Mauldin 690-G User manual

OPERATIONS MANUAL
MODEL 690-G
Machine Serial Number: _ ______________________________
Specification Number: _ ______________________________
Engine Serial Number: _ ______________________________
SOLD & SERVICED BY:

Calder Brothers Corporation Page 2
Model: 690G Gravity Feed Paver 690F Operations Manual Rev 1.1
TABLE OF CONTENTS
SECTION ITEM PAGE
1.0 Daily Start-up Checklist ................................................................................................ 3
2.0 Important Safety Information ....................................................................................... 4
3.0 Service Warning ............................................................................................................ 4
4.0 Paver Operation ............................................................................................................ 5
4.1 Starting The Paver .................................................................................................. 6
4.2 Driving Techniques ................................................................................................ 6
4.3 Steering Tension Adjustment ................................................................................ 6
4.4 Two Speed ............................................................................................................... 6
5.0 Material Feed Operation ............................................................................................... 7
5.1 Automatic Material Feed Setups ........................................................................... 7
5.2 Manual Material Feed Setups ................................................................................ 7
6.0 Freedom Screed ™ ....................................................................................................... 8
6.1 Screed Heating System .......................................................................................... 8
6.2 Crown Setting: Freedom Screed ™ ...................................................................... 9
6.3 Extension Setting: Freedom Screed ™ ................................................................ 10
6.4 Setting the Freedom™ to Pave ............................................................................. 11
7.0 Drive System Adjustments ........................................................................................... 12
7.1 Rubber Tire: chain system tension procedure & settings ................................. 12
7.2 Crawler Track Tensioning procedure & settings ................................................ 12
8.0 Fluid Capacities & Recommendations ........................................................................ 13
8.1 Recommended Fuels & Alternative Fuels ............................................................ 13
8.2 Engine Coolant ....................................................................................................... 13
8.3 Air Intake Cleaning WARNING .............................................................................. 13
9.0 LUBRICATION & SERVICE PROCEDURES ................................................................ 13
9.1 Air Filters ................................................................................................................. 13
9.2 Battery .................................................................................................................... 14
9.3 Engine & Engine Filters ......................................................................................... 15
9.4 Hydraulic System .................................................................................................... 16
9.5 Troubleshooting Guide .......................................................................................... 17
9.6 Component Removal & Installation ...................................................................... 20
9.7 Recommended Preventive Maintenance Intervals .............................................. 21
10.0 Warranty ......................................................................................................................... 22

Calder Brothers Corporation Page 3
Model: 690G Gravity Feed Paver 690F Operations Manual Rev 1.1
Daily Start-up Checklist
1. Check Fluid Levels:
a. Engine Oil
b. Engine Coolant
c. Hydraulic Oil
d. Wash Down fluid
2. With the key switch in the “ON” position:
a. Check Engine Fuel Level
b. Turn on wash down pump and verify operation, turn off when complete.
c. Verify proper operation of engine gauges or indicator lights.
3. Turn Key switch back to “OFF” position.
4. Remove asphalt from all mechanical moving surfaces
5. Remove asphalt from all screed burner heating areas
6. Check Propane Tank level.
Perform All Propane Testing In A Well Ventilated Area Only!
FAILURE TO COMPLY MAY RESULT IN DAMAGE TO EQUIPMENT
AND / OR INJURY OR DEATH TO PERSONNEL.
7. Verify that ALL propane valves are in the closed position.
8. Pressurize the propane system by opening the master valve located on the propane tank.
9. With system pressurized, listen for leaks. Run hand over all propane fittings to feel for
leaks. If any leaks are detected, DO NOT OPERATE UNTIL THEY ARE REPAIRED!
10.Check pressure regulator is set to 4 – 6 PSI on Freedom Screed.
a. If regulated pressure is too high, open main screed valve only allowing gas to
escape.
b. Adjust regulator to 4 – 6 PSI on Freedom Screed.
c. Close main screed valve.
11.Close the master valve located on the propane tank.
12.Verify & if necessary follow procedure to set screed.
13.Perform a machine walk around looking for:
a. Any signs of physical damage
b. Any signs of a leak, (fuel, engine oil, hydraulic oil, engine coolant)
c. Welded steel junctions
d. Hydraulic cylinder pins all secure

Calder Brothers Corporation Page 4
Model: 690G Gravity Feed Paver 690F Operations Manual Rev 1.1
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 PAVER 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 MAINTENANCE SECTION
OF THIS MANUAL.
WARNING: DO NOT OPERATE BURNERS ON SCREED FOR MORE THAN TEN OR FIFTEEN
MINUTES AT A TIME.
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 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 5
Model: 690G Gravity Feed Paver 690F Operations Manual Rev 1.1
PAVER OPERATION SECTION
Prior to starting the following procedures must be completed.
1. Check engine oil level 2. Check engine coolant level 3. Check hydraulic oil level
The paver controls for the 690-F consist of two operators stations. The photograph below will
introduce the control panels as well as familiarize you with the terminology associated with them.
You will want to refer back to this page as you read through the manual.
MAIN CONTROL PANEL
Ignition Switch Neutral Light
High Range Gauges
Engine ThrottleEngine Lights
Steering Handles
Maintenance Decal
Right Side
Hopper &
Extension

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Model: 690G Gravity Feed Paver 690F Operations Manual Rev 1.1
STARTING THE PAVER
1.0 STARTING
To start the paver first check to make sure the forward and reverse levers are in the neutral
position. The paver will not start if the red indicator light is not “ON” indicating a neutral position.
•Turn key switch to the “ON” position, adjust steer handles until red indicator light is “ON”
•Turn key switch back to the left, position “PRE-HEAT” count to 5
•Turn key switch to “START”.
¾If 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 fluid, 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 fine-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 handles have enough tension to stay
in the position the operator chooses, but not so stiff 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.
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 flip the High range switch up.

Calder Brothers Corporation Page 7
Model: 690G Gravity Feed Paver 690F Operations Manual Rev 1.1
MATERIAL FEED OPERATION
The 690-F allows you to configure the auger operation of the paver for both an Automatic mode
and a Manual mode. Use the automatic setting whenever possible 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 flow.
SETUP Each side of the paver must be set independently.
AUTOMATIC AUGER FEED OPERATION
1.0 Go to the LH operators station
2.0 Locate the switch labeled:
“AUTO – MAN”
3.0 Set the switch to “AUTO”
4.0 Locate the switch labeled:
“OUT – LEFT AUGER – IN”
5.0 Set the switch to the “OUT”
6.0 Adjust height of switch by end gate to
control size of the head of material
MANUAL AUGER FEED OPERATION
1.0 Go to the LH operators station
2.0 Locate the switch labeled:
“AUTO – MAN”
3.0 Set the switch to “MAN”
4.0 Locate the switch labeled:
“OUT – LEFT AUGER – IN”
5.0 Set the switch to the “OUT”
6.0 Change this switch from the “LEFT
AUGER” position to the “OUT” and back
to the “LEFT AUGER” position, to
operate.

Calder Brothers Corporation Page 8
Model: 690G Gravity Feed Paver 690F Operations Manual Rev 1.1
SCREED HEATING SYSTEM
The new Freedom Screed ® has one burner in each extension and two main screed burners. The
proper way to light the burner system is the following procedure.
1. Make sure all shutoff valves are in the off position and lighting wand is off.
2. Fully extend the extensions.
3. Turn on gas at tank, and set gauge pressure between at 4-6 p.s.i.
4. Light the lighting wand
5. Turn on the gas to the extensions. One at a time.
6. Quickly point the lighting wand at flap style door towards the bottom inboard zone of the
screed extensions to ignite the burner.
7. The extension burners will have changed from a hissing noise to a roaring noise confirming
ignition.
8. Repeat for other side. After extension burners are lit, turn on gas to the main screed.
9. Quickly light each of the burners on the main screed.
Only use burners for 10 - 15 minutes at any given time. Damage to screed plate will occur.
WARNING: NEVER USE SYSTEM WITHOUT DIRECT CONSTANT SUPERVISION
PERSONAL INJURY OR DEATH MAY RESULT.
WARNING: EXCESS GAS ACCUMULATING BEFORE LIGHTING BURNERS MAY
CAUSE AN EXPLOSION RESULTING IN PERSONAL INJURY OR DEATH.

Calder Brothers Corporation Page 9
Model: 690G Gravity Feed Paver 690F Operations Manual Rev 1.1
FREEDOM SCREED CROWN SETTING
1a. On a flat surface, find the null position of the screed depth handles by adjusting them until
they are free and not in tension.
1b. Run a string across the leading edge (front) of the main screed bottom, as close as possible
to the bullnose of the screed plate, and adjust the forward ratchet jack until there is a slight
gap (approximately 1/16” or less) between the screed plate and the string.
*String MUST be on the flat portion of the screed, not on the radius portion*
2. Place the string across the back of the main screed bottom, near the trailing edge (rear)
curvature of the screed plate, and adjust the rear ratchet jack until the screed plate just
touches the whole length of the string. Pull the string away, at one end, and bring it back to
verify that it contacts the entire length at the same time.
*String MUST be on the flat portion of the screed, not on the radius portion*
3. Place the string across the front of the screed bottom and double check the gap between
the screed bottom and the string. Re-adjust the forward ratchet jack as necessary to obtain
the 1/16” or less gap between the string and screed plate.
4. Place the string across the rear of the screed bottom and double check the gap between the
screed bottom and the string. Re-adjust the rear ratchet jack as necessary to verify the
screed plate just touches the whole length of the string.
5. Repeat steps 3 and 4 until no adjustment is required.

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Model: 690G Gravity Feed Paver 690F Operations Manual Rev 1.1
FREEDOM SCREED EXTENSION SETTING
6. (See Figure 6.1) With the extensions completely closed, adjust the screed depth handle
until the extension screed plate rear curved edge just touches a straight
edge held against the main screed bottom at the outside edge, oriented
in forward to rearward direction.
7. (See Figure 7.1) Next, with the extensions completely closed, run a string across the entire
trailing edge, (rear), width of the screed extension bottoms. Release turnbuckle jam nut and
adjust turnbuckles until there is a slight gap (approximately 1/16” or less) between the
screed extension bottoms and the string.
8. (See Figure 7.1) Lock all ratchet jacks and turnbuckle lock nuts to prevent movement
during paving operations.