PAVER OPERATION MANUAL MODEL 1550-D
Contents
1. MAULDIN BY CALDER BROTHERS PAVER OPERATION MANUAL MODEL 1550 D Paver Serial Number Paver Specification Number Engine Serial Number SOLD amp SERVICED BY SECTION 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 5 1 5 2 5 3 5 4 5 5 6 1 7 1 7 2 7 3 7 4 7 5 7 6 7 7 7 8 TABLE OF CONTENTS ITEM Daily Start up Checklist 1 ideada Important Safety Information elia aiar Starting the Pavel ee PEPPER Screed Operation iii ii Screed Heating System Crowning the Screed 5 eiie iii Setting the Extensions i iii 2 Null your Screed iii amp iii Engine ali LUBRICATION amp SERVICE PROCEDURES nnne nnns Air Filters iii salve DAMA inni Engine 8 Engine Filters Hydra lic System iaa Conveyor Syster sospiran gaaei onespen eese cuida eoe nani enni Troubleshooting Guide Component Removal amp Installation eese Rec2. 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 Calder Brothers Corporation Page 5 Model 1550 D Conveyor Feeding Asphalt Paver 1550 C Paver Operation Manual Rev 1 3 PAVER OPERATION SECTION Prior to starting the following procedures must be completed 1 Check engine oil level 2 Check engine coolant level 3 Check hydraulic oil level STARTING THE PAVER 1 0 STARTING To start the paver first check to make suret forward and reverse levers are in the neutral position The paver will not start if the red indicator light is not ON indicating a neutral position e Turn key switch to the ON position adjust steer handles until red indicator light is ON Turn key switch back to the left position PRE HEAT count to 5 e Turn key switch to START equipped gt lfengine does not start quickly repeat the PRE HEAT step e Adjust engine RPM as needed for smooth idle CAUTION Do not Pre heat more than 5 seconds at a time or Glow Plug failure will occur CAUTION Do not use any starting fluid or engine warranty will be VOID 2 0 DRIVING The paver will move forward by pushing both levers forward and will move backwards by pulling the
3. levers back Steering a course is acco mplished 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 fine tune your direction 3 0 STEERING TENSION The steer handles can be adjusted for operator preference on tensi on 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 handl es 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 stiff as to produce fatigue To adjust tension loosen or tighten the nut locat ed at the center of the aluminum discs were the handles are attached 4 0 TWO SPEED CAUTION INJURY OR DAMAGE MAY OCCUR When switching to high range bring paver to a stop before switching To engage from low to high flip the High range switch up Calder Brothers Corporation Model 1550 D Conveyor Feeding Asphalt Paver Page 6 1550 C Paver Operation Manual Rev 1 3 MATERIAL FEED OPERATION The 1550 D and 1500 C allow you to configure the auger and conveyor operation of the paver for both an Automatic mode and a Manual mode Use the automatic mode whenever possible to increase the useful life of the feed augers and to maintain a more consistent Head of Material in front o
4. to 3 4 turns by hand IMPORTANT Do not over tighten Calder Brothers Corporation Page 14 Model 1550 C Conveyor Feeding Asphalt Paver 1550 C Paver Operation Manual Rev 1 3 b Oil and Filter Changing Stop engine Wait 15 minutes or engine oil to cool before proceeding On the hopper side remove drain plug and position capturing bucket Drain crankcase Unscrew and discard existing filters Fill new elements with fresh oil Lightly coat the seal rings with oil and then screw on filters until seals meet flanges Tighten an additional 1 2 to 3 4 turns by hand NOORWN gt IMPORTANT Do not over tighten 8 Fill crankcase to correct level 9 Start engine and run at low idle Have an assistant visually check seal areas for leaks 10 Stop engine Wait a few minutes and then check engine oil level once again Hydraulic System 1 Hydraulic Fluid Change 9 f Stop engine Allow system pressure to drop and remove filler cap Remove suction hose and drain into appropriate container for disposal Remove hydraulic filter Replace filter element and reinstall RETRACT ALL HYDRAULIC CYLINDERS Replace fluid to approximately 1 from top of reservoir gt Operate paver and recheck level Check visually for oil leaks NOTE Each paver should be thoroughly inspected after each use and during maintenance cycle for Or ONS Tightness of mounting bolts and attaching hardware on bearings co
5. ES IF CONTACT OCCURS FLUSH THE AFFECTED AREA WITH LOTS OF WATER CAUTION DISCONNECT GROUND CABLE FROM THE NEGATIVE BATTERY POST BEFORE ATTEMPTING TO SERVICE OR REMOVE BATTERY 1 Removal a Open engine compartment locate battery to your near left side b Disconnect ground negative cable from battery terminal c Disconnect positive cable from battery terminal 2 Cleaning a Remove battery following correct procedures b Thoroughly clean terminals with a battery cleaning tool c Mixa paste solution of baking soda and water and apply to battery and terminals d Rinse battery and paver area near battery liberally with water 3 Installation a Clean battery following correct procedures b Becertain battery area is clean and clear of debris c Install battery and connect positive cable to terminal CAUTION DO NOT CONNECT NEGATIVE GROUND TERMINAL FIRST ARCING CAN OCCUR POSSIBLY CAUSING SEVERE BURNS AND OR BATTERY EXPLOSION d Connect negative terminal e Close engine compartment 4 Charging a Connect charger leads to proper battery terminals then proceed according to charger manufacturer s instructions Calder Brothers Corporation Page 13 Model 1550 C Conveyor Feeding Asphalt Paver 1550 C Paver Operation Manual Rev 1 3 5 Storage a Remove and clean battery following correct procedures b Bring battery to full charge following charger manufacturer s instructions c Store in a cool dry pla
6. ETTING INSTRUCTIONS PAGE 1 OF 2 CHECK TO MAKE SURE Lao TO MAKE SURE THERE ARE NO GAPS THERE ARE NO GAPS ALONG THESE EDGES ALONG THESE EDGES IVI MA UL DIN PAVING PRODUCTS P Calder 05 15 12 FREEDOM FOURTEEN LOCATIONS FOR STRING WD S209 FINAL ASSEMBLY WHEN SETTING THE SCREED ENGINEER DM GaU BB MODEL NO MODEL SHEET NO aan 111 209000 209 S209 000 03 ADJUSTMENT INSTRUCTIONS 1 RUN BOTH LEFT AND RIGHT EXTENSION OUT TO THE HALF OUT POSITION 2 USE A STRING AND ALIGN WITH TRAILING EDGE OF EXTENSION SCREED PLATE BOTTOM LOOSEN EXTENSION TURNBUCKLE LOCK BOLT ADJUST THE EXTENSTION SLOPE TURNBUCKLE TO MAKE THE EXTENSION SCREED PLATE FLAT WITH THE STRING EXTENSION SLOPE TURNBUCKLE EXTENSION TURNBUCKLE LOCK BOLT POSITION EXTENSION AT HALF WAY OUT POSITION SCREED SETTING INSTRUCTIONS PAGE 20F 2 FUE MAULDIN PAVING PRODUCTS FREEDOM FOURTEEN S209 FINAL ASSEMBLY CAD MODEL NO MODEL SHEET NO 111 209000 209 S209 000 04 MAULDIN Model Freedom 14 Extension Setup PAVING PRODUCTS 01 03 Calder Brothers Corporation Date 01 03 13 Page 1 of 3 Extension Adjustable Bottom 1 2 13 1 5 LONG BOLT WITH LOCK WASHER HINGED EXTENSION SCREEDING PLATE P N 112 209830 FACTORY SETTING FOR BOLT ON CAM NUT IS IN THE HORIZONTAL POSITION OR 3 00 O CLOCK POSITION P N 113 209800 ADJUSTING CAM NUT END VIEW OF EXTENSION BOTTOM ATTACK ANGLE SHOWN IS
7. FACTORY DEFAULT DETAIL OF ADJUSTING CAM NUT POSITION OF ADJUSTING CAM NUT SHOWN IS FACTORY DEFAULT NOTES 1 Extensions are factory shipped with P N 113 209801 non adustable cam nut 2 If adjusting the attack angle of the extension screeding plate is required replace P N 113 209801 with P N 113 209800 adjusting cam nut See the following two 2 pages for instructions to raise or lower the extension screeding plate profile to obtain seemless mat paving performance MAULDIN Model Freedom 14 Extension Setup PAVING PRODUCTS 01 03 Calder Brothers Corporation Date 01 03 13 Page 2of3 Extension Adjustable Bottom BOLT NOT SHOWN FOR CLARITY PAS UP D 12 ap POSITION P N 113 209800 ADJUSTING CAM NUT DETAIL OF ADJUSTING NUT END VIEW OF EXTENSION BOTTOM POSITION OF ADJUSTING CAM NUT ATTACK ANGLE SHOWN IS MAXIMUM SHOWN IS FOR MAXIMUM ATTACK ANGLE NOTES 1 If the extensions are lower than the main screed at full paving widths then increase the extension attack angle see table below Desired Attack Angle Angle from Horizontal O Clock Position 4 0 Factory Default 90 Factory Default 3 00 Factory Default MAULDIN Model Freedom 14 Extension Setup PAVING PRODUCTS 01 03 Calder Brothers Corporation Date 01 03 13 Page 3 of 3 Extension Adjustable Bottom BOLT NOT SHOWN FOR CLARITY P N 113 209800 PX DJUSTING CAM NUT 75 0 DOWN 5 30 POSITION DETAI
8. G WHEN SETTING THE SCREED NOTES 1 VERIFY TURNBUCKLE ASSEMBLY IS FREE TO TURN AND ADJUSTABLE FROM 15 1 4 TO 16 1 4 ADJUSTMENT INSTRUCTIONS 1 INITIAL SETTING FOR 1550 D SERIAL NUMBERS UP TO AND INCLUDING XXX XXXXX XX 15 3 4 2 INITIAL SETTING FOR 1550 D SERIAL NUMBERS AFTER XXX XXXXX XX 16 3 TO RAISE EXTENSION ASSEMBLY DECREASE THE INITIAL SETTING ON THE TURNBUCKLE ASSEMBLY 4 TO LOWER EXTENSION ASSEMBLY INCREASE THE INITIAL SETTING ON THE TURNBUCKLE ASSEMBLY MAULDIN Model Freedom 14 Main Screed Setup PAVING PRODUCTS Date 11 07 12 Calder Brothers Corporation Page 2 of 2 Initial Screed Adjustment Settings EXTENSION SLOPE TURNBUCKLE EXTENSION TURNBUCKLE LOCK BOLT STRING NOTES 1 POSITION EXTENSION AT HALF WAY OUT POSITION ADJUSTMENT INSTRUCTIONS RUN BOTH LEFT AND RIGHT EXTENSION OUT TO THE HALF OUT POSITION USE A STRING AND ALIGN WITH TRAILING EDGE OF EXTENSION SCREED PLATE BOTTOM LOOSEN EXTENSION TURNBUCKLE LOCK BOLT ADJUST THE EXTENSTION SLOPE TURNBUCKLE TO MAKE THE EXTENSION SCREED PLATE FLAT WITH THE STRING AON ADJUSTMENT INSTRUCTIONS 1 TO RAISE EXTENSION ASSEMBLY DECREASE THE 16 DIMENSION ON THE TURNBUCKLE ASSEMBLY 2 TO LOWER EXTENSION ASSEMBLY INCREASE THE 16 DIMENSION ON THE TURNBUCKLE ASSEMBLY EXTENSION TURNBUCKLE LOCK BOLT VERIFY TURNBUCKLE ASSEMBLY IS FREE TO TURN AND ADJUSTABLE FROM 15 3 4 TO 16 1 4 16 000 INITIAL SETTING DIMENSION SCREED S
9. L OF ADJUSTING CAM NUT END VIEW OF EXTENSION BOTTOM POSITION OF ADJUSTING CAM NUT SHOWN IS FOR MINIMUM ATTACK ANGLE ATITASICANGLE SHOWS NOTES 1 If the extensions are higher than the main screed at full paving widths then decrease the extension attack angle see table below Desired Attack Angle Angle from Horizontal O Clock Position 4 0 Factory Default 90 Factory Default 3 00 Factory Default Calder Brothers Corporation Model 1550 C Conveyor Feeding Asphalt Paver Page 11 1550 C Paver Operation Manual Rev 1 3 FLUID CAPACITIES AND RECOMMENDATIONS FLUID Engine oil Hydraulic Grease Engine coolant Diesel CAPACITY 8 U S quarts 7 5 liters 15 5 U S gal 60 liters As required 2 1 U S gal 8 liters 12 5 U S gal 47 liters RECOMMENDATION High quality CC CD multi grade lubricating oil Above 14 deg F use 15W40 or 20W40 High quality anti wear hydraulic oil Original equipment Gulf C 3 torque fluid N G L I consistency 2 high temperature anti friction bearing lubricating grease High quality Above 14 deg F Above 40 5 use No 2 D Below 40 5 use No 1 D Power loss up to 4 can be expected due to lower viscosity ENGINE COOLANT All engines are shipped from the factory with proper engine coolant and levels Customers are responsible for filling and maintaining the engine s cooling system s The use of improper coolant mixtur es
10. RS recommendations ENGINE OIL LEVEL INSPECT DAILY CHANGE 12 MONTHS OR 200 HOURS RADIATOR COOLANT LEVEL INSPECT DAILY CHANGE 12 MONTHS OR 200 HOURS NOTE HYDRAULIC OIL LEVEL INSPECT DAILY Ts een CHANGE 12 MONTHS OR 200 HOURS FAILURE TO PERFORM PROPER SCHEDULED FUEL FILTER CHANGE 12 MONTHS OR 200 HOURS MAINTENACE WILL AD VERSL ENGINE OIL FILTER CHANGE 12 MONTHS OR 200 HOURS HYDRAULIC OIL FILTER CHANGE 12 MONTHS OR 200 HOURS PERFORMANCE OF THE PAVER AND MAY VOID REALE PONTE APPLY GREASE 3 MONTIS OR 400 HOURS YOUR WARRANTY IN PART OR IN ENTIRETY Calder Brothers Corporation Page 20 Model 1550 C Conveyor Feeding Asphalt Paver 1550 C Paver Operation Manual Rev 1 3 MAULDIN CALDER BROTHERS CORPORATION LIMITED PRODUCT WARRANTY Calder Brothers Corporation warrants that the Paver under this program will be free from defects in material and workmanship for a period of 12 tw elve months from date of installation Written notice of any claimed defect must be given to Ca Ider Brothers Corporation within the warranty period and within 30 thirty days a fter such defect is discovered Liability under this warranty is limited to replacing or repairing at Calder Brothers Corporation s election any part or parts deemed defective after examinati on by Calder Brothers Corporat ion or an Authorized Service Representative Any paveror of its parts returned by customer to Calder Brothers Corporation or an Authorized Se r
11. Y THIRD PARTY OR FOR OTHER DIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES Calder Brothers Corporation Page 21 Model 1550 C Conveyor Feeding Asphalt Paver 1550 C Paver Operation Manual Rev 1 3 Notes MAULDIN BY CALDER BROTHERS PAVER OPERATION MANUAL Model 1550 D
12. ation Driveline mechanical failure 2 Vehicle moves in neutral Steering levers are actually engaged Steering calibration adjustment required must be performed by authorized MAULDIN service technician For detailed troubleshooting information on hydrostatic transmission refer to Trouble Shooting Manual Rexroth Hydrostatic Transmissions available from a Rexroth representative or dealer C Electrical System Less than 13 5 or more Alternator or Regulator Running than 14 Volts Malfunction Contact Dealer Won t WontStat o 12 125 DIRE Nos Weak Weak battery ag o Won t Start Less than 12 Volts a elio Charge or Replace Stopped Short Circuit Inspect System D Hydraulic System Thoroughly review description of hydraulic system Use logical steps to determine cause of malfunction Identify the function or functions that require troubleshooting If possible trace malfunction to source pump control motor or cylinder Determine pressure operating the function as specified Calder Brothers Corporation Model 1550 C Conveyor Feeding Asphalt Paver Hydraulic System Pressures Priority circuit triple gear pump 2 500 2 800 p s i Main circuit Rexroth tandem pump 300 400 p s i Main circuit Rexroth tandem pump up to 4 500 p s i Charge circuit Rexroth tandem pump 300 400 p s i Page 17 1550 C Paver Operation Manual Rev 1 3 Relief Pressure Neutral Position Relief Pressure Worn or Malfunctioning pu
13. begin major work before checking all other possibilities Reconsider all known facts and clues before proceeding to more in depth work Correct the basic cause Remember failure of a certain part may be caused by malfunction of another part or system 2 Use of Schematics The Parts amp Service manual incorporates electrical and hydraulic diagrams formatted for ease of use by maintenance and for the training of personnel 3 Troubleshooting chart The troubleshooting chart lists problems that might be encountered in the operation of the vehicle The remedies listed may direct the repairman to a possible faulty component WARNING THE TROUBLESHOOTING CHART AND PROCEDURES OUTLINED IN THIS SECTION SHOULD NOT BE ATTEMPTED BY OTHER THAN EXPERIENCED MECHANICS OR PERSONNEL UNDER THE DIRECT SUPERVISION OF AN EXPERIENCED MECHANIC FAILURE TO COMPLY MAY RESULT IN DAMAGE TO EQUIPMENT AND OR INJURY OR DEATH TO PERSONNEL A Engine For engine troubleshooting see charts indicating faults and recommended repair procedures refer to Manufacturer s Operation and Maintenance Manual If your particular problem is not covered or you are unsure of what steps to take contact your dealer for assistance Calder Brothers Corporation Page 16 Model 1550 C Conveyor Feeding Asphalt Paver 1550 C Paver Operation Manual Rev 1 3 B Transmission 1 Vehicle fails to move under power Inadequate oil level in hydraulic reservoir Damaged wiring loom to steering st
14. ce where there is no possibility of freezing NOTE Check battery every 30 days during storage and return to full charge if necessary Engine and Engine Filters 1 Initial Break In Proper break in procedures are a must to realize maximum engine power output and longest engine life Engine should show noticeable power gain through the first 30 hours service Power gain will continue until approximately 200 hours if properly broken in IMPORTANT Do not operate engine above 3 4 throttle approximately 2100 RPM for the first 25 hours IMPORTANT Use full throttle only for short intervals during the first 25 hours IMPORTANT Do not lug engine during the break in period IMPORTANT Replace the original oil and oil filters after the first 20 hours of operation 2 Fuel Filter Water Separator 1 The fuel filter and water separator is a combined unit PLEASE NOTE it is NOT disposable ii There is also a separate in line fuel pre filter which is disposable CAUTION BOTH DIESEL FUEL AND GASOLINE ARE HIGHLY FLAMMABLE AND EXPLOSIVE UNDER CERTAIN CONDITIONS DO NOT SMOKE OR ALLOW SPARKS OR OPEN FLAME WHEN HANDLING a To Change 1 Stop engine Wait 15 minutes for engine and surrounding parts to cool before proceeding Unscrew and discard fuel and sediment Clean bowl thoroughly and fill cleaned bowl with clean fuel Lightly coat the seal ring with oil then screw on filter separator until seal meets flange Tighten an additional 1 2
15. escape b Adjust regulator to 4 PSI on Freedom IV Screed c Close main screed valve 11 Close the master valve located on the propane tank 12 Verify amp if necessary follow procedure to set screed 13 Perform a machine walk around looking for a Any signs of physical damage b Any signs of a leak fuel engine oil hydraulic oil engine coolant c Welded steel junctions d Hydraulic cylinder pins all secure Calder Brothers Corporation Page 4 Model 1550 D Conveyor Feeding Asphalt Paver 1550 C Paver Operation Manual Rev 1 3 IMPORTANT SAFETY INFORMATION Most accidents involving paver maintenance 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 Read and understand all safety precautions and warnings before operating or performing lubrication and maintenance on this paver WARNING IMPROPER OPERATION LUBRICATION OR MAINTENANCE OF THIS PAVER CAN BE DANGEROUS AND COULD RESULT IN INJURY OR DEATH WARNING DO NOT OPERATE THIS PAVER UNTIL YOU READ AND UNDERSTAND THE INSTRUCTIONS IN THE OPERATION SECTION OF THIS MANUAL 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 WARNING DO NOT OPERATE BURNERS ON SCREED FOR MORE THAN TEN OR FIFTEEN MINUTES AT A TIME SERVICE WARNING General
16. f the screed In either mode the lower selector switch can be set to IN for reverse material flow SETUP AUTOMATIC FEED OPERATION 1 0 2 0 3 0 4 0 5 0 6 0 7 0 Go to the LH operators station Locate the AUTO MAN switch labeled A 27 Set the switch to AUTO Em Locate the CONV amp AUG switches labeled Set the AUG switch to OUT Follow the dotted line and set the CONV switch to the locked setting To control size of the head of material 7 1 1550 D Adjust the control knob to 7 7 2 1500 C Adjust height of switch by end gate Each side of the paver must be set independently MANUAL FEED OPERATION 1 0 2 0 3 0 4 0 5 0 6 0 7 0 Go to the LH operators station Locate the AUTO MAN switch labeled Ti T DR Set the switch to MAN Locate the CONV amp AUG switches labeled Set the AUG switch to OUT 1 Follow the dotted line and set the CONV switch to the locked setting To control size of the head of material set the AUG switch to OUT or OFF as desired Calder Brothers Corporation Page 7 Model 1550 D Conveyor Feeding Asphalt Paver 1550 C Paver Operation Manual Rev 1 3 SCREED HEATING SYSTEM The new Freedom IV Screed has one burner in each extension and two main screed burners The proper way to light the burner system is the following procedure 1 Make sure all shutoff valves are in the off position and ligh
17. in diesel engines can result in serious engine damage due to liner erosion and pitting Refer to the Operator s Manual for information regarding engine coolant antifreeze and change interval recommendations Air Filters LUBRICATION AND SERVICE PROCEDURES IMPORTANT Service the engine air filters only when the need is indicated by the air cleaner service 1 Engine Main Element indicator if equipped or in accordance with the preventative maintenance decal Excessive service will cause premature wear a Unbuckle clips to remove element container end cap b Pull gently to remove main element c Use compressed air with an element cleaning nozzle Calder Brothers Corporation Page 12 Model 1550 C Conveyor Feeding Asphalt Paver 1550 C Paver Operation Manual Rev 1 3 IMPORTANT Main element should be replaced after six cleanings or 500 hours use IMPORTANT Do not attempt to clean element using a standard air nozzle Do not strike element on a hard surface Either action will damage the element 2 Engine Safety Element IMPORTANT Do not remove safety element under heavy dust or blowing conditions in the field Even slight amounts of dust entering the engine can lead to premature wear Inspect safety element for contamination and physical damage IMPORTANT When safety element is dirty it should be replaced Do not attempt to clean Battery CAUTION BATTERY ELECTROLYTE IS A CAUSTIC ACID KEEP IT AWAY FROM SKIN AND EY
18. mp or motor Repair or replace pump or motor No Power or Stuck relief valve cartridge Inadequate Power Repair or replace Low system pressure caused by worn Repair or replace pump pump Air in system due to low level of oil Surging of hydraulic items ging hose etc cavitating pump leaky fittings pinched Correct Removal and Installation of Equipment 1 Preparation WARNING BEFORE PERFORMING INSTALLATION OR REMOVAL PROCEDURES THE FOLLOWING PRECAUTIONS MUST BE ADHERED TO IN ORDER TO PREVENT POSSIBLE DAMAGE TO EQUIPMENT OR INJURY OR DEATH TO PERSONNEL WARNING TURN THE ENGINE OFF BY TURNING THE IGNITION SWITCH TO OFF DISCONNECT THE BATTERY CABLES BEFORE SERVICING THE ENGINE START OR STOP CIRCUITS DISCONNECTING BATTERY NEGATIVE GROUND BEFORE REMOVING OR CONNECTING THE POSITIVE BATTERY CABLE CAN PREVENT SHORT CIRCUITING OF THE BATTERY BY TOOLS Calder Brothers Corporation Model 1550 C Conveyor Feeding Asphalt Paver Page 18 1550 C Paver Operation Manual Rev 1 3 Recommended Preventive Maintenance Intervals INTERVAL ITEM PROCEDURE AFTER FIRST 50 HOURS Change all hydraulic filters Check for hydraulic leaks Change engine oil and filter Check for loose nuts and bolts Check for excessive wear on all working parts Initial Break In Check hydraulic fluid level Check oil level Engine air cleaner system Check for loose bolts Remove asphalt from all working surfaces Daily or 10 ho
19. ommended Preventive Maintenance Intervals es Warranty 10 10 11 11 11 11 12 13 14 14 15 17 18 20 Calder Brothers Corporation Page 3 Model 1550 D Conveyor Feeding Asphalt Paver 1550 C Paver Operation Manual Rev 1 3 oa A C Daily Start up Checklist Check Fluid Levels a Engine Oil b Engine Coolant c Hydraulic Oil d Wash Down fluid With the key switch in the ON position a Check Engine Fuel Level b Turn on wash down pump and verify operation turn off when complete c Verify proper operation of engine gauges or indicator lights Turn Key switch back to OFF position Remove asphalt from all mechanical moving surfaces Remove asphalt from all screed burner heating areas Check Propane Tank level Perform All Propane Testing In A Well Ventilated Area Only FAILURE TO COMPLY MAY RESULT IN DAMAGE TO EQUIPMENT AND OR INJURY OR DEATH TO PERSONNEL 7 Merify that ALL propane valves are in the closed position 8 Pressurize the propane system by opening the master valve located on the propane tank 9 With system pressurized listen for leaks Run hand over all propane fittings to feel for leaks If any leaks are detected DO NOT OPERATE UNTIL THEY ARE REPAIRED 10 Check pressure regulator is set to 4 PSI on Freedom IV Screed a If regulated pressure is too high open main screed valve only allowing gas to
20. ting wand is off 2 Fully extend the extensions 3 Turn on gas at tank and set gauge pressure at 4 p s i 4 Ignite the lighting wand 5 Use the lighting wand to open the flap style burner lighting access door towards the bottom inboard zone of the LEFT HAND screed extension to ignite the burner 6 Turn on the gas to the LEFT HAND extension Repeat step 5 amp 6 for right hand extension N The extension burners will have changed from a hissing noise to a roaring noise confirming ignition 8 After extension burners are ignited position the lighting wand at the opening found on the back side of the LEFT HAND main screed burner 9 Turn on gas to the main screed After ignition of the LEFT HAND main burner quickly reposition the lighting wand and ignite the right hand main burners the same as the left Only use burners for 10 15 minutes at any given time Damage to screed plate will occur WARNING NEVER USE SYSTEM WITHOUT DIRECT CONSTANT SUPERVISION PERSONAL INJURY OR DEATH MAY RESULT WARNING EXCESS GAS ACCUMULATING BEFORE LIGHTING BURNERS MAY CAUSE AN EXPLOSION RESULTING IN PERSONAL INJURY OR DEATH MAULDIN Model Freedom 14 Main Screed Setup PAVING PRODUCTS Date 11 07 12 Calder Brothers Corporation Page 1 of 2 Initial Screed Adjustment Settings EXTENSION TURNBUCKLE LOCK BOLT SEE NOTE 1 INITIAL SETTING DIMENSION CHECK TO MAKE SURE THERE ARE NO GAPS ALONG THESE EDGES LOCATIONS FOR STRIN
21. uplings frame etc Leaks cracks and loose electrical and fluid fittings Malfunctioning indicators or controls Worn or damaged tires Cleanliness Conveyor System SN Conveyor drive system should be inspected annually Check for worn sprockets and chain Check keys and keyways for wear Replace keys if needed Tighten large conveyor chains with slack adjustors mounted to the underside of the conveyor Tighten until the chains pull up to within 7 8 of the underside of the conveyor deck Measurement should be made from the peak of the arc in the chains Do not over tighten Calder Brothers Corporation Page 15 Model 1550 C Conveyor Feeding Asphalt Paver 1550 C Paver Operation Manual Rev 1 3 TROUBLESHOOTING 1 General Proper troubleshooting begins with an organized approach to the problem at hand Begin with investigation of the most probable cause following the guidelines below Study the problem thoroughly before taking action Did warning signs precede the problem If so what were they What would they indicate Is scheduled maintenance current on all parts and systems involved Has similar trouble occurred before What action was taken at that time Can engine be operated without further damage CAUTION IF RUNNING INSPECTION MUST BE MADE GET ASSISTANCE OPERATOR SHOULD REMAIN ON PAVER THROUGHOUT INSPECTION MAKE SURE TRANSMISSION IS IN NEUTRAL POSITION Check the most convenient things first Don t
22. urs AII 10 hour items All bearings Tires tire units only Track system tension etc AII linkages 50 hours All 50 hour items Engine air cleaner Engine crankcase Engine oil filter Fuel tank Hydraulic return filter 250 hours Tighten as necessary Add as necessary Add as necessary Check service indicator and inspect Tighten as necessary Spray down with approved release agent and clean off As above Grease Visual Inspection Adjust if necessary Grease As above Replace element Drain and refill Replace Drain water and sediment Replace 500 hours All 250 hour items As above Fuel filters Replace All 500 hour items Hydraulic system Engine Radiator 1000 hours or yearly As above Drain and refill Adjust valves Clean fins with degreaser Change after first 50 hours service every 250 thereafter and replace with BP Energol HVI 46 or equal hydraulic fluid Calder Brothers Corporation Page 19 Model 1550 C Conveyor Feeding Asphalt Paver 1550 C Paver Operation Manual Rev 1 3 A copy of this schedule is attached to the paver in the form of a decal It can be seen to the right PREVENTATIVE MAINTENANCE GUIDE MAULDIN ITEM ACTION INTERVAL Be sure to follow the Hour interval recommendations CLEANER ET S whenever the paver is equipped with an engine hour CHANGE 12 MONTHS OR 200 HOURS meter Time intervals are considered not to exceed IN DUSTY AREA CHANGE 2 MONTHS OR 75 HOU
23. vice Representative via prepaid transportation and which is found to be defective will be repaired or replaced and returned to the customer via prepaid surface transportation within the continental United States Should any part be found not defective Calder Brothers Corporation or an Au thorized Service Representative may charge inspection and handling to the customer EXCLUSIONS This warranty does not apply to routine wearable parts of the Mauldin paver such as seals points plugs hoses or similar items This warranty does not extend to any paver or part replaced or repaired under this warranty This warranty does not cover any repair or replacement labor of any part or parts found defective after examination by Calder Brothers Corpor ation or an Authorized Service Representative This warranty does not apply to defects caused by casualty or unreasonable use including faulty repairs by others and failure to provide reasonable and necessary maintenance THIS WARRANTY SET FORTH HEREIN IS IN LIEU OF AND EXCLUDES ANY AND ALL OTHER WARRANTIES EXPRESSED OR IMPLIED ARISING BY OPERATION OF LAW OR OTHERWISE INCLUDING BUT NOT Ll MITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND CUSTOMER WAIVES ANY OBLIGATION OF LIABILITY OF CALDER BROTHERS CORPORATION ARISING IN TORT OR STRICT LIABILI TY INTORT OR FOR LOSS OR USE REVENUE OR PROFIT WITH RESPECT TO MAULDIN PAVER AND OR PARTS FOR ANY LIABILTIY OF CUSTOMER TO AN
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