Mauldin M415XT MAINTAINER Manual Download

Page: 36 / 78

2/3/2020

Page 36 of 78

Calder Brothers Corporation

Model: M415XT Maintainer

M415XT

Section G - Troubleshooting

PROBLEM

CAUSE

REMEDY

Two-Speed Not Working Properly

Electric switch inoperative.
Electric solenoid inoperative.
Low or no voltage to switch (wiring

short).
Electrically activated control valve

inoperative.

Consult an authorized Service Dealer.

Drive System Sluggish With Low

Power

Low hydraulic fluid.
Restricted transmission pump

suction screen.
Pump controller or linkage needs

adjustment.
Plugged pump orifice.
Low transmission pump charge

pressure.
Hydraulic motor failure.

Fill to proper level.

Clean or replace.

Adjust.

Consult an authorized Service Dealer.

Brakes Engaging Prematurely or

When Slowing Machine Down

Excessive worn drive motor causing

loss of charge pressure.
Excessive worn drive pump.
Brake malfunction.

Consult an authorized Service Dealer.

Consult an authorized Service Dealer.
Consult an authorized Service Dealer.

Summary of Contents for M415XT MAINTAINER

Page 1: ...M415XT MAINTAINER OWNER OPERATOR M415XT Maintainer Serial Number M415XT Maintainer Specification Number Sold Serviced by...

Page 2: ......

Page 3: ...ges 13 Section C Controls Accessories Pages 17 Section D Operations Pages 25 Section E Fuels Lubrication Pages 31 Section F Transportation Theft Deterrents Pages 37 Section H Service Trouble Shooting...

Page 4: ...when designing our machinery and we guard exposed moving parts for the operator s protection However some areas can NOT be guarded or shielded in order to assure proper operation Therefore this Opera...

Page 5: ...and work applications for the machine and operate it at speeds slow enough to insure complete control at all times When working on slopes or near drop offs use good judgment ONLY operators with suffic...

Page 6: ...Brake BEFORE leaving the Operator s Station Do NOT refill the Fuel Tank when the Engine is hot Allow Engine to cool down BEFORE refilling A hot Engine can ignite the fuel if it should spill or splash...

Page 7: ...OPS in accordance with industry standards It is intended to offer protection to the operator from roll over and falling objects but cannot protect against every possible impact Therefore it should not...

Page 8: ...oration Model M415XT Maintainer M415XT Section A Safety Part 100A3706 A Located on either side of platform Part 165924 Located either side of the radiator Part 065927 Located at various places on the...

Page 9: ...2 3 2020 Page 9 of 78 Calder Brothers Corporation Model M415XT Maintainer M415XT Section A Safety Part 108787 Located beside operator s seat on seat deck Part 108785 Located at each wheel...

Page 10: ...ty Equipment Neutral Start Safety Switch Backup Alarm noise level 84 dba w cab Seat Belt SAE ROPS Certified Neutral Safety Start Switch Loader Boom Safety Prop Moldboard Dimensions Width G 120 3 66m H...

Page 11: ...not start unless the Speed Control Pedal is in neutral NOTE If equipped in cold weather conditions 40 F and below push grid heater button and hold for 20 to 40 seconds then start while holding button...

Page 12: ...y burn the skin Wait for the engine to cool BEFORE relieving the pressure and removing the Radiator Cap Hourmeter The Hourmeter indicates the operating time of the machine and should be used to keep a...

Page 13: ...Pull out the Dipstick and wipe off Re insert and pull out to read engine oil level Radiator Level The Fill Cap is located on the top rear of the Engine Hood CAUTION this Cap is pressurized Battery Fl...

Page 14: ...ed mode There are 3 Travel modes to choose from CREEP has the lowest speed setting WORK Mode is the middle setting allowing for a slightly high speed limit TRAVEL mode is the highest speed setting TRA...

Page 15: ...machine could move or roll and cause death or serious injury to operator or bystanders Operator Mode Selector The M415XT has 2 Operator Modes One mode to operate the Boom Bucket and Scarifier impleme...

Page 16: ...ht Left Blade Lift Pull the Joystick directly BACK Y Axis to lift the Blade evenly Push the Joystick FORWARD Y Axis to lower blade evenly If you PUSH the Joystick directly RIGHT X Axis the Right Side...

Page 17: ...Inspect the work area Make sure you know where you will be grading and making turns Look over the terrain of the job site for holes obstacles slopes slippery surfaces and soft or deep mud If the machi...

Page 18: ...mendations set forth in the Section A Safety of this manual Know how to STOP the machine before starting it 1 Make sure the floor of the operator s station and the foot controls are free of debris and...

Page 19: ...ravel Work positions 8 Release the Park Brake 9 Move the machine FORWARD by depressing either Direction Speed Control Pedal to the forward position REVERSE the machine by depressing either Pedal to th...

Page 20: ...d be done in low CREEP or WORK speed TRAVEL speed should be used for moving the machine from place to place 1 When ditching or sloping you may find it necessary to raise and or lower one or both ends...

Page 21: ...grading or backfilling application should determine the best choice for using hydraulic equipment and attachments on the machine Back Blading with the Bucket 1 To back blade loose material in front of...

Page 22: ...the ground BEFORE turning End of Work Session 1 Always check the hydraulic fluid level at operating temperature preferably at the end of the work day Park on a level surface and stop the Engine accor...

Page 23: ...e Engine when filling the Fuel Tank ALWAYS ground the fuel nozzle against the filler neck to avoid sparks NEVER fuel the machine when smoking or near a fire or open flame Avoid spilling fuel If a spil...

Page 24: ...uivalent Greasing Wipe dirt from the Fittings before greasing them to prevent the dirt from being forced into the Bearings of the pivot joints Replace any missing or damaged fittings when necessary To...

Page 25: ...2 3 2020 Page 25 of 78 Calder Brothers Corporation Model M415XT Maintainer M415XT Section E Fuels Lubrication Tool Bar Assembly 6 Grease Zerks Z...

Page 26: ...2 3 2020 Page 26 of 78 Calder Brothers Corporation Model M415XT Maintainer M415XT Section E Fuels Lubrication Front Axle Frame Assembly 3 Grease Zerks Z...

Page 27: ...2 3 2020 Page 27 of 78 Calder Brothers Corporation Model M415XT Maintainer M415XT Section E Fuels Lubrication Moldboard Assembly 25 Grease Zerks Z...

Page 28: ...ramps MUST be firmly attached to the truck or trailer bed with NO step between the bed and the ramps 3 Incline of ramps MUST be less than 15 ramp length MUST be at least 16 feet long 4 Ramp width MUS...

Page 29: ...grease to prevent rusting 5 Cover Exhaust Pipe to prevent entrance of water When transporting the machine know the overall height to allow clearance of obstructions Remove or tape over the slow moving...

Page 30: ...from unattended machines 2 Attach secure and lock all anti vandalism and anti theft devices on the machine 3 Lock doors of cabs when NOT in use 4 Inspect the gates and fences of the vehicle storage y...

Page 31: ...Tighten connections charge or replace battery Add fuel Open valve Clean cap Replace Replace Refer to Engine Manual Refer to Engine Manual Hard Starting Refer to Engine Manual for complete list See Ca...

Page 32: ...efer to Engine Manual for complete list Inoperative or missing thermostat Refer to Engine Manual Engine Knocks Refer to Engine Manual for complete list Loss of Lube oil or internal damage Shut down Re...

Page 33: ...noperative Engine Starter Solenoid inoperative Low battery voltage Check for proper voltage 12 VDC Check for proper voltage 12 VDC Adjust or replace Refer to Engine Manual Charge battery Unit Will Not...

Page 34: ...fluid level Suction hose fittings leaking pump cavitations Fill to proper level Tighten connections replace damaged hose Hydraulic Cylinders Operating Slow or Will Not Move Low hydraulic fluid level...

Page 35: ...Consult an authorized Service Dealer Transmission Pump Noisy Low hydraulic fluid level Transmission pump filter restricted Drive plate Drive link assembly loose Internal pump problems Fill to proper l...

Page 36: ...Drive System Sluggish With Low Power Low hydraulic fluid Restricted transmission pump suction screen Pump controller or linkage needs adjustment Plugged pump orifice Low transmission pump charge pres...

Page 37: ...ith battery acid Wear a helmet or goggles with special lenses when you weld or cut with a torch When working beneath a raised machine always use blocks jack stands or other rigid and stable supports A...

Page 38: ...en when the machine is unattended Keep bystanders away if access doors are open OPERATORS SERVICING DUTIES NOTE Some of the operator related services will require access to components located inside v...

Page 39: ...ep flames or sparks away from the Battery area Make sure Battery is charged in a well ventilated area NEVER lay a metal object on top of a Battery A short circuit can result Battery acid is harmful to...

Page 40: ...semble as follows 1 Remove empty and wipe out the Air Intake Bowl Pre cleaner 2 Loosen the Clamp ring and remove the End Cap Remove the Dust Cup Wipe the End Cap and Cup completely clean Reassemble th...

Page 41: ...Apply a thin coat of clean oil to the new oil filter gasket Spin tighten Refill the crankcase with new oil Follow specifications for type and viscosity of the replacement oil See Section E Fuels and...

Page 42: ...on The hydraulic fluid should be replaced every 500 hours every season or sooner if fluid becomes contaminated Stop the Engine and lower all attachments Drain the Reservoir Fill the Reservoir with app...

Page 43: ...yte solution is up to the proper level In addition place a clean cloth over the uncapped filler holes to prevent the electrolyte solution from boiling over CAUTION If acid comes in contact with your s...

Page 44: ...oothly have the second person shut the jumper vehicle OFF Next that person should remove the Jumper Cables from the jumper vehicle Battery and then from the machine while making sure NOT to short the...

Page 45: ...Service 3 Check Radiator Cooling System Refer to Section H Service 4 Check Hydraulic Oil Tank Level Refer to Section H Service 5 Check Hydraulic System for leaks Refer to Section H Service 6 Check Fu...

Page 46: ...40 HOURS or WEEKLY COMPONENT SERVICE REQUIRED PROCEDURE SECTION TOPIC REFERENCE 1 Check Battery Fluid Level and Connections 2 Check Fan Belt Tension Wear 3 Check Tire pressure 4 Check Wheel Nuts Refe...

Page 47: ...D PROCEDURE SECTION TOPIC REFERENCE 1 Change Engine Oil and Filter 2 Inspect Clean Air Cleaner Element 3 Replace Fuel Filters 4 Check Fluid in Power Wheel Hubs 5 Check Cylinder Attach Bolts Pin Setscr...

Page 48: ...Refer to Section H Service Refer to Section H Service DATE SERVICE IS COMPLETED MAINTENANCE LOG SERVICE AS REQUIRED COMPONENT SERVICE REQUIRED PROCEDURE SECTION TOPIC REFERENCE 1 Change Hydraulic Flu...

Page 49: ...ne inside where it will remain dry If it MUST be stored outside park it on lumber laid on flat level ground or on a concrete slab and cover the machine with a tarp DURING STORAGE 1 About once each mon...

Page 50: ...wiring connector coil faults Replace coil s Paramaters incorrect Check parameters in BODAS Service Blade Lift Left DSD Error 0x8003 coil currents incorrect function disabled Check wiring connector co...

Page 51: ...disabled Check wiring connector coil faults Replace coil s Paramaters incorrect Check parameters in BODAS Service Blade Rotation A Coil Error 0x800A coil disconnected function disabled Check wiring c...

Page 52: ...Error 0x8010 coil disconnected function disabled Check wiring connector Wiring issues loose connection Replace coil Current draw too high as a coil with a different resistance is used possible at low...

Page 53: ...rvice Coil damaged Check coil parameters in BODAS service Bucket B Coil Error 0x8016 coil disconnected function disabled Check wiring connector Wiring issues loose connection Replace coil Current draw...

Page 54: ...between display and controller Error between Display and Controller modes Make sure termination resistors are used Can Rx Data HMI 2 Error 0x801F CAN channel error Will not be able to change AUX Chec...

Page 55: ...rror between Display and Controller Will not be able to send driver acknowledge command to controller Make sure termination resistors are used Will not be able to float boom Will not be able to float...

Page 56: ...nel error Unable to view engine def level Check harness between display and controller Error between Display and Controller Unable to view steering mode Make sure termination resistors are used Unable...

Page 57: ...tus Blade float status Scarifier float status Engine speed override Skip intro screens Aux solenoid error Scarifier solenoid error Boom solenoid error Blade tilt solenoid error Blade rotation error so...

Page 58: ...er Angle Error 0x8030 Sensor damaged Unable to change steering mode Check sensor Wire harness issue Replace sensor if needed Check wiring harness Inertial Sensor Error 0x8031 Sensor damaged Bucket lev...

Page 59: ...x8038 Joystick damaged Machine implement functionality disabled Check joystick CAN communication error Replace if necessary Wiring harness damaged Check wiring harness Ensure termination resistors use...

Page 60: ...cessary Connection issue Check connection Pressure Sensor Pump 2 Ma Error 0x8047 Pump pressure sensor error ePOR disabled Check sensor Sensor damaged eEP disabled Check wiring harness Wiring issue pum...

Page 61: ...connector Wiring issues loose connection Replace coil Current draw too high as a coil with a different resistance is used possible at lower temperatures Coil damaged Pump 2A Angle Error 0x8053 Not Use...

Page 62: ...onnected Function Disabled Check wiring connector Wiring issues loose connection Replace coil Current draw too high as a coil with a different resistance is used possible at lower temperatures Coil da...

Page 63: ...ure sensors pump goes intp ET mode check pump angle sensors check wiring harness eEP Logic Left Tracking Lost 0x8066 difference between pump desired angle and actual angle exceeds 15 eEP disabled chec...

Page 64: ...rness wiring harness issue Righ Angle snsr param out of 0x806E angle sensor parameters out of range eEP disabled check parameters in BODAS service rng pump goes intp ET mode Righ Angle snsr input out...

Page 65: ...ut of rng 0x8078 incorrect parameter eEP disabled Check parameters in BODAS service pump goes intp ET mode Right Pres Prop input out of rng 0x8079 sensor input out of range eEP disabled check sensor i...

Page 66: ...pressure sensors Pump operates in ET mode CAN 1 Error 0x8082 CAN channel disconnected BODAS Service disabled Check wiring No termination resistance Add termination resistor Wiring issue CAN 2 Error 0x...

Page 67: ...amaged Rear Motor LS 0x808A coil disconnected Functionality disabled Check wiring connector Wiring issues loose connection Replace coil Current draw too high as a coil with a different resistance is u...

Page 68: ...ow side too high Torque mode disabled Check pump coil wiring Coil disconnected ePOR disabled Check coils Coil damaged Pump goes into ET mode Check if pump is damaged Pump damaged Check wiring harness...

Page 69: ...n Authorized Service Representative EXCLUSIONS This warranty does not apply to routine wearable parts of the Mauldin machine such as seals points plugs hoses or similar items This warranty does not ex...

Page 70: ...entrusted to people who do this work It is therefore important that the people assigned to such work receive detailed information about restoring the correct conditions that guarantee operation of the...

Page 71: ...t be organized and held by authorized personnel Repair work must only be done after having read and completely understood all what is written in the instruction Manual as regards to repairs Before doi...

Page 72: ...e recommend Shell Donax TD Brake oil Use only Agip ATF II D mineral oil or alternatively ATF Dexron II oil for the braking system Grease We recommend using Shell Retinax HDX2 grease The maintenance in...

Page 73: ...stallation instruction card of the 128 axle series Filling the rigid axle For the filling oil instruction see the first time installation card of the 128 axle series Filling the steering axle For the...

Page 74: ...cation 2 Lubricant is dirty 3 Wrong lubricant or with impoverished additives 4 Pinion bearings are worn causing incorrect axial clearance of the pinion and contact between pinion and gear Replace the...

Page 75: ...arance Replace the flange Check that the grooving of the pinion is not excessively worn Replace the bevel gear if necessary Beam The axle s lateral beam is damaged 1 Vehicle overloaded 2 Vehicle invol...

Page 76: ...much clearance between the gear and pinion 2 Pinion and gear are worn 3 The pinion bearings are worn 4 Pinion bearings with clearance 5 Differential bearings are worn 6 Differential bearings with cle...

Page 77: ...usually heard when idling even if not very loud Incorrect clearance etween pinion and gear the oise heard when decelerating sappears as speed increases Pinion or inlet flange s ooved coupling is worn...

Page 78: ...y remove the dirt from each single piece throwing away all those parts that due to their nature when assembling have to be replaced with others in perfect condition gaskets seals worn bearings screws...

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