Falcon RME Series Operating instructions

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FALCON RME
DIESEL ASPHALT HOT PATCHERS
OPERATION, PARTS AND REPAIR MANUAL
FALCON ROAD MAINTENANCE EQUIPMENT, INC.
2600 W Salzburg Rd
FREELAND, MI 48623
Phone [phone]
Fax [phone]
www.falconrme.com

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TABLE OF CONTENTS
MATERIAL SAFETY DATA SHEETS CAN BE FOUND IN THE
"RESOURCES" SECTION OF THE WEBSITE WWW.FALCONRME.COM
Safety Alert Symbols and Signal Words ........................................... 5
Operator Warnings (Read before using equipment) ... 6
General Trailer Safety Information ..................................................... 11
Reporting Safety Defects .................................................................11
Major Hazards
Driving Too Fast ................................................................... 12
Failure to Adjust Handling While Towing a Trailer ................ 12
Trailer Not Properly Coupled to the Hitch ............................. 13
Incorrect Use of Breakaway Brake ........................................ 14
Mismatch of Trailer and Hitch ................................................ 15
Unsafe Tires, Lug Nuts or Wheels ........................................ 15
Do Not Exceed GVWR .......................................................... 17
No Riders .............................................................................. 17
Keep Flammable Liquids Away From Trailer ....................... 17
Check Electrical Components ................................................ 18
Hazards From Modifying Your Trailer ................................... 18
Axle Bolts, Frame, Suspension and Structure ..................... 18
Lug Nuts (Bolts) .................................................................... 19
Wheel Rims ........................................................................... 19
Falcon RME Asphalt Hot Patcher Limited Warranty ........................ 20
Inspection, Service and Preparation BEFORE EACH USE ............. 21
Inspection, Service and Preparation TWO TIMES PER MONTH ...... 22
Inspection, Service and Preparation MONTHLY .............................. 22
Inspection, Service and Preparation EVERY THREE MONTHS ...... 23
Inspection, Service and Preparation EVERY SIX MONTHS ............ 23
Inspection, Service and Preparation EVERY 12 MONTHS .............. 23
Lubrication Schedule ......................................................................... 24
Recommended Fluid Maintenance Schedule .................................... 25
Attaching Patcher to Tow Vehicle ...................................................... 26

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TABLE OF CONTENTS
(CONTINUED)
Loading Slip-in Patcher into Tow Vehicle .......................................... 27
Filling Hopper and Loading Door Instructions .................................. 28
Operation of Manual Material Metering Door ..................................... 30
Operation of Hydraulic Material Metering Door .................................. 31
Starting the Main Hopper Diesel Burner and ................................ 32
Setting the Temperature Controller
TROUBLESHOOTING THE BECKETT BURNER
Dump Box Operating Instructions ...................................................... 37
Lowering Dump Box Instructions ....................................................... 39
Patcher Shutdown ............................................................................ 40
Keeping Hot Mix Overnight ..................................................... 40
Replacement Parts and Numbers ...................... 42
Non-Heated Tack Tank Instructions ................................................... 44
Heated Tack Tank Operation .............................................................. 45
Tack Tank Spray System Operation ................................................... 47
Flush Spray System Procedure .......................................................... 49
Refilling Tack Tank ........................................................................... 49
Two-Burner Recycling Option Instructions ........................................ 50
Battery Charging Instructions ........................................................... 52
Electric Overnight Heat Option Instructions ....................................... 53
Manual Hoist Option Instructions ....................................................... 54
Diesel Fuel Pre-Heater Option Instructions ....................................... 55
Wiring Color Code ............................................................................. 56

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TABLE OF CONTENTS
(CONTINUED)
Tire Safety Information ....................................................................... 57
"Before You Begin" Instructions Summarized ............................. 67
Beckett Burner Manual ..................................................................... 74
Beckett Burner Parts ........................................................................ 87
Beckett Burner Primary Controller ...................................................... 88
Omega Temperature Controller .......................................................... 90
Beckett Burner Relay Wiring ............................................................... 91
Electric Breakaway Instructions .......................................................... 92
Dump Box Hydraulic Pump Parts Breakdown .................................... 93
MATERIAL SAFETY DATA SHEETS CAN BE FOUND IN THE "RESOURCES" SECTION OF THE
WEBSITE WWW.FALCONRME.COM

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Danger
Warning
Caution
Notice
SAFETY ALERT SYMBOLS AND SIGNAL WORDS
This manual references the words DANGER, WARNING, CAUTION and NOTICE. The level of risk
is indicated by the following signal words. Do not attempt to use the asphalt hot patcher until
reading and understanding the safety and operational considerations of the equipment.
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DANGER -Immediate hazards which WILL result in
severe personal injury or death if the warning is
ignored.
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WARNING -- Hazards or unsafe practices which
COULD result in severe personal injury or death if
the warning is ignored.
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CAUTION -- Hazards or unsafe practices which
could result in minor or moderate injury if the
warning is ignored.
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NOTICE -- Practices that could result in damage to
the trailer or other property.

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OPERATOR WARNINGS
WARNING INSTRUCTIONS ARE SUMMARIZED BELOW AND APPEAR THROUGHOUT THE
MANUAL WHERE APPLICABLE. DO NOT USE THE ASPHALT HOT PATCHER UNTIL YOU
HAVE READ AND UNDERSTOOD ALL THE SAFETY INFORMATION CONTAINED IN THIS
DOCUMENT.
SHOULD ANY SAFETY OR WARNING DECALS BECOME UNREADABLE, NOTIFY FALCON
at [phone] AND REPLACEMENTS WILL BE PROVIDED AT NO CHARGE.
General Warnings
DANGER: NEVER USE FLAMMABLE MATERIAL IN OR NEAR THE HOPPER. DOING SO
MAY CAUSE SERIOUS INJURY.
DANGER: THE DIESEL BURNER SHOULD ONLY BE SERVICED BY AN AUTHORIZED
SERVICE PERSON. SERIOUS INJURY OR DEATH COULD RESULT FROM IMPROPER
SERVICING OF THE DIESEL BURNER.
DANGER: TO AVOID INJURY OR DEATH WHEN USING THE ASPHALT HOT PATCHER,
STAND BACK WHEN ASPHALT IS FLOWING OUT THE MATERIAL DOOR OF A TILTED
HOPPER (i.e. DUMP BOX TRAILER or SLIP-IN PATCHER MOUNTED ON DUMP TRUCK
BED).
DANGER: RAISE JACK BEFORE MOVING TRAILER. FAILURE TO RAISE THE JACK CAN
CAUSE THE TRAILER TO FLIP AND CAUSE SERIOUS INJURIES.
DANGER: NEVER ATTEMPT TO SERVICE THE HOT PATCHER WHEN OIL OR
COMPONENTS ARE NOT COLD OR SERIOUS INJURY COULD OCCUR.
DANGER: ALWAYS USE SAFETY CHAINS AND CONFIRM PROPER COUPLING OF TRAILER
TO TOWING VEHICLE BEFORE MOVING AN ASPHALT TRAILER.
DANGER: FAILURE TO USE LOCKING PINS LOCATED ON SIDEWALLS OF HOPPER TO
HOLD MANUALLY OPERATED LOADING DOORS OPEN COULD CAUSE DOORS TO CLOSE
ON THE OPERATOR CAUSING SERIOUS INJURY.
DANGER: ENSURE THAT ALL EQUIPMENT IS SECURED TO THE PATCHER BEFORE
MOVING OR SERIOUS INJURY AND OR DEATH COULD RESULT.
DANGER: DO NOT ALLOW THE DIESEL BURNER(S) TO RUN IN AN AREA THAT IS NOT
WELL-VETILATED.
DANGER: TO PREVENT ACCIDENTAL MOVEMENT OF TRAILER WHEN UNHOOKED FROM
TOW VEHICLE, ALWAYS USE WHEEL CHOCKS AND STORE ON A FLAT SURFACE.

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OPERATOR WARNINGS
(GENERAL WARNINGS CONTINUED)
DANGER: SECURE ALL EQUIPMENT TO THE HOT PATCHER BEFORE MOVING OR
SERIOUS INJURY COULD BE CAUSED BY EQUIPMENT FALLING OFF THE PATCHER.
WARNING: WHEN PLUGGING IN 24-HOUR TIMER OR BATTERY CHARGER TO BUILDING
POWER, ENSURE THAT A 120VAC GROUND FAULT CIRCUIT INTERRUPT OUTLET IS
USED. USE A HEAVY-DUTY UL APPROVED EXTENSION CORD AND PLUG EXTENSION
CORD INTO ASPHALT HOT PATCHER BEFORE CONNECTING TO GROUND FAULT
BUILDING POWER OUTLET.
WARNING: ONLY CHANGE TRANSFER OIL IN TACK TANK, OIL-JACKETED HOPPER AND
50/550 THERMOMETERS WHEN OIL IS COLD.
WARNING: DO NOT RAISE OR LOWER MATERIAL LOADING DOORS UNLESS LOADING
DOOR HANDLES ARE FULLY EXTENDED OR INJURY COULD OCCUR.
WARNING: REWIRING THE PATCHER IMPROPERLY MAY CAUSE COMPONENT FAILURE.
CAUTION: STANDING TOO CLOSE TO THE PATCHER WHILE CLOSING THE LOADING
DOORS COULD CAUSE OPERATOR INJURY.
CAUTION: THE SHOVELING PLATFORM OF THE PATCHER IS HOT. BE CAREFUL WHEN
WORKING NEAR THE SHOVELING PLATFORM AND NEVER TOUCH THE PLATFORM
WITHOUT PROTECTIVE GEAR.
CAUTION: FALCON RME RECOMMENDS WEARING PROTECTIVE CLOTHING WHILE
OPERATING OR CLEANING THE ASPHALT HOT PATCHER AND TACK TANK.
CAUTION: NEVER EXCEED THE LOAD LIMIT OF THE HOPPER.
NOTICE: NEVER HANG ON MATERIAL METERING DOOR CROSSBAR.
NOTICE: REWIRING THE PATCHER WITHOUT PRIOR AUTHORIZATION VOIDS THE
WARRANTY.
Dump Trailers
DANGER: NEVER LIFT THE DUMP BOX TRAILER OR SLIP-IN ASPHALT HOT
PATCHER WITHOUT FIRST OPENING THE MATERIAL DOOR TO THE DESIRED
POSITION.
DANGER: NEVER LEAVE THE HOPPER OF A DUMP BOX TRAILER RAISED WHEN
MOVING THE PATCHER.

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OPERATOR WARNINGS
(CONTINUED)
Dump Trailers Continued
WARNING: LEAVING OUTRIGGERS DOWN WHEN THE TRAILER IS MOVING CAN
CAUSE THE TRAILER TO FLIP AND CAUSE SERIOUS INJURIES OR DEATH.
CAUTION: STAND BACK 10 FEET FROM PATCHER ANYTIME THE DUMP BOX
HOPPER IS IN MOTION.
CAUTION: ALWAYS USE THE CYLINDER GUARD (STORED ON THE HINGED SIDE
OF THE HYDRAULIC PUMP STORAGE TOOLBOX) WHEN THE DUMP BOX HOPPER
IS IN THE RAISED POSITION AND REMOVE/REPLACE BEFORE LOWERING.
CAUTION: BEFORE THE DUMP BOX HOPPER IS RAISED, LOWER BOTH
OUTRIGGERS AND INSERT PIN INTO POSITION SUCH THAT THE BASE OF THE
OUTRIGGER IS AS CLOSE TO THE GROUND AS POSSIBLE. SHOULD THE
PATCHER ACCIDENTALLY UNCOUPLE FROM THE TOW VEHICLE, THE
OUTRIGGERS WILL PREVENT THE PATCHER FROM TIPPING BACKWARDS.
CAUTION: NEVER RAISE DUMP BOX WITH TOP DOORS OPEN.
NOTICE: PROTECT THE REMOTE HOPPER CONTROL FROM BEING DAMAGED AT
ALL TIMES. IF CONTROLLER IS EVER DAMAGED, REPAIR OR REPLACE BY AN
AUTHORIZED SERVICE TECHNICIAN. DO NOT ALLOW CONTROLLER CORD TO
GET PINCHED WHEN DUMP BOX LOWERS.
Slip-In Units
DANGER: STAND BACK WHILE CONFIRMING THAT SLIP-IN PATCHER IS SECURED
IN DUMP BOX. IF NOT SECURED PROPERLY, PATCHER COULD FALL OUT AND
CAUSE SERIOUS INJURY OR DEATH.
WARNING: TO AVOID SERIOUS INJURY, ENSURE THAT ONLY TRAINED
PERSONNEL LOAD AND SECURE A SLIP-IN UNIT TO THE TOWING VEHICLE PER
OWNER PROCEDURES.
WARNING: REMOVE ALL ASPHALT FROM PATCHER BEFORE LOADING OR
UNLOADING A SLIP-IN UNIT.
WARNING: ENSURE LOADING/UNLOADING EQUIPMENT (I.E. FORKTRCK) HAS
CAPACITY TO HANDLE THE WEIGHT OF THE PATCHER BEFORE MOVING.

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OPERATOR WARNINGS
(CONTINUED)
Slip-In Units Continued
WARNING: DUE TO THE WEIGHT OF THE SHOVELING APRON, USE FORK TRUCK
TO LIFT AND LOWER ONTO PATCHER OR SERIOUS INJURY COULD OCCUR.
CAUTION: DO NOT ATTEMPT TO TRANSPORT SLIP-IN UNIT WITH A FORK TRUCK
WITHOUT USING FORK POCKETS.
Hydraulic Operated Units
WARNING: PRIOR TO OPENING HYDRAULIC LOADING DOORS, MAKE SURE
THERE IS CLEARANCE ABOVE AND AROUND THE ENTIRE PERIMETER OF THE
PATCHER WHILE LOADING DOORS ARE OPEN/OPENING.
WARNING: TO PREVENT SERIOUS INJURY AND TO PREVENT DAMAGE TO THE
ASPHALT HOT PATCHER AND TOW VEHICLE, IT IS ESSENTIAL THAT A QUALIFIED
HYDRAULICS TECHNICIAN PERFORM HYDRAULIC CONNECTIONS AND
ADJUSTMENTS.
CAUTION: TO AVOID SERIOUS INJURY, DO NOT PUT HANDS NEAR HYDRAULIC
MATERIAL DOOR WHEN LIFTING OR LOWERING.
Tack Tanks
WARNING: ALLOW TACK MATERIAL TO COOL BEFORE REMOVING EXCESS TACK
FROM THE TANK AT THE END OF THE DAY.
CAUTION: NEVER FILL THE TOP CYLINDER OF THE TACK TANK WITH TACK
MATERIAL.
NOTICE: DO NOT SPRAY TACK MATERIAL THROUGH SPRAY SYSTEM UNLESS IT
HAS BEEN DILUTED ACCORDING TO MANUFACTURER'S DIRECTIONS.
INSUFFICIENTLY DILUTED TACK MATERIAL SPRAYED THROUGH THE SPRAY
SYSTEM WILL CAUSE THE SPRAY SYSTEM TO FAIL.
NOTICE: FAILURE TO PERFORM SPRAY SYSTEM FLUSH PROCEDURE AFTER
EACH USE WILL CAUSE THE SPRAY SYSTEM COMPONENTS TO FAIL.

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OPERATOR WARNINGS
(CONTINUED)
Oil Jacketed Tack Tank and/or Hopper
DANGER: THE FACTORY SETTING HIGH TEMPERATURE LIMIT ON THE OIL
CONTROLLER OF AN OIL-JACKETED HOPPER OR TACK TANK IS SET FOR A
MAXIMUM TEMPERATURE OF 275F-290F. NEVER REPROGRAM THIS HIGH
TEMPERATURE LIMIT WITHOUT INSTRUCTION FROM FALCON OR THE OIL MAY
OVERHEAT AND IGNITE CAUSING SERIOUS INJURY OR DEATH.
WARNING: NEVER OVERFILL THE OIL LEVEL IN THE OIL JACKET OF THE HOPPER
OR TACK TANK. CHECK OIL LEVEL BEFORE EACH USE WHEN OIL IS COLD AND
NEVER FILL BEYOND THE FILL LINE IDENTIFIED ON THE DIP STICK.
WARNING: ALWAYS CHECK HEAT TRANSFER OIL LEVEL WHEN EQUIPMENT IS
LEVEL TO AVOID OVERFILLING.
OIL-JACKETED HOPPER HEATING DESIGN
A thermocouple in the oil measures/regulates the oil temperature and a thermocouple in the
material measures/regulates the asphalt material temperature. Each thermocouple is connected to
a separate digital temperature controller but one toggle switch regulates both controllers. The
material temperature controller is set up as a slave to the oil temperature controller. When the
toggle switch is flipped up, both temperature controller displays illuminate. Instructions to set the
temperature can be found on page 32.
When the system determines a need for heat the diesel burner ignites. A "call for heat" can be
issued by either temperature controller when the actual temperature is less than the
set/programmed controller temperature unless the oil temperature is already at its set/programmed
temperature. The reason for this design is to prevent the burner from igniting if the oil is already at
the set temperature. When either the oil set temperature is reached or the material set
temperature is reached, the burner will stop running. A 10-degree temperature drop of either the
oil or hopper contents will result in a "call for heat" which results in the diesel burner igniting.
The factory setting for the oil temperature high limit is between 275F and 290F. The high limit
should never be altered without consultation with the manufacturer. The ideal material
temperature setting is determined by the asphalt material manufacturer/supplier or established by
street crew experience.

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GENERAL TRAILER SAFETY INFORMATION
Loss of control of the trailer or trailer/tow vehicle combination can result in death or serious injury.
The most common causes for loss of control of the trailer are:
•Driving too fast for the weather conditions
•Driving too fast (maximum speed when towing a trailer is 60 mph)
•Overloading the hopper
•Trailer improperly coupled to the hitch
•Inadequate tow vehicle or towing hitch
•No braking on trailer
•Not maintaining proper tire pressure
•Not keeping lug nuts tight and
•Not properly maintaining the trailer structure.
An owner's manual that provides general trailer information cannot cover all of the specific details
necessary for the proper combination of every trailer, tow vehicle and hitch, therefore, you must
read, understand and follow the instructions given by the tow vehicle and trailer hitch
manufacturers, as well as the instructions in this manual.
Reporting Safety Defects
If you believe that your vehicle has a defect that could cause a crash or could cause injury or
death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA)
in addition to notifying Falcon RME at 120 Waldo Ave., Midland, MI 48642 Phone [phone].
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety
defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA
cannot become involved in individual problems between you, your dealer, or Falcon RME.
To contact NHTSA, you may call the Vehicle Safety Hotline toll-free at 1-888-327-4236
(TTY: 1-800-424-9153), go to http://www.safercar.gov; or write to: Administrator, NHTSA, 12 New
Jersey Avenue SE, Washington, DC 20590. You can also obtain other information about motor
vehicle safety from http://www.safercar.gov.

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Warning
MAJOR HAZARDS
Driving Too Fast
With ideal road conditions, the maximum speed when safely towing a trailer is 60 mph. If
you drive too fast, the trailer tires will overheat and possibly blow out. As your speed
increases, you are more likely to suddenly lose control. Never exceed 60 mph while towing
the trailer.
Failure to Adjust Handling While Towing a Trailer
When towing a trailer, you will have decreased acceleration, increased stopping distance,
and increased turning radius (which means you must make wider turns to keep from hitting
curbs, vehicles, and anything else that is on the inside corner). In addition, you will need a
longer distance to pass, due to slower acceleration and increased length.
•Be alert for slippery conditions. You are more likely to be affected by slippery road
surfaces when driving a tow vehicle with a trailer.
•Anticipate the trailer "swaying". Swaying is the trailer's reaction to the air pressure wave
caused by passing trucks and busses. Continued pulling of the trailer provides a
stabilizing force to correct swaying. Do not apply the brakes to correct trailer swaying.
•Check rearview mirrors frequently to observe the trailer and traffic.
•Use Low gear when driving down steep or long grades. Use the engine and transmission
as a brake. Do not ride the brakes, as they can overheat and become ineffective.
•Be aware of your trailer height.
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Driving too fast for conditions can result in loss of control and cause death
or serious injury.
Decrease your speed as road, weather and lighting conditions deteriorate.

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Warning
Warning
Trailer Not Properly Coupled to the Hitch
It is critical that the trailer be securely coupled to the hitch, and that the safety chains are
correctly attached. Uncoupling may result in death or serious injury.
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Proper selection and condition of the coupler and hitch are essential to
safely towing your trailer. A loss of coupling may result in death or
serious injury.
Be sure the hitch load rating is equal to or greater than the load rating of
the coupler.
Be sure the hitch size matches the coupler size.
Observe the hitch for wear, corrosion and cracks before coupling.
Replace worn, corroded or cracked hitch components before coupling the
trailer to the tow vehicle.
Be sure the hitch components are tight before coupling the trailer to the
tow vehicle.
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An improperly coupled trailer can result in death or serious injury.
Do not move the trailer until:
1) The coupler is secured and locked to hitch
2) The safety chains are secured to the tow vehicle; and
3) The trailer jack is fully retracted.
Do not tow the trailer on the road until:
1) Tires and wheels are checked
2) The trailer brakes are checked
3) The breakaway switch is connected to the tow vehicle
4) Everything is secured to the trailer (i.e. tools,
compactor, toolbox closed, electrical enclosure closed, fuel cap on).
5) The trailer lights are connected and checked.

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Warning
Warning
Incorrect Use of Breakaway Brake
Falcon trailers are equipped with a breakaway brake system that can apply the brakes on
your trailer, should your trailer come loose from the hitch for any reason. The safety chains
and breakaway brake system must be in good condition and properly rigged to be effective.
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Improper rigging of the safety chains can result in loss of control of the
trailer and tow vehicle, leading to death or serious injury, if the trailer
uncouples from the tow vehicle.
1) Fasten chains to frame of tow vehicle. Do not fasten chains to any part
of the trailer hitch.
2) Cross chains underneath hitch and couple with enough slack to permit
turning and to hold tongue up should the trailer come loose.
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An ineffective or inoperative breakaway brake system can result in a
runaway trailer, leading to death or serious injury if the coupler or hitch
fails.
The lanyard should be long enough to allow for turning corners, yet short
enough to disengage the pin from the switch before the safety chains on
the hitch become taut in a trailer disconnect situation.
The breakaway cable must be connected to the tow vehicle -- NOT to any
part of the hitch.
Before towing the trailer, test the breakaway brake system. If the
breakaway brake system is not working, do not tow the trailer but have it
serviced or repaired before moving.

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Danger
Warning
Mismatch of Trailer and Hitch
Unsafe Tires, Lug Nuts or Wheels
It is essential to inspect the trailer tires before each use. If the tire has a bald spot, bulge,
cuts, is showing any cords, or is cracked, replace the tire before towing. Tires with
inadequate tread will not provide adequate tracking on wet roadways and can result in loss
of control, leading to death or serious injury.
Improper tire pressure causes an unstable trailer and can result in a tire blowout and loss of
control. Before each tow, you must check the tire pressure. Tire pressure must be checked
when tires are cold. Allow three hours cool-down after driving as much as 1 mile at 40 MPH
before checking tire pressure. NOTE: Tire pressure identified on VIN tag is the tire pressure
at the time the equipment was delivered. Check the pressure rating on the tire to determine
the pressure requirements of the tire in case they have been changed.
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Use of a hitch with a load rating less than the load rating of the trailer can
result in loss of control and may lead to death or serious injury.
Use of a tow vehicle with a towing capacity less than the load rating of the
trailer can result in loss of control, and may lead to death or serious injury.
Be sure your hitch and tow vehicle are rated for the Gross Vehicle Weight
Rating identified on the VIN tag of your trailer.
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Improper tire pressure can result in a blowout and loss of control which
can lead to death or serious injury.
Be sure tires are inflated to pressure indicated on side wall of tire before
towing trailer.

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Warning
Warning
Warning
Lugnuts on trailer wheels are prone to loosen. Before each tow, check to make sure they
are tight.
Lug nuts are also prone to loosen after first being assembled. When driving a new trailer
(or after wheels have been remounted), check to make sure they are tight after the first 10,
25 and 50 miles of driving and before each tow thereafter.
Failure to perform this check could lead to a wheel parting from the trailer and result in a
crash, leading to death or serious injury.
1.2.8 Overload
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Metal creep between the wheel rim and lug nuts will cause rim to loosen
and could result in a wheel coming off, leading to death or serious injury.
Tighten lug nuts before each tow to 100 foot pounds. (See page 19)
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Lug nuts are prone to loosen after initial installation, which can lead to
death or serious injury.
Check lug nuts for tightness on a new trailer or when wheel(s) have been
remounted after the first 10, 25 and 50 miles of driving. Use tightening
pattern shown on page 19.
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Improper lug nut torque can cause a wheel parting from the trailer,
leading to death or serious injury.
Be sure lug nuts are tight before each tow using pattern on page 19.

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Warning
Warning
Warning
Do Not Exceed GVWR
The total weight of the load you put in or on the trailer, plus the empty weight of the trailer
itself, must not exceed the trailer's Gross Vehicle Weight Rating (GVWR). The maximum
load and the GVWR are printed on the VIN tag of the equipment.
No Riders
Keep Flammable Liquids Away from Trailer
Heat generated from the burners of the asphalt hot patcher may ignite a
flammable liquid.
1.2.11 Inoperable Brakes and Lights
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An overloaded trailer can result in loss of control of the trailer, leading to
death or serious injury.
Do not exceed the trailer Gross Vehicle Weight Rating (GVWR).
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A person riding on the hot patcher could fall off leading to death or
serious injury.
Never allow anyone to ride on a moving trailer.
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Heat generated from the burners of the asphalt hot patcher may ignite a
flammable liquid, leading to death or serious injury.
Never clean the hopper or use a flammable liquid near the asphalt hot
patcher.

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Warning
Lug Nuts (Bolts)
Tighten the lug nuts to 100 foot-pounds to prevent wheels from coming loose. Use a torque
wrench to tighten the fasteners. Over-tightening will result in breaking the studs or
permanently deforming the mounting stud holes in the wheels.
Wheel Rims
If the trailer has been struck or impacted on or near the wheels, or if the trailer has struck a
curb, inspect the rims for damage (i.e. being out of round) and replace any damaged wheel.
Inspect the wheels for damage every year, even if no obvious impact has occurred.
FIGURE 1 LUG NUT SEQUENCE OF TIGHTENING
1 1
6 3
4 3 8 7 7
4 5 5
2 5 2
5-BOLT 8-BOLT
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Lug nuts are prone to loosen after initial installation, which can lead to
death or serious injury.
Follow the sequencing diagram in Figure 1 above based on the number of
lug nuts on your axle.
Make three passes through each lug nut -- first at 25 foot pounds, second
at 50 foot pounds and third at 100 foot pounds.

FALCON RME ASPHALT HOT PATCHER LIMITED WARRANTY
Falcon Road Maintenance Equipment, Incorporated (Falcon RME) warrants that the Hot Patcher will be
free from defects in material and workmanship under normal use for a period of one (1) year from the
date of purchase provided that no unauthorized modifications are made to the equipment.
Users of any fuel not meeting manufacturers' published fuel specification requirements
assume warranty liability for failure of components or emissions certification traceable
to the fuel.
Falcon RME will, at its option, repair or replace, any defective part returned to Falcon RME during the
one (1) year warranty period. Defective parts must be returned before credit is issued.
Shipping, and transportation costs, in connection with repair or replacement of defective parts, is the
sole responsibility of the original purchaser.
This limited warranty does not apply, and no warranty, either expressed or implied, shall be applicable
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a) to damages resulting from an accident, normal wear and tear (i.e. tires, nozzle, cad
cell, fuel filters), unauthorized alteration, misuse or abuse,
b) if the product is not operated and maintained according to procedures recommended
by Falcon RME.
In no event shall Falcon RME have any monetary liability to the original purchaser in excess of the price
paid by the original purchaser for the product in question.
This warranty shall extend only to the original purchaser and is non-transferable.
IMPLIED WARRANTIES INCLUDING THAT OF MERCHANTABILITY AND FITNESS FOR
A PARTICULIAR PURPOSE ARE EXPRESSLY LIMITED IN DURATION TO THE
DURATION OF THIS WARRANTY. FALCON RME DISCLAIMS ANY LIABILITY FOR
SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES. Some states/provinces do not
allow limitations on how long an implied warranty lasts, or the exclusion or limitation of special,
incidental or consequential damages so these limitations and exclusions may not apply to the original
purchaser. This warranty gives you specific legal rights. You may also have other rights which vary from
state/province to state/province.
NO DEALER, DISTRIBUTOR OR OTHER REPRESENTATIVE OF FALCON RME IS
AUTHORIZED TO CHANGE THIS WARRANTY IN ANY WAYOR TO GRANT ANY OTHER
WARRANTY.
NOTICE: Falcon equipment is designed to allow diesel burner(s) to run while being towed
without damaging burner components and Falcon equipment is designed to allow diesel burner(s)
to run while dump box hopper is in the up position without damaging burner components.
‘NOTICE: Any and all warning, safety and instructional labels affixed to the machine must not be
removed or covered. Falcon RME agrees to replace warning, safety and instructional labels that
become damaged, free of charge.
December 13, 2005