Calder Brothers MAULDIN 1450 Quick start guide

PARTS & SERVICE MANUAL
MODEL 1450/3000/4000
Document: 1450/3000/4000 Parts & Service Manual Rev. 1.5
Covers Serial Number Range:
018-XC14CGH1YG-00018 thru ____________________
SOLD & SERVICED BY

Calder Brothers Corporation Page 1
Model: 1450/3000/4000 Steel Drum Roller 1450-3000-4000 Table Of Contents 1.0.doc
TABLE OF CONTENTS
ITEM PAGE
Roller Service & Operation Section...................................................3
Steering Assembly ............................................................................15
Drive Compartment...........................................................................16
Seat & Tank Assembly......................................................................17
Battery Assembly..............................................................................17
Engine Assembly - Front...................................................................18
Engine Assembly - Rear....................................................................19
Drum Assembly - Front .....................................................................20
Drum Assembly - Rear......................................................................21
Vibrator Assembly.............................................................................22

Calder Brothers Corporation Page 2
Model: 1450/3000/4000 Steel Drum Roller 1450-3000-4000 Notes 1.0.doc
NOTES

Calder Brothers Corporation Page 3
Model: 1450/3000/4000 Steel Drum Roller 1450-3000-4000 Roller Service & Operation Section 1.0.doc
Serial Number Range: 018-XC14CGH1YG-00018 thru ____________________
IMPORTANT SAFETY INFORMATION
Most accidents involving roller maintenance are caused by failure to observe basic safety rules or
precautions. An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs.
Read and understand all safety precautions and warnings, before operating or performing
lubrication and maintenance on this roller.
WARNING: IMPROPER OPERATION, LUBRICATION OR MAINTENANCE OF THIS
ROLLER CAN BE DANGEROUS AND COULD RESULT IN INJURY OR
DEATH.
WARNING: DO NOT OPERATE THIS ROLLER UNTIL YOU READ AND UNDERSTAND
THE INSTRUCTIONS IN THE OPERATION SECTION OF THIS MANUAL.
WARNING: DO NOT PERFORM ANY LUBRICATION AND MAINTENANCE ON THIS
ROLLER UNTIL YOU READ AND UNDERSTAND THE INSTRUCTIONS IN
THE MAINTENANCE SECTION OF THIS MANUAL.
SERVICE WARNING
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.
Check all systems for proper operation. Check chassis and all components for physical damage
and security of all fasteners and connectors.

Calder Brothers Corporation Page 4
Model: 1450/3000/4000 Steel Drum Roller 1450-3000-4000 Roller Service & Operation Section 1.0.doc
Serial Number Range: 018-XC14CGH1YG-00018 thru ____________________
FLUID CAPACITIES AND RECOMMENDATIONS
FLUID CAPACITY RECOMMENDATION
Engine oil Varies with engines High quality CC/CD multi-grade lubricating
oil. Above 14 deg. F use 15W40 or 20W40.
Hydraulic 7 U.S gal High quality anti-wear hydraulic oil
(Original equipment, Gulf C-3 torque fluid).
Grease As required N.G.L.I. consistency #2, high temperature,
anti-friction, bearing lubricating grease.
Engine coolant Varies with engines High quality
Above 14 deg. F
Gasoline 3 ½ U.S gal Regular, unleaded, non-alcohol blend.
Diesel 3 ½ U.S. gal above 40°, (5° C), use No. 2-D.
Below 40°, (5° C), use No. 1-D. Power loss up to
4% can be expected due to lower viscosity
LUBRICATION AND SERVICE PROCEDURES
Air Filters
IMPORTANT: Service the engine air filters only when the need is indicated by the air cleaner
service indicator, (if equipped), or in accordance with the preventative
maintenance decal. Excessive service will cause premature wear.
1. Engine Main Element
a. Unbuckle clips to remove element container end cap.
b. Pull gently to remove main element.
c. Use compressed air with an element-cleaning nozzle
IMPORTANT: Main element should be replaced after six cleanings or 500 hours use.
IMPORTANT: Do not attempt to clean element using a standard air nozzle. Do not strike
element on a hard surface. Either action will damage the element.

Calder Brothers Corporation Page 5
Model: 1450/3000/4000 Steel Drum Roller 1450-3000-4000 Roller Service & Operation Section 1.0.doc
Serial Number Range: 018-XC14CGH1YG-00018 thru ____________________
2. Engine Safety Element
IMPORTANT: Do not remove safety element under heavy dust or blowing conditions (in the
field). Even slight amounts of dust entering the engine can lead to premature
wear.
Inspect safety element for contamination and physical damage.
IMPORTANT: When safety element is dirty, it should be replaced. Do not attempt to clean.
Battery
CAUTION: BATTERY ELECTROLYTE IS A CAUSTIC ACID. KEEP IT AWAY FROM
SKIN AND EYES. IF CONTACT OCCURS, FLUSH THE AFFECTED AREA
WITH LOTS OF WATER.
CAUTION: DISCONNECT GROUND CABLE FROM THE NEGATIVE BATTERY POST
BEFORE ATTEMPTING TO SERVICE OR REMOVE BATTERY.
1. Removal:
a. Disconnect ground (negative) cable from battery (-) terminal.
b. Remove battery retaining rod.
c. Disconnect positive cable from battery (+) terminal.
2. Cleaning:
a. Remove battery, following correct procedures.
b. Thoroughly clean terminals with a battery-cleaning tool.
c. Mix a paste solution of baking soda and water and apply to battery and terminals.
d. Rinse battery and roller area near battery liberally with water.
3. Installation:
a. Clean battery, following correct procedures.
b. Be certain battery area is clean and clear of debris.
c. Install battery and retaining rod.
d. Connect positive (+) cable to terminal.
CAUTION: DO NOT CONNECT NEGATIVE (GROUND) TERMINAL FIRST. ARCING
CAN OCCUR, POSSIBLY CAUSING SEVERE BURNS AND/OR BATTERY
EXPLOSION.

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Model: 1450/3000/4000 Steel Drum Roller 1450-3000-4000 Roller Service & Operation Section 1.0.doc
Serial Number Range: 018-XC14CGH1YG-00018 thru ____________________
e. Connect negative (-) terminal
4. Charging:
Connect charger leads to proper battery terminals then proceed according to charger
manufacturer's instructions.
5. Storage:
a. Remove and clean battery, following correct procedures.
b. Bring battery to full charge, following charger manufacturer's instructions.
c. Store in a cool dry place where there is no possibility of freezing.
NOTE: Check battery every 30 days during storage and return to full charge if necessary.
Engine and Engine Filters
1. Initial Break-In:
Proper break-in procedures are a must to realize maximum engine power output and
longest engine life. Engine should show noticeable power gain through the first 30
hours service. Power gain will continue until approximately 200 hours if properly
broken-in.
IMPORTANT: Do not operate engine above 3/4 throttle, for the first 25 hours.
IMPORTANT: Use full throttle only for short intervals during the first 25 hours.
IMPORTANT: Do not "lug" engine during the break-in period.
IMPORTANT: Replace the original oil and oil filters after the first 20 hours of operation.
2. Fuel Filters:
Both fuel filters are disposable.
CAUTION: BOTH DIESEL FUEL AND GASOLINE ARE HIGHLY FLAMMABLE AND
EXPLOSIVE UNDER CERTAIN CONDITIONS. DO NOT SMOKE OR ALLOW
SPARKS OR OPEN FLAME WHEN HANDLING.

Calder Brothers Corporation Page 7
Model: 1450/3000/4000 Steel Drum Roller 1450-3000-4000 Roller Service & Operation Section 1.0.doc
Serial Number Range: 018-XC14CGH1YG-00018 thru ____________________
To Change:
a) Stop engine. Wait 15 minutes for engine and surrounding parts to cool
before proceeding.
b) Unscrew and discard existing filters.
c) Fill new filter with clean fuel.
d) Lightly coat the seal ring with oil, then screw on filter until seal meets
flange.
e) Tighten an additional 1/2 to 3/4 turns by hand.
IMPORTANT: Do not over tighten.
3. Oil and Oil Filter Changing:
a) Stop engine. Wait 15 minutes or engine oil to cool before proceeding.
b) Drain crankcase.
c) Unscrew and discard existing filters.
d) Fill new elements with fresh oil.
e) Lightly coat the seal rings with oil, and then screw on filters until seals
meet flanges.
f) Tighten an additional 1/2 to 3/4 turns by hand.
IMPORTANT: Do not over tighten.
g) Fill crankcase to correct level.
h) Start engine and run at low idle. Have an assistant visually check seal
areas for leaks.
i) Stop engine. Wait a few minutes, and then check engine oil level once
again.
Hydraulic System
Hydraulic Fluid Change:
a) Stop engine. Allow system pressure to drop and remove filler cap.
b) Remove suction hose and drain into appropriate container for disposal.
c) Remove hydraulic filter. Replace filter element and reinstall.
d) Replace fluid to approximately 1" from top of reservoir. Operate roller and recheck level.
e) Check visually for oil leaks.

Calder Brothers Corporation Page 8
Model: 1450/3000/4000 Steel Drum Roller 1450-3000-4000 Roller Service & Operation Section 1.0.doc
Serial Number Range: 018-XC14CGH1YG-00018 thru ____________________
NOTE: Each roller should be thoroughly inspected after each use and during
maintenance cycle for:
a) Tightness of mounting bolts and attaching hardware on bearings, couplings, frame, etc.
b) Leaks, cracks and loose electrical and fluid fittings.
c) Malfunctioning indicators or controls.
d) Worn or damaged tires.
e) Cleanliness.
TROUBLESHOOTING
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.
• Study the problem thoroughly before taking action!
• Did warning signs precede the problem? If so, what were they? What would they indicate?
• Is scheduled maintenance current on all parts and systems involved?
• Has similar trouble occurred before? What action was taken at that time?
• Can engine be operated without further damage?
CAUTION: IF RUNNING INSPECTION MUST BE MADE, GET ASSISTANCE.
OPERATOR SHOULD REMAIN SEATED ON ROLLER THROUGHOUT
INSPECTION. SET PARKING BRAKE. MAKE SURE TRANSMISSION IS IN
NEUTRAL POSITION.
• Check the most convenient things first.
• Don't begin major work before checking all other possibilities.
• Reconsider all known facts and clues before proceeding to more in-depth work.
• Correct the basic cause.

Calder Brothers Corporation Page 9
Model: 1450/3000/4000 Steel Drum Roller 1450-3000-4000 Roller Service & Operation Section 1.0.doc
Serial Number Range: 018-XC14CGH1YG-00018 thru ____________________
• Remember, failure of a certain part may be caused by malfunction of another part or
system
2. Troubleshooting chart:
The troubleshooting chart lists problems that might be encountered in the operation of the
vehicle. The remedies listed may direct the repairman to a possible faulty component.
WARNING: THE TROUBLESHOOTING CHART AND PROCEDURES OUTLINED IN THIS
SECTION SHOULD NOT BE ATTEMPTED BY OTHER THAN EXPERIENCED
MECHANICS OR PERSONNEL UNDER THE DIRECT SUPERVISION OF AN
EXPERIENCED MECHANIC. FAILURE TO COMPLY MAY RESULT IN DAMAGE
TO EQUIPMENT AND/OR INJURY OR DEATH TO PERSONNEL.
A. Engine
For engine troubleshooting see charts indicating faults and recommended repair
procedures. Refer to engine Manufacturer's Operation and Maintenance Manual.
If your particular problem is not covered or you are unsure of what steps to take, contact
your dealer for assistance.
B. Transmission
1. Vehicle fails to move under power:
a) Inadequate oil level in hydraulic reservoir.
b) Control cable broken or loose.
c) Driveline mechanical failure.
d) Inadequate oil flow through transmission suction filter.
2. Vehicle moves in neutral:
a) Stroke control needs adjustment.
b) Control cable damage.
For detailed troubleshooting information on hydrostatic transmission, refer to Trouble Shooting
Manual, Sundstrand Hydrostatic Transmissions, available from a Sundstrand representative or
dealer.

Calder Brothers Corporation Page 10
Model: 1450/3000/4000 Steel Drum Roller 1450-3000-4000 Roller Service & Operation Section 1.0.doc
Serial Number Range: 018-XC14CGH1YG-00018 thru ____________________
C. Electrical System
Engine Voltmeter
Status Reading Indicates To Correct
Running 13.5 - 14 Volts Normal Condition
Running Less than 13.5 or Alternator or Regulator Contact Dealer
more than 14 Volts Malfunction
Won't Start 12-12.5 Volts Weak battery Charge
Won't Start Less than 12 Volts Weak battery or Charge or Replace
Defective Cell
Stopped Excessive current Short Circuit Inspect System
Draw
D. Hydraulic System
• Thoroughly review description of hydraulic system.
• Use logical steps to determine cause of malfunction.
• Identify the function or functions that require troubleshooting.
• If possible, trace malfunction to source: pump, control, motor or cylinder.
• Determine pressure operating the function as specified:
HYDRAULIC SYSTEM PRESSURES
Priority circuit, Sundstrand pump: 900psi
Main circuit Sundstrand pump: 2500psi
HYDRAULIC SYSTEM FLOWS
Priority circuit, Sundstrand pump: 2gpm
Main circuit, Sundstrand pump: 8gpm

Calder Brothers Corporation Page 11
Model: 1450/3000/4000 Steel Drum Roller 1450-3000-4000 Roller Service & Operation Section 1.0.doc
Serial Number Range: 018-XC14CGH1YG-00018 thru ____________________
(Actual flow determined by engine rpm’s)
Problem Possible Cause To Correct
No Power or Worn or Malfunctioning pump or motor. Repair or replace pump or motor.
Inadequate Power
Stuck relief valve cartridge. Repair or replace.
Low system pressure caused by worn pump. Repair or replace pump.
Surging of Air in system due to low level of oil, Add oil, tighten fittings, reroute
hydraulic items cavitating pump, leaky fittings, pinched hose, etc. hose(s).
Removal and Installation of Equipment
1. Preparation
WARNING: BEFORE PERFORMING INSTALLATION OR REMOVAL PROCEDURES,
THE FOLLOWING PRECAUTIONS MUST BE ADHERED TO IN ORDER
TO PREVENT POSSIBLE DAMAGE TO EQUIPMENT OR INJURY OR
DEATH TO PERSONNEL.
WARNING: TURN THE ENGINE OFF BY TURNING THE IGNITION SWITCH TO OFF.
DISCONNECT THE BATTERY CABLES BEFORE SERVICING THE
ENGINE START OR STOP CIRCUITS. DISCONNECTING BATTERY
NEGATIVE GROUND BEFORE REMOVING OR CONNECTING THE
POSITIVE BATTERY CABLE CAN PREVENT SHORT CIRCUITING OF
THE BATTERY BY TOOLS.

Calder Brothers Corporation Page 12
Model: 1450/3000/4000 Steel Drum Roller 1450-3000-4000 Roller Service & Operation Section 1.0.doc
Serial Number Range: 018-XC14CGH1YG-00018 thru ____________________
Recommended Preventive Maintenance Intervals
INTERVAL ITEM PROCEDURE
Initial Break-In Hydraulic Filter Change
(After 1st 50 hours) Engine Oil & Filter Change
Hydraulic Leaks Inspect & Tighten as required
Loose Nuts & Bolts Inspect & Tighten as required
Daily or Hydraulic oil level Inspect & add as necessary
10 hours Engine oil level Inspect & add as necessary
Engine air cleaner system Check service indicator and/or inspect
Engine coolant level system Inspect & add as necessary
Radiator Clean and inspect
Fuel system Drain water from separator
100 hours All 10 hour Items As above
Steering rod ends Grease
Bearings Grease
Tires (optional tow package) Check pressure
250 hours All 100 hour items As above
Engine air cleaner Replace element
Engine crankcase Drain and refill*
Engine oil filter Replace*
Fuel tank Drain water and sediment
Hydraulic filter Replace*
500 hours All 250 hour items As above
Fuel filters Replace
Engine Have serviced by authorized Dealer
1000 hours All 500 hour items As above
Hydraulic system Drain and refill
*Change after first 50 hours service, every 250 thereafter.

Calder Brothers Corporation Page 13
Model: 1450/3000/4000 Steel Drum Roller 1450-3000-4000 Roller Service & Operation Section 1.0.doc
Serial Number Range: 018-XC14CGH1YG-00018 thru ____________________
MAULDIN™
CALDER BROTHERS CORPORATION
(LIMITED) PRODUCT WARRANTY
Calder Brothers Corporation warrants that the Roller under this program will be free from defects
in material and workmanship for a period of (12) twelve months from date of installation. Written
notice of any claimed defect must be given to Calder Brothers Corporation within the warranty
period and within (30) thirty days after such defect is discovered. Liability under this warranty is
limited to replacing or repairing, at Calder Brothers Corporation’s election, any part or parts
deemed defective after examination by Calder Brothers Corporation or an Authorized Service
Representative. Any roller or any of its parts returned by customer to Calder Brothers Corporation
or an Authorized Service Representative via prepaid transportation and which is found to be
defective will be repaired or replaced and returned to the customer via prepaid surface
transportation within the continental United States. Should any part be found not defective, Calder
Brothers Corporation or an Authorized Service Representative may charge inspection and
handling to the customer.
EXCLUSIONS:
This warranty does not apply to routine wearable parts of the Mauldin roller such as seals, points,
plugs, hoses or similar items. This warranty does not extend to any roller or part replaced or
repaired under this warranty. This warranty does not cover any repair or replacement labor of any
part or parts found defective after examination by Calder Brothers Corporation or an Authorized
Service Representative. This warranty does not apply to defects caused by casualty or
unreasonable use, including faulty repairs by others and failure to provide reasonable and
necessary maintenance.
THIS WARRANTY SET FORTH HEREIN IS IN LIEU OF AND EXCLUDES ANY AND ALL
OTHER WARRANTIES, EXPRESSED OR IMPLIED, ARISING BY OPERATION OF LAW OR
OTHERWISE, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, AND CUSTOMER
WAIVES ANY OBLIGATION OF LIABILITY OF CALDER BROTHERS CORPORATION ARISING
IN TORT OR STRICT LIABILITY IN TORT, OR FOR LOSS OR USE, REVENUE OR PROFIT
WITH RESPECT TO MAULDIN ROLLER AND/OR PARTS FOR ANY LIABILTIY OF CUSTOMER
TO ANY THIRD PARTY, OR FOR OTHER DIRECT, INCIDENTAL OR CONSEQUENTIAL
DAMAGES.

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Model: 1450/3000/4000 Steel Drum Roller 1450-3000-4000 Notes 1.1.doc
NOTES

Calder Brothers Corporation Page 15
Model: 1450/3000/4000 Steel Drum Roller 1450-3000-4000 Steering Assembly 1.0.doc
Serial Number Range: 018-XC14CGH1YG-00018 thru ____________________
STEERING ASSEMBLY
1
3
2 4
5
6
8
7
910
1. Steering Wheel..................................................................................050-0030
2. Steering Wheel Mounting Disk (Rubber)...........................................015-0074
3. Steering Shaft Assembly...................................................................082-0013
4. Steering Shaft.................................................................................082-0013A
5. Steering Shaft Bushing...................................................................050-0004
6. Steering Column.............................................................................082-0008
7. Control Box Mounting Bushing..........................................................050-0068
8. Steering Control Box.........................................................................050-0031
9. Steering Box Control Arm (from steering box to linkage assy) (not shown)...050-0032
10.Steering Linkage Assembly (not shown) ..............................................See Drum-Front

Calder Brothers Corporation Page 16
Model: 1450/3000/4000 Steel Drum Roller 1450-3000-4000 Drive Compartment 1.0.doc
Serial Number Range: 018-XC14CGH1YG-00018 thru ____________________
DRIVE COMPARTMENT
1
1. Brake Handle............................050-0018
2. Brake Cable..............................050-0008
3. Drive Handle.............................083-0024
4. Drive Handle Grip .................050-0334
5. Choke Cable.............................050-0025
6. Throttle Cable...........................050-0024
7. Drive Cable...............................050-0008
8. Drive Cable Ball Joint...............030-0237
9. Neutral Safety Switch...............020-0002
10. Drive Motor...............................013-0010
11. Drive Motor Shaft Sprocket ......015-0014
12. Hydraulic Filter Assembly.........021-0001
13. Hydraulic Filter Head ............021-0087B
14. Hydraulic Filter Element........021-0002
15. Vibrator Valve...........................017-0005
16. Drive Chain Assembly..............See Drum-Rear
17. Hydraulic Tank Sight Guide......See Tank Assy
18. Brake Handle Mounting Yoke...030-0179
10
9
8
7
65
4
3
2
17
16
18
15
12
11 13
14

Calder Brothers Corporation Page 17
Model: 1450/3000/4000 Steel Drum Roller 1450-3000-4000 Seat, Tank, Battery Assembly 1.1.doc
Serial Number Range: 018-XC14CGH1YG-00018 thru ____________________
SEAT & TANK ASSEMBLY
BATTERY ASSEMBLY
1
1. Seat Assembly...........................050-0017
2. Water Tank Assembly................081-0029
3. Inspection Cap........................050-0026
4. Ball Valve................................017-0043
5. Water Tank Filter....................021-0059
6. Hydraulic Tank Breather Cap ....050-0016
7. Fuel Tank
(not shown)...................050-0027
8. Fuel Tank Cap (not shown)........050-0188
9. Hydraulic Tank Sight Guide.......060-0068
10. Seat Stand.................................082-0079
1. Battery........................................020-0019
2. Battery Cable (Positive).............020-0361
3. Battery Cable (Negative) ...........020-0318
4. Battery Retaining Rod................093-0046
5
3
6
4
2
9
7
8
10
3 4 2
1

Calder Brothers Corporation Page 18
Model: 1450/3000/4000 Steel Drum Roller 1450-3000-4000 Engine Assembly - Front 1.0.doc
Serial Number Range: 018-XC14CGH1YG-00018 thru ____________________
ENGINE ASSEMBLY – FRONT
1
2
6
5
34
8
1. Kohler CH18S Engine.......................................................................010-0275
2. Muffler ............................................................................................010-0302
3. Engine Oil Filter..............................................................................021-0026
4. Fuel Filter .......................................................................................021-0027
5. Main Drive Pump...............................................................................011-0138
6. Drive Pump Control Arm ...................................................................082-0021
7. Drive Pump Control Arm Ball Joint (not shown) ...................................030-0237
8. Rubber Engine Mount (x4) (not shown)................................................See Engine-Rear