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 Dened .......................................................................................................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

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Calder Brothers Corp
V2.0
Serial Number Range:
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Page 4
Model: 1560 Paver
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2
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

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Calder Brothers Corp
V2.0
Serial Number Range:
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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.

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V2.0
Serial Number Range:
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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.

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Calder Brothers Corp
V2.0
Serial Number Range:
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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.

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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.

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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 dened 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.

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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 Dened
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.

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Calder Brothers Corp
V2.0
Serial Number Range:
848-S-56TCG9Y2*03848 to _____________
Page 11
Model: 1560 Paver
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.
024-0174
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.

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Calder Brothers Corp
V2.0
Serial Number Range:
848-S-56TCG9Y2*03848 to ________________
Page 12
Model: 1560 Paver
2
4
47
31
2.4.2 Safety Decals on Machine
3
4
4
8
2

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Calder Brothers Corp
V2.0
Serial Number Range:
848-S-56TCG9Y2*03848 to _____________
Page 13
Model: 1560 Paver
3 Paver Operation
3.1 Machine Functions Explained
1. Hopper Open and Close. Left or Both Hoppers
2. Hopper Open and Close Right Hopper (optional)
3. Forward Hopper Lights On/o
4. Screed Vibrator On/o
5. Horn
6. Screed Lights On/O
7. Wash down pump On/o
8. Travel speed High or Low speed. Paving and Machine loading/unloading should always be done in low
speed range.
9. Beacon Light (Optional)
10. Engine Speed: this is to select a set RPM for idle or high RPM for work mode.
11. Engine RPM Adjustment: this increases or decreases the idle or work RPM a small increment.
12. Screed Heat On/o. This turns the screed heat on or o. The desired temperature is set in the digital
display. See Screed Heating Section.
13. Conveyor Reverse. This reverses the conveyor direction to return material to the hopper.
14. Accessory. This is for extra options.
15. Left Drive Lever
16. Right Drive Lever

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Calder Brothers Corp
V2.0
Serial Number Range:
848-S-56TCG9Y2*03848 to ________________
Page 14
Model: 1560 Paver
17. Left Auger Direction In/Out
18. Left Conveyor Feed AUTO/Manual
19. Right Conveyor Feed AUTO/Manual
20. Right Auger Direction In/Out
21. Auger Control AUTO/Manual. Auto uses the sonic sensors to determine when to turn on the feed system
(augers and conveyors). The feed system will turn o once it reaches the desired head of material.
22. Screed Lever Up/Down. Push the Lever forward to raise the screed, pull the lever down to lower the screed.
To oat the screed pull the lever down passed the detent, the lever will stay and the screed will be in oat
mode.
23. Right Extension Lever. This extends and retracts the right hand screed extension.

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Calder Brothers Corp
V2.0
Serial Number Range:
848-S-56TCG9Y2*03848 to _____________
Page 15
Model: 1560 Paver
24. Left Extension Lever. This extends and retracts the left hand screed extension
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.

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Calder Brothers Corp
V2.0
Serial Number Range:
848-S-56TCG9Y2*03848 to ________________
Page 16
Model: 1560 Paver
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. (not available on 1560)
13. Machine hour meter.
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, o, or fault icon.
3. Main screed status. Display will show ready to pave,
wait to pave, o, or fault icon.

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Calder Brothers Corp
V2.0
Serial Number Range:
848-S-56TCG9Y2*03848 to _____________
Page 17
Model: 1560 Paver
4. Right screed extension status. Display will show ready to pave, wait to pave, o, 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.
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

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Calder Brothers Corp
V2.0
Serial Number Range:
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Page 18
Model: 1560 Paver
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
Explosion, fire, or personal injury.
This engine is equipped with an air intake heater.
Do not use starting fluid.
Use of starting fluid can cause an explosion, fire, personal injury or damage to the engine and
other property.
1. Turn key switch to on position, pause light indicator should be on.
2. Turn key switch to start and release. During cooler temperatures, there may be slight delay before starter
engages while engine preheat is engaged.
3. Run engine at low idle to warm up.
4. Press active station control to enable the driving/steering control on that operators station. Left hand station
is the default active station. When engine is started, it will be in pause. The engine will start with a track
control lever out of neutral, but you must recenter the levers and toggle pause/resume switch to begin driving.
3.2.2 Driving
The paver will move forward by pushing both levers forward and will move backwards by pulling the levers back.
Steering a course is accomplished by adjusting the speed of one handle relative to the other. HINT - to make
driving easy, push both handles forward to desired speed, then use only one handle to ne-tune your direction.
3.2.3 Steering Tension
The steer handles can be adjusted for operator preference on tension, (or drag). In a loose position the handles
will spring return to neutral, this requires constant pressure on the handles by the operator. Tension can be
added to the point were the handles are locked and cannot be moved. The ideal setting is somewhere in-
between were the handles have enough tension to stay in the position the operator chooses, but not so sti as
to produce fatigue.
To adjust tension: loosen or tighten the nut located at the center of the aluminum discs were the handles are
attached.
3.2.4 Two Speed
CAUTION: INJURY/OR DAMAGE MAY OCCUR: When switching to high range, bring paver to a stop before

19
Calder Brothers Corp
V2.0
Serial Number Range:
848-S-56TCG9Y2*03848 to _____________
Page 19
Model: 1560 Paver
R
PAVING PRODUCTS
MAULDIN
Calder Brothers Corporation
INITIAL
SETTING
DIMENSION
EXTENSION SLOPE TURNBUCKLE LOCK BOLT
SEE NOTE 1
CHECK TO MAKE SURE
THERE ARE NO GAPS
ALONG THESE EDGES.
LOCATIONS FOR STRING
WHEN SETTING THE SCREED.
NOTES:
VERIFY EXTENSION RAISE/LOWER TURNBUCKLE ASSEMBLY IS FREE TO TURN AND ADJUSTABLE
1.
FROM 15-1/4" TO 16-1/4"
ADJUSTMENT INSTRUCTIONS:
INITIAL SETTING: 16"
1.
TO RAISE EXTENSION ASSEMBLY, DECREASE THE INITIAL SETTING ON THE TURNBUCKLE
2.
ASSEMBLY.
TO LOWER EXTENSION ASSEMBLY, INCREASE THE INITIAL SETTING ON THE TURNBUCKLE
3.
ASSEMBLY.
Model: Freedom 14 Main Screed Setup
Initial Screed Adjustment Settings
Date: 08-01-19
Page: 1 of 2
4 Screed Setup
4.1 Initial Screed Setup

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Calder Brothers Corp
V2.0
Serial Number Range:
848-S-56TCG9Y2*03848 to ________________
Page 20
Model: 1560 Paver
R
PAVING PRODUCTS
MAULDIN
Calder Brothers Corporation
B
EXTENSION TURNBUCKLE LOCK BOLT
EXTENSION SLOPE TURNBUCKLE
STRING
NOTES:
POSITION EXTENSION AT HALF WAY OUT POSITION.
1.
ADJUSTMENT INSTRUCTIONS:
RUN BOTH LEFT AND RIGHT EXTENSION OUT TO THE HALF OUT POSITION.
1.
USE A STRING AND ALIGN WITH TRAILING EDGE OF EXTENSION SCREED PLATE BOTTOM.
2.
LOOSEN EXTENSION TURNBUCKLE LOCK BOLT.
3.
ADJUST THE EXTENSTION SLOPE TURNBUCKLE TO MAKE THE EXTENSION SCREED PLATE
4.
FLAT WITH THE STRING.
Model: Freedom 14 Main Screed Setup
Initial Screed Adjustment Settings
Date: 08-01-19
Page: 2 of 2
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