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.