Mauldin 1360 User manual

Operation Manual

Model: 1360

Sold & Served By:

Covers Serial Number Range:

_____________________through____________________

Model: 1360 PaverCalder Brothers Corp

V1.0

Serial Number Range:

____________________ to ___________

Table of contents

V Preface ..................................................................................... 1

1 General safety instructions ........................................................................ 2

1.1 Laws, guidelines, accident prevention regulations ..................................... 2

1.2 Safety signs, signal words ......................................................................... 3

"Danger"! ............................................................................................... 3

"Warning" ! ............................................................................................. 3

"Caution" ! .............................................................................................. 3

"Note" ! ................................................................................................... 3

1.3 Other supplementary information ............................................................... 3

1.4 Warnings .................................................................................................... 4

1.5 Prohibitive symbols .................................................................................... 6

1.6 Protective equipment ................................................................................. 7

1.7 Environmental protection ........................................................................... 8

1.8 Fire prevention ........................................................................................... 8

1.9 Additional information ................................................................................ 9

2 CE identification and Declaration of Conformity ...................................... 10

3 Guarantee conditions ............................................................................... 10

4 Residual risks ........................................................................................... 11

5 Sensibly predictable incorrect usage ....................................................... 12

A Correct use and application ................................................... 1

B Vehicle description ................................................................. 1

1 Application ................................................................................................. 1

2 Description of assemblies and functions .................................................... 2

2.1 Vehicle ....................................................................................................... 3

Construction ........................................................................................... 3

3 Danger zones ............................................................................................. 6

4 Safety devices ............................................................................................ 7

5 Technical data, standard configuration ...................................................... 9

5.1 Dimensions (all dimensions in inch) ........................................................... 9

5.2 Permissible approach angle ..................................................................... 10

5.3 Weights 1360 Paver (all weights in Ibs) ................................................... 11

5.4 Performance data 1360 Paver ................................................................. 11

5.5 Travel drive/traction unit ........................................................................... 12

5.6 Engine EU 3B / Tier 4f ............................................................................. 12

5.7 Material compartment (hopper) ................................................................ 13

5.8 Material transfer ....................................................................................... 13

5.9 Material distribution .................................................................................. 13

5.10 Electrical system ...................................................................................... 13

5.11 Permissible temperature ranges .............................................................. 13

6 Identification points .................................................................................. 14

6.1 Warning signs .......................................................................................... 17

6.2 Information signs ...................................................................................... 19

6.3 Instructive symbols, prohibitive symbols, warning symbols ..................... 21

Model: 1360 PaverCalder Brothers Corp

V1.0

Serial Number Range:

____________________ to ___________

6.4 Identification label for the paver finisher (41) ........................................22

6.5 Explanation of 17-digit PIN serial number ................................................23

6.6 Engine type plate ......................................................................................24

7 EN standards ............................................................................................25

7.1 Continuous sound pressure level .............................................................25

7.2 Vibration acting on the entire body ...........................................................26

7.3 Vibrations acting on hands and arms .......................................................26

7.4 Electromagnetic compatibility (EMC) .......................................................26

C10.12 Transportation........................................................................ 1

1 Safety regulations for transportation ..........................................................1

2 Directing of the vehicle ...............................................................................2

3 Transportation on low-bed trailers ..............................................................3

3.1 Preparations ...............................................................................................4

4 Securing the load .......................................................................................6

4.1 Prepare the low-bed trailer .........................................................................7

4.2 Driving onto the low-bed trailer ...................................................................8

4.3 Lashing equipment .....................................................................................9

Lashing equipment - contact surfaces not swept clean and not free of

frost, ice and snow .................................................................................9

Lashing equipment - contact surfaces swept clean and free of frost,

ice and snow ........................................................................................10

4.4 Loading .....................................................................................................11

4.5 Preparing the vehicle ................................................................................12

5 Securing the load .....................................................................................13

5.1 Securing in direction of travel ...................................................................13

5.2 Securing opposite direction of travel ........................................................15

5.3 After transportation ...................................................................................17

6 Transportation ..........................................................................................18

6.1 Preparations .............................................................................................18

6.2 Driving mode ............................................................................................20

7 Loading by crane ......................................................................................21

8 Towing ......................................................................................................23

9 Safely parking the vehicle ........................................................................25

9.1 Lifting the vehicle with hydraulic lifts, lifting points ...................................26

D10.12 Operation ................................................................................1

1 Safety regulations .......................................................................................1

2 Controls ......................................................................................................3

2.1 Operating panel ..........................................................................................3

Electric heating element (o) .................................................................42

Gas heating element (o) .......................................................................44

3 Remote control .........................................................................................46

Model: 1360 PaverCalder Brothers Corp

V1.0

Serial Number Range:

____________________ to ___________

D24.12 Operating the display ............................................................ 1

1 Operation of the input and display terminal ............................................... 2

Button layout on the display ................................................................... 2

Display of activated functions ................................................................ 4

1.1 Menu operation - procedure for adjusting parameters ............................... 5

Selecting and changing an adjustment parameter in a menu ................ 6

2 Menu structure ........................................................................................... 7

Menu of the "Home" displays ................................................................. 7

Displays: ................................................................................................ 7

"Home" functions / "Quick Settings" ...................................................... 8

"Particulate Filter Regeneration" menu (o) /

Engine measured value display ............................................................. 9

Drive engine measured value display .................................................. 11

"Screed Heater" adjustment and display menu .................................. 12

"Error Memory" menu .......................................................................... 13

Detailed display "Error Messages With Travel Drive Stop" ................. 14

Detailed display "Vehicle Warning Messages" .................................... 15

Detailed display "Engine Error Messages" .......................................... 16

"Info" menu .......................................................................................... 17

Display of the following information: .................................................... 17

"Display" set-up menu ......................................................................... 18

3 Terminal error messages ......................................................................... 19

Status, warning and error messages symbols ..................................... 19

3.1 Drive engine error codes .......................................................................... 24

4 Menu structure of the setting and display menus .................................... 28

D30.12 Mode of operation .................................................................. 1

1 Control elements on the paver finisher ...................................................... 1

1.1 Control elements on the operator's control station ..................................... 1

Control platform ..................................................................................... 2

Control platform, transportation

position, ................................................................................................. 3

Running board extension ....................................................................... 4

Fuse box ................................................................................................ 5

Batteries ................................................................................................. 6

Main battery switch ................................................................................ 6

Hopper transport safeguard ................................................................... 7

Crossbeam lock, mechanical ................................................................. 7

Paving thickness indicator - at bottom ................................................... 8

Paving thickness indicator - at top ......................................................... 8

Headlight for auger compartment (o) ..................................................... 9

LED working light (o) ............................................................................. 9

LED working light, magnetic foot (o) ...................................................... 9

Auger height adjustment ratchet (o) .................................................... 10

Auger height displays .......................................................................... 10

Sensor rod / sensor rod extension ...................................................... 11

Manual separator fluid spray (o) .......................................................... 13

Separator fluid spraying system (o) ..................................................... 14

Model: 1360 PaverCalder Brothers Corp

V1.0

Serial Number Range:

____________________ to ___________

Conveyor limit switches ........................................................................15

Auger limit switches .............................................................................16

24 volt sockets (o) ...............................................................................17

USB interface .......................................................................................17

Fire extinguisher (1) (o) ........................................................................18

First-aid kit (2) (o) .................................................................................18

Rotary beacon (o) ................................................................................19

D40.12 Mode of operation ..................................................................1

1 Preparing for operation ...............................................................................1

Required devices and aids .....................................................................1

Before starting work

(in the morning or when starting paving) ................................................3

Check list for the vehicle operator ..........................................................3

1.1 Starting the paver finisher ..........................................................................6

Before starting the paver finisher ...........................................................6

"Normal" starting ....................................................................................6

External starting (starting aid) ................................................................8

After starting .........................................................................................11

Observe indicator lamps ......................................................................11

Battery charge indicator (1) ..................................................................11

Oil pressure indicator lamp for the diesel engine (2) ............................11

1.2 Preparation for transportation ...................................................................13

Driving and stopping the paver finisher ................................................15

1.3 Preparations for paving ............................................................................16

Separator fluid ......................................................................................16

Screed heater .......................................................................................16

Direction marks ....................................................................................17

Loading/conveying material .................................................................19

Filling function ......................................................................................19

1.4 Starting for paving ....................................................................................21

1.5 Checks during paving ...............................................................................22

Paver function ......................................................................................22

Quality of the layer ...............................................................................22

1.6 Interrupting/terminating operation ............................................................24

During breaks in paving (e.g. delay due to material trucks) .................24

During longer breaks (e.g. lunch break) ...............................................24

When work is finished ..........................................................................26

1.7 Problems during paving ............................................................................27

1.8 Malfunctions on the paver finisher or screed ............................................29

E10.12 Set-up and modification ........................................................1

1 Special safety instructions ..........................................................................1

2 Distribution auger .......................................................................................3

2.1 Height adjustment ......................................................................................3

2.2 Auger width extension and material shaft with protective cover

(Optional equipment) 4

3 Push roller crossbar, adjustable ................................................................6

Model: 1360 PaverCalder Brothers Corp

V1.0

Serial Number Range:

____________________ to ___________

4 Connecting the automatic levelling system ................................................ 7

Connecting the slope controller /

height controller ..................................................................................... 8

5 Limit switch ................................................................................................ 9

5.1 Install auger limit switches

(left and right) ............................................................................................. 9

F10 Maintenance ............................................................................ 1

1 Notes regarding safety ............................................................................... 1

F2.12 Maintenance overview ............................................................ 1

1 Maintenance overview ............................................................................... 1

F3.12 Maintenance - conveyor ......................................................... 1

1 Maintenance - conveyor ............................................................................. 1

1.1 Maintenance intervals ................................................................................ 3

1.2 Maintenance points .................................................................................... 4

Chain tension, conveyor (1) ................................................................... 4

Replace conveyor / conveyor drive - wear parts (2) .............................. 7

F4.12 Maintenance - auger assembly.............................................. 1

1 Maintenance - auger assembly .................................................................. 1

1.1 Maintenance intervals ................................................................................ 3

1.2 Maintenance points .................................................................................... 4

Auger drive chains (1) ............................................................................ 4

Auger box (2) ......................................................................................... 6

Seals and sealing rings (3) .................................................................... 7

Auger segments (4) ............................................................................... 8

F5.12 Maintenance - engine assembly ............................................ 1

1 Maintenance - engine assembly ................................................................ 1

1.1 Maintenance intervals ................................................................................ 3

1.2 Maintenance points .................................................................................... 6

Engine fuel tank (1) ............................................................................... 6

Engine lube oil system (2) .................................................................... 7

Engine fuel system (3) .......................................................................... 9

Engine air filter (4) ............................................................................... 11

Engine cooling system (5) ................................................................... 12

Engine drive belt (6) ............................................................................. 15

Model: 1360 PaverCalder Brothers Corp

V1.0

Serial Number Range:

____________________ to ___________

F6.12 Maintenance - hydraulic system ............................................1

1 Maintenance - hydraulic system .................................................................1

1.1 Maintenance intervals ................................................................................3

1.2 Maintenance points ....................................................................................5

Hydraulic oil tank (1) ..............................................................................5

Suction/return flow hydraulic filter (2) .....................................................7

High-pressure filter (3) ...........................................................................8

Pump distribution gear (4) ......................................................................9

Bleeder ................................................................................................10

Hydraulic hoses (5) ..............................................................................11

Marking hydraulic hoses /

storage period, period of use ...............................................................13

Auxiliary flow filter (6) ...........................................................................14

F7.12 Maintenance - drive unit .........................................................1

1 Maintenance - drive unit .............................................................................1

1.1 Maintenance intervals ................................................................................3

1.2 Maintenance points ....................................................................................6

Chain tension (1) ....................................................................................6

Checking / adjusting chain tension (grease tensioners) .........................6

Bottom plates (2) ....................................................................................8

Rollers (3) ...............................................................................................9

Planetary gear (4) ................................................................................10

F8.12 Maintenance - electrical system ............................................1

1 Maintenance - electrical system .................................................................1

1.1 Maintenance intervals ................................................................................3

1.2 Maintenance points ....................................................................................4

Batteries (1) ............................................................................................4

Recharging the batteries ........................................................................5

Alternator (2) ..........................................................................................6

Cleaning the alternator ...........................................................................8

Check belts ............................................................................................9

Checking belt tension .............................................................................9

Adjusting belt tension ...........................................................................10

2 Electrical fuses .........................................................................................11

2.1 Main fuses (1) ...........................................................................................11

2.2 Fuses in main terminal box (operating panel) ..........................................12

Relays ..................................................................................................14

Model: 1360 PaverCalder Brothers Corp

V1.0

Serial Number Range:

____________________ to ___________

F11.12 Lubricants and

operating substances ............................................................. 1

1 Lubricants and operating substances ........................................................ 1

1.1 Capacities .................................................................................................. 3

2 Operating substance specifications ........................................................... 4

2.1 Notes on diesel fuel ................................................................................... 4

2.2 Drive engine TIER IV (o) - fuel specification .............................................. 4

2.3 Engine - lubricating oil ................................................................................ 5

2.4 Cooling system .......................................................................................... 5

2.5 Hydraulic system ........................................................................................ 5

2.6 Pump distribution gear ............................................................................... 5

2.7 Drive unit planetary gear ............................................................................ 5

2.8 Auger box .................................................................................................. 6

2.9 Grease ...................................................................................................... 6

2.10 Separator emulsion ................................................................................... 6

2.11 Hydraulic oil ............................................................................................... 7

F100 Checking, shutdown ... ........................................................... 1

1 Tests, checks, cleaning, shutdown and disposal ....................................... 1

1.1 Maintenance intervals ................................................................................ 2

2 General visual inspection ........................................................................... 3

3 Check that the bolts and nuts fit firmly ....................................................... 3

4 Inspection by an expert .............................................................................. 4

5 Cleaning ..................................................................................................... 5

5.1 Cleaning the hopper ................................................................................... 6

5.2 Cleaning the conveyor and auger .............................................................. 6

5.3 Cleaning optical or acoustic sensors ......................................................... 7

6 Preserving the paver finisher ..................................................................... 8

6.1 Shutdowns for up to 6 months ................................................................... 8

6.2 Shutdowns lasting from 6 months to 1 year ............................................... 8

6.3 Recommissioning the machine .................................................................. 8

7 Environmental protection, disposal ............................................................ 9

7.1 Environmental protection ........................................................................... 9

7.2 Disposal ..................................................................................................... 9

8 Bolts - torques .......................................................................................... 10

8.1 Standard metric threads - strength class 8.8 / 10.9 / 12.9 ....................... 10

8.2 Fine metric threads - strength class 8.8 / 10.9 / 12.9 ............................... 11

F200 Warranty .................................................................................. 1

1 Product Warranty ....................................................................................... 1

Model: 1360 PaverCalder Brothers Corp

V1.0

Serial Number Range:

____________________ to ___________

Table of contents

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