Mauldin 1560 User manual

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

Contents
Safety............................................................................................................................1
Machine Decals............................................................................................................4
Operator Functions .....................................................................................................6
Starting tthe Paver.......................................................................................................8
Material Feed Controls................................................................................................10
Digital Display..............................................................................................................13
Screed Setup................................................................................................................16
Extension Bottom Setup.............................................................................................18
Machine Maintenance .................................................................................................21
Machine Troubleshooting...........................................................................................26
Maintenance Guide......................................................................................................29
Notes.............................................................................................................................31
Warranty .......................................................................................................................35

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Calder Brothers Corp
V1.0
Serial Number Range:
848-S-56TCG9Y2*03848 to ________________
Page 1
Model: 1560 Paver
Safety
IMPORTANT SAFETY INFORMATION
Most accidents involving paver 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 paver.
WARNING: IMPROPER OPERATION, LUBRICATION OR MAINTENANCE OF THIS PAV-
ER CAN BE DANGEROUS AND COULD RESULT IN INJURY OR DEATH.
WARNING: DO NOT OPERATE THIS PAVER UNTIL YOU READ AND UNDERSTAND
THE INSTRUCTIONS IN THE OPERATION SECTION OF THIS MANUAL.
WARNING: DO NOT PERFORM ANY LUBRICATION AND MAINTENANCE ON THIS
PAVER UNTIL YOU READ AND UNDERSTAND THE INSTRUCTIONS IN THE MAINTE-
NANCE SECTION OF THIS MANUAL.
DANGER: RELEASE, RESTRAIN, OR OTHERWISE RENDER SAFE ALL POTENTIAL
HAZARDOUS STORED OR RESIDUAL ENERGY. IF A POSSIBILITY EXISTS FOR RE-
ACCUMULATION OF HAZARDOUS ENERGY, REGULARLY VERIFY DURING THE
SERVICE AND MAINTENANCE THAT SUCH ENERGY HAS NOT REACCUMULATED
TO HAZARDOUS LEVELS.

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Calder Brothers Corp
V1.0
Serial Number Range:
848-S-56TCG9Y2*03848 to _____________
Page 2
Model: 1560 Paver
SERVICE WARNING
General
Operating personnel must perform service checks regularly to be sure systems are in
good operating condition. If abnormal conditions are detected, inform maintenance per-
sonnel immediately.
Check all systems for proper operation. Check chassis and all components for physical
damage and security of all fasteners and connectors.
Safety Identiers
Throughout this manual there are safety identiers. The same identiers are located on
safety decals on the machine. Each identier has their own meaning.
Indicates a hazardous condition that could result in serious
injury if not performed appropriately.
Indicates a hazardous condition that could result in serious
injury or death if not performed appropriately.
Indicates a hazardous condition that will result in serious
injury or death if not performed appropriately.
Safety Decals Denition
Danger fuel and or ammable uid is present. Do not smoke or
use any open ame.

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V1.0
Serial Number Range:
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Model: 1560 Paver
Danger Crush Hazard. There are moving objects with sharp and
or hard edges. Failure to observe moving parts and keep clear can
and will result in serious injury.
Danger Stand Back. There are moving objects that could result in
harm, please stand back a safe distance to avoid harm. Failure to
keep back may result in serious injury or death.
Danger Keep Clear. There are moving objects that could result
in harm, please keep clear of the moving objects. Failure to keep
clear may result in serious injury or death.
Caution Moving Augers. Keep clear of the moving augers,
failure to do so may result in serious injury or death. Do not
stand on or near the augers at any time, even if the machine
is not running.
Danger High Voltage. This machine uses 250v to operation.
Avoid working on any electrical components while the engine
is on.

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Calder Brothers Corp
V1.0
Serial Number Range:
848-S-56TCG9Y2*03848 to _____________
Page 4
Model: 1560 Paver
Safety Decal Location
Machine Decals

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Calder Brothers Corp
V1.0
Serial Number Range:
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Page 5
Model: 1560 Paver

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Calder Brothers Corp
V1.0
Serial Number Range:
848-S-56TCG9Y2*03848 to _____________
Page 6
Model: 1560 Paver
PAVER OPERATION SECTION
Machine Functions Explained
1. Hopper Open and Close. *If your machine is optioned with dual hopper control this toggle is just
the left hopper*
2. Hopper Open and Close (optional). *If your machine is optioned with dual hopper control this
toggle is the right hopper. If your machine does not have dual control this hole is empty.
3. Forward Hopper Lights On/o󰀨
4. Screed Vibrator On/o󰀨
5. Horn
6. Screed Lights On/O󰀨
7. Wash down pump On/o󰀨
8. Travel speed High or Low speed. Paving and Machine loading/unloading should
always be done in low speed range.
9. Beacon Lights. (Optional)
10. Engine Speed: this is to select a set RPM for idle or high RPM for work mode.
11. Engine RPM Adjustment: this increases or decreases the idle or work RPM a
small increment.
12. Screed Heat On/o󰀨. This turns the screed heat on or o󰀨. The desired tempera-
ture is set in the digital display. See Screed Heating Section.
13. Conveyor Reverse. This reverses the conveyor direction to return material to the
hopper.
14. Accessory. This is for extra options.
15. Left Drive Lever
16. Right Drive Lever
Operator Functions

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Calder Brothers Corp
V1.0
Serial Number Range:
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Page 7
Model: 1560 Paver
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). The feed system will turn o󰀨 once
it reaches the desired head of material.
22. Screed Lever Up/Down. Push the Lever forward to raise the screed, pull the lever
down to lower the screed. To oat the screed pull the lever down passed the detent,

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Calder Brothers Corp
V1.0
Serial Number Range:
848-S-56TCG9Y2*03848 to _____________
Page 8
Model: 1560 Paver
the lever will stay and the screed will be in oat mode.
23. Right Extension Lever. This extends and retracts the right hand screed extension.
Left Extension Lever. This extends and retracts the left hand screed extension
STARTING THE PAVER
Prior to starting the machine the following procedures must be completed.
1. Check engine oil level
2. Check engine coolant level
3. Check hydraulic oil level
4. Check around the to insure nothing is on or underneath the machine
1.0 STARTING
To start the paver rst check to make sure the forward and reverse levers are in the neu-
tral position. The paver will not start if the red indicator light is not “ON” indicating a neutral
position(1).
Turn key switch to the “ON” position, adjust steer handles until red
indicator light is “ON” (1)
Turn key switch to the right more before you engage the starter
(you will feel a stop in the key position before it starts the engine)
position “PRE-HEAT” count to 5
Turn key switch to “START”.
Starting tthe Paver

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Calder Brothers Corp
V1.0
Serial Number Range:
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Page 9
Model: 1560 Paver
If engine does not start quickly, repeat the PRE-HEAT step
• Adjust engine RPM as needed for smooth idle.
CAUTION: Do not Pre-heat more than 5 seconds at a time, or Glow Plug failure will
occur.
CAUTION: Do not use any starting uid, or engine warranty will be VOID!!!!
2.0 DRIVING
The paver will move forward by pushing both levers forward and will move backwards by
pulling the levers back. Steering a course is accomplished by adjusting the speed of one
handle relative to the other. HINT - to make driving easy, push both handles forward
to desired speed, then use only one handle to ne-tune your direction.
3.0 STEERING TENSION
The steer handles can be adjusted for operator preference on tension, (or drag). In a
loose position the handles will spring return to neutral, this requires constant pressure
on the handles by the operator. Tension can be added to the point were the handles are
locked and cannot be moved. The ideal setting is somewhere in-between were the han-
dles have enough tension to stay in the position the operator chooses, but not so sti󰀨 as to
produce fatigue.
To adjust tension: loosen or tighten the nut located at the center of the aluminum discs
were the handles are attached.

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Calder Brothers Corp
V1.0
Serial Number Range:
848-S-56TCG9Y2*03848 to _____________
Page 10
Model: 1560 Paver
Material Feed Controls
4.0 TWO SPEED
CAUTION: INJURY/OR DAMAGE MAY OCCUR: When switching to high range, bring
paver to a stop before switching. To engage from low to high ip the High range switch up.
MATERIAL FEED OPERATION
The 1560 allows you to congure the auger and conveyor operation of the paver for
both an Automatic mode and a Manual mode. Use the automatic mode whenever pos-
sible to increase the useful life of the feed augers, and to maintain a more consistent
“Head of Material” in front of the screed. In either mode the lower selector switch can
be set to “IN” for reverse material ow.
Figure A
SETUP
Each side of the paver must be set independently.
AUTOMATIC FEED OPERATION
1. Go to the LH operators’ station

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Calder Brothers Corp
V1.0
Serial Number Range:
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Model: 1560 Paver
2. Locate the AUTO – MAN switch labeled:
3. Set the switch to “AUTO”
4. Locate the CONV & AUG switches labeled:
5. Set the AUG switch to “OUT” Labeled 1 in Figure A
6. Follow the dotted line and set the CONV switch to the “locked” setting. Labeled 2
in Figure A
7. To control size of the head of material:
See Display Screen Section

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Calder Brothers Corp
V1.0
Serial Number Range:
848-S-56TCG9Y2*03848 to _____________
Page 12
Model: 1560 Paver
MANUAL FEED OPERATION
1. Go to the LH operators’ station
2. Locate the AUTO – MAN switch labeled:
3. Set the switch to “MAN”
4. Locate the CONV & AUG switches labeled:
5. Set the AUG switch to “OUT”. Labeled (1) in Figure A.
6. Follow the dotted line and set the CONV switch to the
“locked” setting. Labeled (2) in Figure A.
7. To control size of the head of material set the AUG switch to
OUT or OFF as desired.

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Calder Brothers Corp
V1.0
Serial Number Range:
848-S-56TCG9Y2*03848 to ________________
Page 13
Model: 1560 Paver
Digital Display
Digital Display
This digital display indicates engine oil pressure, engine coolant temperature, battery voltage, engine speed,
engine torque being used, diesel exhaust uid tank level, diesel fuel tank level and engine hours.
Engine Warning Lamps
1. Wait to start indicator. Icon is illuminated when engine
preheat is activated.
2. Engine warning code present. Warning symbol (12) will also
be illuminated. Check engine codes as soon as possible.
3. Coolant level low. Indicates coolant level is too low. Stop
engine immediately.
4. Coolant temperature high. Indicates coolant temperature is
too high. Stop engine immediately.
5. Battery voltage low.
6. Oil temperature high. Indicates oil temperature is too high.
Stop engine immediately.
7. High speed. Indicates travel switch is in high.
8. Warning indicator. Indicates an minor engine warning code is present. Check engine codes as soon as
possible. A red stop sign indicates a serious engine code is present and engine must be stopped immediately.
Engine Screen
1. Machine hour meter.
2. Press to display engine code(s) if present.
3. RPM gauge.
4. Fuel tank level.
5. Screed heat status. Indicates status of screed heat
zones.
6. Coolant temperature gauge.
7. Force regen. Press to start exhaust regen.
8. Press to move to next screen.
9. Day/night mode.
1 542 3 6 7
8
9
1
6
2
3
7
89
4
5

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Calder Brothers Corp
V1.0
Serial Number Range:
848-S-56TCG9Y2*03848 to _____________
Page 14
Model: 1560 Paver
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.
1. Selected station indicator. This symbol will be displayed
on operators station screen with active travel controls.
2. Screed heat status. Indicates status of screed heat
zones.
3. Right material height indicator (sonic).
4. Right side material height adjustment. Select low,
medium or high.
5. Press to move to next screen.
6. Press to change feed mode. Select dual or single.
7. Press to display engine code(s) if present.
8. Left side material height adjustment. Select low, medium or high.
9. Left material height indicator (sonic).
Screed Temperature Screen
1. Selected station indicator. This symbol will be displayed
on operators station screen with active travel controls.
2. Left screed extension status. Display will show ready to
pave, wait to pave, o󰀨, or fault icon.
3. Main screed status. Display will show ready to pave,
wait to pave, o󰀨, or fault icon.
4. Right screed extension status. Display will show ready
to pave, wait to pave, o󰀨, or fault icon.
5. Screed heat status icons. Press and hold help button
(8) to show icons.
6. Press to lower screed temperature set point.
7. Press to move to next screen.
8. Press to show icon legend.
9. Press to display engine code(s) if present.
10. Press to raise screed temperature set point.
11. Selected screed heat setpoint. Default temperature is 230°F.
1
4
3
567
8
9
2
1
6
11
789
10
5
2
34

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Calder Brothers Corp
V1.0
Serial Number Range:
848-S-56TCG9Y2*03848 to ________________
Page 15
Model: 1560 Paver
Password Screen
Password screen should only be accessed while being
directed by a Mauldin service technician.
1. Selected station indicator. This symbol will be displayed
on operators station screen with active travel controls.
2. Screed oat mode indicator. When illuminated, screed
is in oat mode.
3. Program version.
4. Display serial number.
5. Machine engine model.
6. Password input eld.
7. Press to accept input eld value.
8. Press to move to next screen.
9. Press to enter number in input eld.
10. Press to cancel input eld value.
1
7
8910
4
3
5
6
2

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Calder Brothers Corp
V1.0
Serial Number Range:
848-S-56TCG9Y2*03848 to _____________
Page 16
Model: 1560 Paver
R
PAVING PRODUCTS
MAULDIN
Calder Brothers Corporation
INITIAL
SETTING
DIMENSION
EXTENSION SLOPE TURNBUCKLE LOCK BOLT
SEE NOTE 1
CHECK TO MAKE SURE
THERE ARE NO GAPS
ALONG THESE EDGES.
LOCATIONS FOR STRING
WHEN SETTING THE SCREED.
NOTES:
VERIFY EXTENSION RAISE/LOWER TURNBUCKLE ASSEMBLY IS FREE TO TURN AND ADJUSTABLE 1.
FROM 15-1/4" TO 16-1/4"
ADJUSTMENT INSTRUCTIONS:
INITIAL SETTING: 16" 1.
TO RAISE EXTENSION ASSEMBLY, DECREASE THE INITIAL SETTING ON THE TURNBUCKLE 2.
ASSEMBLY.
TO LOWER EXTENSION ASSEMBLY, INCREASE THE INITIAL SETTING ON THE TURNBUCKLE 3.
ASSEMBLY.
Model: Freedom 14 Main Screed Setup
Initial Screed Adjustment Settings
Date: 08-01-19
Page: 1 of 2
Screed Setup

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Calder Brothers Corp
V1.0
Serial Number Range:
848-S-56TCG9Y2*03848 to ________________
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Model: 1560 Paver
R
PAVING PRODUCTS
MAULDIN
Calder Brothers Corporation
B
EXTENSION TURNBUCKLE LOCK BOLT
EXTENSION SLOPE TURNBUCKLE
STRING
NOTES:
POSITION EXTENSION AT HALF WAY OUT POSITION. 1.
ADJUSTMENT INSTRUCTIONS:
RUN BOTH LEFT AND RIGHT EXTENSION OUT TO THE HALF OUT POSITION. 1.
USE A STRING AND ALIGN WITH TRAILING EDGE OF EXTENSION SCREED PLATE BOTTOM. 2.
LOOSEN EXTENSION TURNBUCKLE LOCK BOLT. 3.
ADJUST THE EXTENSTION SLOPE TURNBUCKLE TO MAKE THE EXTENSION SCREED PLATE 4.
FLAT WITH THE STRING.
Model: Freedom 14 Main Screed Setup
Initial Screed Adjustment Settings
Date: 08-01-19
Page: 2 of 2