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.