Mauldin 1860 User manual

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

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.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary.
For more information go to www.P65Warnings.ca.gov/diesel
^WARNING
Batteries, battery posts, battery terminals, and related accessories can expose you to chemicals
including lead and lead compounds, which are known to the State of California to cause cancer
and birth defects or other reproductive harm.
For more information go to www.P65Warnings.ca.gov

III
Calder Brothers Corp
V 1.0
Serial Number Range:
874-S-86TCX5Y2*03874 to _____________
Model: 1860 Paver
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
2.2 Operation Hazards............................................................................................ 3
2.2.1 ^ Pressurized Fluids..........................................................................................5
2.2.2 ^Hazardous Chemicals ....................................................................................6
2.2.3 California Proposition 65 Warnings...................................................................6
2.2.4 Hazards From Modifying Equipment .................................................................6
2.3 Maintenance Hazards ....................................................................................... 6
2.3.1 ^Maintenance And Service ..............................................................................7
2.3.2 ^Fire Or Explosion Prevention .......................................................................7
2.4 Safety Decals .................................................................................................... 7
3. Paver Operation.................................................................................... 10
3.1 Operators Station ........................................................................................... 10
3.2 Digital Display ................................................................................................. 12
3.2.1 Engine Warning Lamps.....................................................................................12
3.2.2 Engine Screen....................................................................................................12
3.2.3 Material Feed Screen.........................................................................................13
3.2.4 Screed Temperature Screen .............................................................................13
3.2.5 Password Screen...............................................................................................14
3.3 Prestart Checks .............................................................................................. 14
3.4 Start Engine..................................................................................................... 14
3.5 Idle/Pave And Engine Speed.......................................................................... 15
3.6 Emergency Stop ............................................................................................. 15
3.7 Active Station .................................................................................................. 16
3.7.1 Single Operator Mode ......................................................................................16
3.7.2 Dual Operator Mode .........................................................................................16
3.8 Driving ............................................................................................................. 16
3.9 Pause/Resume ................................................................................................ 17

IV
Calder Brothers Corp
V 1.0
Model: 1860 Paver
SN:
Serial Number Range:
874-S-86TCX5Y2*03874 to _____________
3.10 Travel Speed.................................................................................................. 17
3.11 Tow Point ....................................................................................................... 18
3.12 Exhaust Aftertreatment Regeneration ........................................................ 18
3.13 Generator....................................................................................................... 19
3.14 Match Height ................................................................................................. 19
3.15 Hopper ........................................................................................................... 19
3.16 Prime Fuel System........................................................................................ 20
3.17 Paver Shutdown............................................................................................ 20
3.18 Drive Disconnect .......................................................................................... 20
4. Material Feed......................................................................................... 22
4.1 Automatic Material Feed Operation .............................................................. 22
4.2 Manual Material Feed Operation ................................................................... 24
4.3 Sonic Sensors................................................................................................. 25
4.4 Screed Heating System.................................................................................. 26
5. Screed Setup......................................................................................... 27
5.1 Crown Setting.................................................................................................. 27
5.2 Extension Setting ........................................................................................... 29
5.2.1 Prepare Paver For Screed Adjustments..........................................................29
5.2.2 Set Match Height ...............................................................................................29
5.2.3 Set Extension Slope..........................................................................................30
5.2.4 Set Extension Bottom Angle Of Attack ...........................................................30
5.3 Pre-Strike Off Setting ..................................................................................... 31
5.4 Setting Screed To Pave .................................................................................. 32
5.4.1 Before Paving ....................................................................................................32
5.4.2 Nulling The Screed And Setting Angle Of Attack ...........................................32
6. Inspections And Maintenance ............................................................... 33
6.1 Inspection And Maintenance Chart .............................................................. 33
6.2 Prepare Paver For Inspections And Maintenance ....................................... 34
6.3 Daily Before Use ............................................................................................. 34
6.3.1 Check Engine Oil Level.....................................................................................34
6.3.2 Check Engine Coolant Level ............................................................................34
6.3.3 Check Engine Fuel And DEF Levels ................................................................35
6.3.4 Check Hydraulic Oil Level ................................................................................36

V
Calder Brothers Corp
V 1.0
Serial Number Range:
874-S-86TCX5Y2*03874 to _____________
Model: 1860 Paver
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
6.4 Daily After Use ................................................................................................ 37
6.4.1 Clean Residue After Use...................................................................................37
6.4.2 Wash Paver ........................................................................................................37
6.5 After Initial 50 Hours....................................................................................... 37
6.5.1 Change Hydraulic Filters ..................................................................................37
6.5.2 Change Engine Oil And Oil Filter .....................................................................38
6.6 Monthly / Every 250 Hours............................................................................. 38
6.6.1 Inspect Conveyor And Drive System...............................................................38
6.6.2 Change Engine Oil And Oil Filter .....................................................................39
6.7 Yearly / 500 Hours ........................................................................................... 39
6.7.1 Change Hydraulic Oil And Filters ....................................................................39
6.7.2 Change Engine Coolant ....................................................................................40
6.7.3 Change Engine Fuel Filters ..............................................................................40
6.5.4 Change Engine Air Filter...................................................................................40
6.7.5 Clean Engine Radiator Fins And Screen......................................................... 40
6.7.6 Battery ................................................................................................................40
7. Troubleshooting ................................................................................... 42
7.1. General ........................................................................................................... 42
7.2 Engine Codes.................................................................................................. 43
7.3 Troubleshooting Chart ................................................................................... 43
8. Warranty ................................................................................................ 45

VI
Calder Brothers Corp
V 1.0
Model: 1860 Paver
SN:
Serial Number Range:
874-S-86TCX5Y2*03874 to _____________

1
Calder Brothers Corp
V 1.0
Serial Number Range:
874-S-86TCX5Y2*03874 to _____________
Model: 1860 Paver
1. Introduction
1.1 Machine Components
1. Hopper
2. Push Beam
3. Shipping Front Tie Down (Both Sides)
4. Tow Point Cylinder
5. Screed Lift Cylinder
6. Right Hand Control Panel
7. Shipping D-Ring
8. Sonic Sensor
9. Right Hand End Gate Angle Adjustment
10. Right Hand End Gate Depth Adjustment
11. Right Hand Extension
12. Main Screed
13. Right Hand Depth Adjustment
14. Walk Board
15. Left Hand Extension
16. Left Hand Depth Adjustment
17. Left Hand Control Panel
18. Engine Enclosure

2
Calder Brothers Corp
V 1.0
Model: 1860 Paver
SN:
Serial Number Range:
874-S-86TCX5Y2*03874 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.
Serial Number:____________________________
Date Of Purchase:_________________________
1.3 Operator Orientation
1. Front
2. Right Side
3. Rear
4. Left Side

3
Calder Brothers Corp
V 1.0
Serial Number Range:
874-S-86TCX5Y2*03874 to _____________
Model: 1860 Paver
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.
Check all systems for proper operation. Check chassis and all components for physical damage and security of
all fasteners and connectors.
2.1.1 Safety Alert And Signal Words
The safety information in this manual is denoted by the safety alert symbol: ^This symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS INVOLVED!
^DANGER
Indicates a hazardous condition that will result in serious injury or death if not performed
appropriately.
^WARNING
Indicates a hazardous condition that could result in serious injury or death if not performed
appropriately.
^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.
2.2 Operation Hazards
The following hazards are possible during the operation of the paver. All operators, maintenance and service
personal, or any one working with or near the paver must be familiar all hazards.
^WARNING
Do not operate this paver until you read and understand the instructions in the operation section
of this manual.
^WARNING
Do not operate, work on or around paver while under the influence of alcohol, drugs or if feeling
ill.

4
Calder Brothers Corp
V 1.0
Model: 1860 Paver
SN:
Serial Number Range:
874-S-86TCX5Y2*03874 to _____________
^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.
^WARNING
Loud noise hazard.
Prolonged exposure to loud noise can cause impairment or loss of hearing.
Operators, workers and bystanders must use ear protection while machine is in operation.
^WARNING
Entanglement hazard.
Do not wear loose fitting clothing.
Loose fitting clothing and long hair can become entangled in moving or rotating parts. Keep all
personnel clear of moving parts when engine is running or about to be started.
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.
During aftertreatment regeneration, exhaust gas temperature could reach 1500°F (800°C).
Exhaust system surface could exceed 1300°F (700°C) which is hot enough to ignite or melt
common materials and burn the skin.
Exhaust and exhaust components can remain hot after engine has been stopped.
To avoid risk of fire, burns and property damage or personal injury, allow the exhaust system to
cool before service or repairs.
Be sure there are no combustible materials located where they are likely to come in contact with
hot exhaust or exhaust components.

5
Calder Brothers Corp
V 1.0
Serial Number Range:
874-S-86TCX5Y2*03874 to _____________
Model: 1860 Paver
^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.
^WARNING
Diesel exhaust fluid (DEF) hazard.
In case of contact with eyes, immediately flush eyes with water. Obtain medical attention
immediately.
In case of skin contact, wash all exposed skin area with mild soap and water, followed by warm
water rinse.
If ingested, obtain medical attention immediately.
^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.
Always fully close hopper and lower screed to ground or engage screed service locks when
parking paver or preparing paver for inspections, service and maintenance.
NOTICE
Dispose of waste properly.
Improper disposal of waste can harm the environment.
Use leak proof container when draining fluids. Do not use food or beverage containers.
Contact your local environmental or recycling center for the proper way to recycle or dispose
of waste.
2.2.1 ^ Pressurized Fluids
Hydraulic oil and grease injected into your skin can cause serious injury or death. Keep your hands and body
away from any pressurized leak. Tighten connections before applying pressure. Never use your hand to check
for leaks; use a piece of wood or cardboard. If uid is injected into the skin, it must be surgically removed within
a few hours or gangrene may result. Get immediate medical attention.

6
Calder Brothers Corp
V 1.0
Model: 1860 Paver
SN:
Serial Number Range:
874-S-86TCX5Y2*03874 to _____________
2.2.2 ^Hazardous Chemicals
Lubricants and coolants can be hazardous. Before operating, check the Material Safety Data Sheet (MSDS) to
understand each product, safe handling procedures, and rst aid measures relating to the product. Clean up
spilled uids immediately.
Do not drain or pour any uids or lubricants on the ground. Check with local environmental agencies or recycling
centers for proper disposal information.
2.2.3 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.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary.
For more information go to www.P65Warnings.ca.gov/diesel.
^WARNING
Batteries, battery posts, battery terminals, and related accessories can expose you to chemicals
including lead and lead compounds, which are known to the State of California to cause cancer
and birth defects or other reproductive harm.
For more information go to www.P65Warnings.ca.gov.
2.2.4 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.
Most accidents 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.

7
Calder Brothers Corp
V 1.0
Serial Number Range:
874-S-86TCX5Y2*03874 to _____________
Model: 1860 Paver
^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.
2.3.1 ^Maintenance And Service
Before performing inspections, service or maintenance:
• Park paver on rm level surface.
• Lower screed to ground or engage screed support locks.
• Fully open or close hoppers.
• Turn engine off and remove ignition key.
• Attach a Do Not Operate tag or similar warning tag to the ignition switch.
• Follow lockout/tag out procedure as dened by your company.
After performing inspections, service or maintenance, verify all guards have been installed and all safety devices
are functional.
Always wear face or eye protection, safety shoes, and other protective items as required by your company.
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.
If you must service machine with an attachment raised, block up that attachment in a safe position.
2.3.2 ^Fire Or Explosion Prevention
^Engine fuel can cause an explosion or re. Do not service fuel system with engine running or near open re.
Do not weld or smoke near fuel system. Do not spill fuel or hydraulic oil on hot machine components. Clean up
spilled fuel or oils immediately.
^Keep sparks and ames away from batteries to prevent explosion of hydrogen gas in and near a battery.
Other precautions include:
• When disconnecting battery cables, disconnect negative (-) cable rst.
• When connecting battery cables, connect negative (-) cable last.
• Do not short circuit battery posts with metal items.
2.4 Safety Decals
Safety decals are located on the paver to identify operational and maintenance hazards. The safety decals are
placed according to the hazard in that area of the paver. Read and understand each of the safety decals and the
hazard it references. These safety messages are additional information to the safety content described in this
operator’s manual.
All safety decals must be legible at all times. Avoid using harsh chemicals or pressure washing. If the safety decal
is no longer legible, replace it with a new one. Contact your dealer for new decals.

8
Calder Brothers Corp
V 1.0
Model: 1860 Paver
SN:
Serial Number Range:
874-S-86TCX5Y2*03874 to _____________
1 - Danger High Voltage. The generator provides 250v for screed heater
operation. Avoid working on any electrical components while the engine
is on.
2 - Danger Keep Clear. There are moving objects that could result in
harm. Keep clear of moving objects. Failure to keep clear may result in
serious injury or death.
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.
4 - 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.
5 - Fan Hazard. Keep away from moving fan.
6 - Danger High Voltage. This machine uses 250v to operation. Avoid
working on any electrical components while the engine is on.
7 - Caution Moving Augers. Keep clear of 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.
8 - Danger. Fuel and or ammable uid is present. Do not smoke or use
any open ame. Decal is inside engine enclosure.

9
Calder Brothers Corp
V 1.0
Serial Number Range:
874-S-86TCX5Y2*03874 to _____________
Model: 1860 Paver

10
Calder Brothers Corp
V 1.0
Model: 1860 Paver
SN:
Serial Number Range:
874-S-86TCX5Y2*03874 to _____________
3. Paver Operation
3.1 Operators Station
Left Side Station
Right Side Station

11
Calder Brothers Corp
V 1.0
Serial Number Range:
874-S-86TCX5Y2*03874 to _____________
Model: 1860 Paver
1. Left Hand Slope (Optional). Adjusts left extension to either at or angled positions.
2. Crown (Optional). Adjust screed crown.
3. Right Hand Slope (Optional). Adjusts Right extension to either at or angled positions..
4. Screed Vibrator On/Off. Vibrator only runs when paver is moving forward and screed is in oat.
5. Generator: Provides electrical power for screed heat.
6. Left Hand Auger Auto/Manual: Operate auger in auto or manuals mode.
7. Left Hand Auger Direction: Augers material to extensions or center of paver for retracting extensions.
8. Right Hand Auger Direction: Augers material to extensions or center of paver for retracting extensions.
9. Right Hand Auger Auto/Manual: Operate auger in auto or manuals mode.
10. Left Hand Conveyor Feed Auto/Manual.
11. Conveyor Reverse: Reverses conveyor direction to return material to the hopper.
12. Right Hand Conveyor Feed Auto/Manual: Operate conveyor in auto or manuals mode.
13. Exhaust Aftertreatment Regeneration Force Regen/Normal Operation/Inhibit Regen Switch.
14. Beacon Light On/Off.
15. Engine RPM Adjustment: Increase or decrease engine speed in 50 rpm increments.
16. Lights On/Off.
17. Active Station Control: Enables driving/steering control of that station.
18. Wash Down Pump On/Off.
19. Feed Mode Auto/Manual.
20. Digital Display.
21. Hopper: Controls opening and closing of the hopper sides.
22. Screed: Raises and lowers screed. Toggle switch down to place screed in oat mode. In oat mode, the
weight of the screed is dragging the ground, no hydraulics are holding screed up, or pressing it down. The
oat (down position) of the switch is not momentary. If right hand station has switch in oat, and left hand
stand toggles switch raise screed, screed will raise up then fall back down to oat.
23. Horn.
24. Tow Point: Tow point cylinders adjust the angle of the screed.
25. Left Extension: Extends and retracts left hand screed extension.
26. Match Height: Match screed extension height to center screed.
27. Left Track Control.
28. Right Track Control.
29. Idle/Pave Engine Speed: Select a preset RPM for idle or pave mode.
30. Travel Speed: Select high or low speed.
31. Pause/Resume: This function can pause, then resume drive and feed functions.
32. Right Extension: Extends and retracts right hand screed extension.
33. Emergency Stop: Press to stop all paver functions. Pull button out to reset. All functions must be restarted.
34. Ignition Switch. Start and stop paver engine.
Note: In sections 3.2 - 3.15, the left hand operators station is illustrated. The same functions can be performed
from the right hand operators station except where noted.

12
Calder Brothers Corp
V 1.0
Model: 1860 Paver
SN:
Serial Number Range:
874-S-86TCX5Y2*03874 to _____________
3.2 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.
3.2.1 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. DEF tank level low.
9. Force regen. Indicates forced exhaust regen has been activate.
10. Exhaust temperature high. Indicates exhaust temperature is too high.
11. Regen inhibit. Indicates exhaust regen inhibit has been selected.
12. Screed vibration. Icon indicates vibration requested. Screed vibration only operates when paver is moving
forward.
13. 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.
3.2.2 Engine Screen
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. 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.
10. Press to display engine code(s) if present.
11. Regen inhibit. Press to inhit exhaust regen.
12. DEF tank level.
13. Machine hour meter.

13
Calder Brothers Corp
V 1.0
Serial Number Range:
874-S-86TCX5Y2*03874 to _____________
Model: 1860 Paver
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.
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. Feed control mode indicator.
10. Left material height indicator (sonic).
3.2.4 Screed Temperature Screen
Note: Screed temperature 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. Left screed extension status. Display will show ready to
pave, wait to pave, off, or fault icon.
3. Main screed status. Display will show ready to pave,
wait to pave, off, or fault icon.
4. Right screed extension status. Display will show ready
to pave, wait to pave, off, 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.

14
Calder Brothers Corp
V 1.0
Model: 1860 Paver
SN:
Serial Number Range:
874-S-86TCX5Y2*03874 to _____________
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.
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.
3.3 Prestart Checks
Prior to starting the machine, the following procedures must be completed.
Note: Refer to OEM engine manual for important safety, operational and maintenance information.
1. Check engine oil level.
2. Check engine coolant level.
3. Check hydraulic oil level.
4. Check fuel and DEF levels.
5. Check wash down tank level.
6. Check around machine to verify nothing is on or under the machine.
3.4 Start Engine
^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.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary.
For more information go to www.P65Warnings.ca.gov/diesel.