Mauldin 1560 User manual

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

Contents
1. Introduction............................................................................................. 4
1.1 Machine Components ...................................................................................... 4
1.2 Serial Number Plate.......................................................................................... 5
2. Safety....................................................................................................... 5
2.1 General Safety Information.............................................................................. 5
2.1.1 Safety Alert And Signal Words...........................................................................5
2.2 Operation Hazards............................................................................................ 6
2.2.1 ⚠Pressurized Fluids ...........................................................................................8
2.2.2 ⚠Hazardous Chemicals .....................................................................................8
2.2.3 California Proposition 65 Warnings...................................................................8
2.2.4 Hazards From Modifying Equipment .................................................................9
2.3 Maintenance Hazards ....................................................................................... 9
2.3.1 ⚠Maintenance And Service ...............................................................................9
2.3.2 ⚠Fire Or Explosion Prevention ......................................................................10
2.4 Safety Decals .................................................................................................. 10
2.4.1 Safety Decals Dened .......................................................................................................10
2.4.2 Safety Decals on Machine ................................................................................12
3 Paver Operation..................................................................................... 13
3.1 Machine Functions Explained ............................................................................................13
3.2 Digital Display ................................................................................................. 15
3.2.1 Engine Warning Lamps.....................................................................................15
3.2.2 Engine Screen....................................................................................................15
3.2.3 Material Feed Screen.........................................................................................16
3.2.4 Screed Temperature Screen .............................................................................16
3.2.5 Password Screen...............................................................................................17
3.3 Prestart Checks .............................................................................................. 17
3.4 Start Engine..................................................................................................... 17
3.2.2 Driving ................................................................................................................18
3.2.3 Steering Tension................................................................................................18
3.2.4 Two Speed..........................................................................................................18

4 Screed Setup.......................................................................................... 19
4.1 Initial Screed Setup ........................................................................................ 19
4.2 Extension Bottom Setup ................................................................................ 21
5 Fluid Capacities and Recommendations ............................................ 24
5.1 Engine Coolant................................................................................................ 24
5.2 Lubrication and Service Procedures ............................................................ 24
5.2.1 Air Filters............................................................................................................24
5.3 Battery ............................................................................................................. 24
5.3.1 Removal..............................................................................................................25
5.3.2 Cleaning .............................................................................................................25
5.3.3 Installation..........................................................................................................25
5.3.4 Charging.............................................................................................................25
5.3.5 Storage ...............................................................................................................25
5.4 Engine and Engine Filters.............................................................................. 26
5.4.1 To Change Fuel Filter ........................................................................................26
5.4.2 Oil and Filter Changing .....................................................................................26
5.5 Hydraulic System............................................................................................ 26
5.5.1 Hydraulic Fluid Change ....................................................................................27
5.6 Conveyor System .................................................................................................27
6 Troubleshooting ................................................................................... 28
6.1 General ............................................................................................................ 28
6.1.1 Use of Schematics.............................................................................................28
6.1.2 Troubleshooting chart.......................................................................................28
6.2 Engine.............................................................................................................. 29
6.2.1 Transmission .....................................................................................................29
6.4 Hydraulic System............................................................................................ 29
6.4.1 Hydraulic System Pressures............................................................................30
6.5 Recommended Preventive Maintenance Intervals ...................................... 31
7 Warranty ................................................................................................. 32

4
Calder Brothers Corp
V2.0
Serial Number Range:
848-S-56TCG9Y2*03848 to ________________
Page 4
Model: 1560 Paver
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1. Introduction
1.1 Machine Components
1. Sight Gauge Rod (both sides)
2. Front Tie Down (both sides)
3. Rear D-ring Tie Down (both sides)
4. Sonic Sensor
5. Left Extension
6. Left Mat Thickness Adjustment
7. Left Extension Match Height Adjustment
8. Screed Heat Control Box
9. Screed Crown Adjustment
10. Right Extension
11.Right Extension Match Height
12. Right Mat Thickness Adjustment
13. Dash
14. Machine Steering Levers
15. Operator Display
16. Engine Compartment
17. Hopper

5
Calder Brothers Corp
V2.0
Serial Number Range:
848-S-56TCG9Y2*03848 to _____________
Page 5
Model: 1560 Paver
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:_____________________
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.

6
Calder Brothers Corp
V2.0
Serial Number Range:
848-S-56TCG9Y2*03848 to ________________
Page 6
Model: 1560 Paver
⚠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.
⚠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.

7
Calder Brothers Corp
V2.0
Serial Number Range:
848-S-56TCG9Y2*03848 to _____________
Page 7
Model: 1560 Paver
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.
⚠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.

8
Calder Brothers Corp
V2.0
Serial Number Range:
848-S-56TCG9Y2*03848 to ________________
Page 8
Model: 1560 Paver
⚠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.
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.

9
Calder Brothers Corp
V2.0
Serial Number Range:
848-S-56TCG9Y2*03848 to _____________
Page 9
Model: 1560 Paver
⚠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.
⚠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 o󰀨 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.

10
Calder Brothers Corp
V2.0
Serial Number Range:
848-S-56TCG9Y2*03848 to ________________
Page 10
Model: 1560 Paver
If you must troubleshoot machine with engine running, have someone in constant visual contact who can shut
o󰀨 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.
2.4.1 Safety Decals Dened
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.