm. Failure to keep clear will result in injury. *Inside Access Panel *Inside Access Panel...

  • Page 16: Paver Operation

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 3. Paver Operation 3.1 Operators Station 024-0260 024-0260 Left Side Station Right Side Station...
  • Page 17 Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 1. Screed Lock Out/Disable: Disables Slope and Power Crown Adjustments 2. Left Hand Slope (Optional). Adjusts left extension to either flat or angled positions. 3. Crown (Optional). Adjust screed crown.

  • Page 18: Digital Display

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 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 19: Material Feed Screen

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 12. DEF tank level. 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 20: Password Screen

    416-V-86TCX5Y2*04123 to _____________ V 1.0 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 21: Idle/Pave And Engine Speed

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 For more information go to www.P65Warnings.ca.gov/diesel. ^ WARNING Explosion, fire, or personal injury. This engine is equipped with an air intake heater. Do not use starting fluid.

  • Page 22: Active Station

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 3.7 Active Station 3.7.1 Single Operator Feed Control Mode This will allow a single operator to control both left and right feed control zones. 1. Start paver engine or move key switch to on position.

  • Page 23: Pause/Resume

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 3.9 Pause/Resume The paver is equipped with a pause/resume function. Pause/resume function allows you to stop the paver and feed function without moving the joystick or feed toggle switches.

  • Page 24: Tow Points

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 3.11 Tow Points There are two switches at each operators station. Left switch (1) will adjust left hand tow point cylinder, and right switch (2) will adjust right hand tow point cylinder.

  • Page 25: Screed Heat

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 3.13 Screed Heat Toggle screed heat/generator switch (1) to start/stop generator. The generators only function is to provide electrical power to the screed heating system. Go to the digital display to set screed heat temperature.

  • Page 26: Prime Fuel System

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 3.16 Prime Fuel System If engine has run out of fuel, the fuel system will need to be primed after refueling. Loosen primer (1) on fuel/water separator and pump until resistance is felt.
  • Page 27 Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 5. Pull fast sun gear (5) out using and cap screw removed in step 1. 6. Remove cap screw (1) from sun gear and install into housing as shown.

  • Page 28: Material Feed

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 4. Material Feed 4.1 Automatic Material Feed Operation Single Operator Feed Setup Active operators station controls all feed systems. Both operator stations can control hopper screed and extensions at any time regardless if dual or single mode is selected.
  • Page 29 Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 Dual Operator Feed Setup Left hand operators station controls left hand feed systems. Right hand operators station controls right hand feed system. Both operator stations control hopper, screed and extension functions.

  • Page 30: Manual Material Feed Operation

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 4.2 Manual Material Feed Operation Operators less familiar with automatic feeding controls may want to use the manual mode for the first several hours of operation to become familiar with the other controls and operation.

  • Page 31: Sonic Sensors

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 4.3 Sonic Sensors The automatic material feed system uses sonic sensors (1). Sonic sensing will allow you to maintain the amount of material that you prefer on the end of the extension, regardless of adverse paving conditions.

  • Page 32: Screed Heating System

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 4.4 Screed Heating System The screed has heating elements in the main screed and on each extension. Heating system is thermostatically controlled. Generator will cycle on/off as needed to keep screed at selected temperature. The factory recommended setting is 230°F (110°C).

  • Page 33: Screed Setup

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 5. Screed Setup 5.1 Crown Setting 1. Start paver engine. See Section 3.4 Start Engine. 2. Toggle tow point switches (1) and (2) to expose an equal amount of the cylinder rod on each cylinder.
  • Page 34 Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 ^ WARNING Crush hazard. Paver can be inadvertently started and moved. Stop engine, remove key and place a Do Not Operate tag on ignition switch. 7. Stop paver engine, remove key and place a Do Not Operate tag on ignition switch.

  • Page 35: Extension Setting

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 5.2 Extension Setting 5.2.1 Prepare Paver For Screed Adjustments 1. Start paver engine. See Section 3.4 Start Engine. ^ WARNING Crush hazard. A raised screed may lower unexpectedly.

  • Page 36: Set Extension Slope

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 3. With screed extensions retracted, run a string across the entire trailing edge (5) of the screed extension bottoms. 5.2.3 Set Extension Slope 1. Prepare paver for screed adjustments. See Section 5.2.1 Prepare Paver For Screed Adjustments.

  • Page 37: Pre-Strike Off Setting

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 5.3 Pre-Strike Off Setting 1. Start paver engine. See Section 3.4 Start Engine. ^ WARNING Crush hazard. A raised screed may lower unexpectedly. Engage screed support locks to support screed.

  • Page 38: Setting Screed To Pave

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 10. Raise center walk board (4) exposing the cam style adjustment (5) for each side. Loosen jam nut on locator bolt and fully remove the locator bolt. Rotate the cam bolt clockwise to raise pre-strike off.

  • Page 39: Inspections And Maintenance

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 6. Inspections And Maintenance 6.1 Inspection And Maintenance Chart Daily Daily Initial Initial Monthly/ Yearly/ 5 Year/ Item Before After 50 Hrs 100 Hrs 250 Hrs...

  • Page 40: Fluid Capacities

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 6.1.1 Fluid Capacities Fluid Capacity Recommendation Engine Oil 11 Qt 15W-40 Hydraulic Oil 30 Gal AW 46 Coolant 7 Gal Extended Life Grease As Needed NLGI Grade 2...

  • Page 41: Check Engine Coolant Level

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 6.3.2 Check Engine Coolant Level WARNING WARNING Hot pressurized liquid. Burn hazard. Do not remove cap when hot. NOTICE NOTICE Do not add coolant to a hot engine. Engine can be damaged.

  • Page 42: Check Hydraulic Oil Level

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 Adding chemicals/additives to the diesel exhaust fluid may damage the aftertreatment system. 1. Prepare paver for inspections and maintenance. See Section 6.2 Prepare For Inspections And Maintenance.

  • Page 43: Drain Fuel/Water Separator

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 6.3.9 Drain Fuel/Water Separator 1. Prepare paver for inspections and maintenance. See Section 6.2 Prepare For Inspections And Maintenance. 2. Wear personal protective equipment appropriate for the task.

  • Page 44: Change Engine Oil And Oil Filter

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 6.5.2 Change Engine Oil And Oil Filter 1. See OEM engine operators manual for oil and filter specification. 2. Fully open hopper doors. 3. Prepare paver for inspections and maintenance.

  • Page 45: Change Engine Oil And Oil Filter

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 6.6.2 Change Engine Oil And Oil Filter 1. See OEM engine operators manual for oil and filter specifications. 2. Fully open hopper doors. 3. Prepare paver for inspections and maintenance.

  • Page 46: Change Engine Coolant

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 and check hydraulic oil level. Add hydraulic oil if necessary. 9. Dispose of hydraulic oil in an environmentally safe manner. 6.7.2 Change Engine Coolant 1. Prepare paver for inspections and maintenance. See Section 6.2 Prepare For Inspections And Maintenance.

  • Page 47: Fill/Drain Planetary Fluid

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 For more information go to www.P65Warnings.ca.gov ^ WARNING Avoid injury. Battery electrolyte contains sulfuric acid. It is poisonous and can cause serious burns. • Wear eye protection and gloves.

  • Page 48: Troubleshooting

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 planetary until the fluid level hole (2) is at the 3 oclock position, and Fill/drain hole (1) will be at the 12 oclock position. 5. Remove the plug from the Fluid level hole (2).

  • Page 49: Engine Codes

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 7.2 Engine Codes Press button (1) to display any active engine codes. See OEM engine manual for explanation of error codes. 7.3 Troubleshooting Chart Issue Probable Cause Corrective Action No power or inadequate power.

  • Page 50: Screed Automation Control System

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 Issue Probable Cause Corrective Action Engine stops. Smart shut down activated. See engine OEM manual. Manual shut down button activated. Reset e-stop when it is safe to do No steering control.

  • Page 51: Stringline Mode (4-Head Averaging Sensor Only)

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 8.2.3 Stringline Mode (4-Head Averaging Sensor Only) When the sensor is in stringline mode the large display must be lit. When the sensor is in ground mode the small display must be lit.

  • Page 52: Hand Held Controller Setup

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 8.3 Hand Held Controller Setup 8.3.1 Manual Mode Functions MODE MODE MODE MODE MODE MODE MODE 8.3.2 Auto Mode Functions AUTO MODE MODE 8.3.3 Factory Default Settings Minimum Pulse: 3 or 4 Working Window: 1”...

  • Page 53: Changing Hand Held Out Put

    V 1.0 8.3.4 Changing Hand Held Out Put 1860B uses a PNP output signal to activate the hydraulic valve coil. Grade systems are interchangeable with older Mauldin models. Some older models used NPN trigger system. Follow these instructions to change the output setting.

  • Page 54: Error Codes

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 8.5 Error Codes Hand Held Slope Single Sonic Sensor & 4-Head Sonic Sensor...

  • Page 55: Daily Automation Setup

    Serial Number Range: Calder Brothers Corp Model: 1860B Paver 416-V-86TCX5Y2*04123 to _____________ V 1.0 8.6 Daily Automation Setup 4. Lower the screed to the desired material thickness and make the machine ready for paving 5. Place the handset into the cradle at the operator’s station. Route cable over the resting bolt.

  • Page 56: Limited Product 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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