LeeBoy Rosco Maximizer 4B Guide

Safety and Operations Manual
Maximizer 4B Distributor
This manual applies to
Serial Number 243966
and above.
Manual No. 1027819-SOP
REV A

22
33
44
55
11
SPECIFICATIONS
componentS
operation
maintenance
Thank you for purchasing theRosco Maximizer 4B
Distributor. We wish you many years of safe and efcient
operation of your machine.
READ THIS MANUAL PRIOR TO OPERATING the unit.
This is an important part of the machine and should be
kept in the dedicated storage container at all times.
Though you may be familiar with similar equipment,
you MUST read and understand this manual before
operating this machine to help prevent injury or damage
to the unit. If this manual becomes lost or damaged,
contact your authorized LeeBoy Dealer immediately
to order a replacement (see Contact Information in
Section 2).
This manual is intended as a guide for the safe and
efcient use for proper operation and maintenance
of the machine. This manual contains information that
was available at the time of printing and are subject to
change without notice.
Use this manual along with all related supplemental
books, engine and transmission manuals included
with your machine. Related Service Bulletins should
be reviewed to provide information regarding some of
the recent changes. Contact your authorized LeeBoy
dealer for the latest available information.
LeeBoy is also proud to be an accredited ANAB manufacturer, which is a certication
process comprised of quality standards established by the American National
Standards Institute (ANSI) and the American Society for Quality (ASQ). The ANSI-ASQ
National Accreditation Board plays an important role in ensuring the safety and quality
of goods and services, along with protecting the environment.
LeeBoy is proud to be ISO 9001 certied. The International Standards Organization
(ISO) establishes guidelines to ensure that products and services are safe, reliable,
and of good quality. ISO certies companies who demonstrate compliance with all
aspects of product safety, customer satisfaction, efciency, environmental
stewardship and social responsibility. Our teams work hard to deliver quality
industrial machines that exceed customer expectations and we strive for continuous
improvement in everything we do. The LeeBoy family of companies is committed to
total quality management with a strong focus on meeting customer needs.
Introduction
SAFETY
Contains general and specic safety guidelines
for product and safety label locations.
Contains warranty, contact information, machine
specication tables, and machine dimensions.
Contains overview of major component
locations and functions.
Contains instructions for safe operation and
information for optional equipment.
Contains routine maintenance procedures,
mechanical adjustments, component re-
placement and troubleshooting charts.
Rosco Maximizer 4B Distributor iii

Rosco Maximizer 4B Distributoriv
Legal Notices
Disclaimer
All information, illustrations and specications in this manual are based on the latest information available
at the time of publishing. The illustrations used in this manual are intended as representative reference
views only. Moreover, because of our continuous product improvement policy, we may modify information,
illustrations and/or specications to explain and/or exemplify a product, service or maintenance
improvement. We reserve the right to make any change at any time without notice. ST Engineering
LeeBoy, Inc., dba LeeBoy, (“LeeBoy”), is referred to as LeeBoy throughout this manual.
Title 40, Code of Federal Regulations (CFR) 1068Title 40, Code of Federal Regulations (CFR) 1068
This product meets certied-emission requirements set by the EPA (Environmental Protection Agency),
governed by Title 40 CFR 1068, which species actions that are prohibited by law and lists civil penalties
for noncompliance. As part of those regulations, modication or rendering inoperative any emission-
related component can subject you to government penalties (and void your warranty). Tampering with
emission controls is in violation of federal law, and can result in monetary penalties for each day an engine
or piece of equipment is operated in violation.
Please be aware that you are responsible for maintaining the machine and the certied emission engine
installation. Failure to comply to comply could result in penalties as listed above and void the warranty on
this engine and this machine.
For more information, visit: https://www.epa.gov/laws-regulations/regulations
California Proposition 65 WarningCalifornia Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
Battery posts, terminals and other related accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and other reproductive harm. Wash hands after handling.
2023 LeeBoy2023 LeeBoy
LeeBoy reserves all copyright and other rights in this manual and its content. No part of this manual may
be reproduced or used in any way without the written permission of LeeBoy, except as necessary to
operate LeeBoy equipment.

TABLE OF CONTENTSTABLE OF CONTENTS
Rosco Maximizer 4B Distributor v
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Machine Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Hot Material Precautions. . . . . . . . . . . . . . . . . . . . . . . 1-7
Hydraulic Systems Precautions . . . . . . . . . . . . . . . . . . . 1-7
Burner Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Refueling Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Battery Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . 1-8
Parking Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Poor Visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Storage Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . 1-9
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Safety Decal Locations . . . . . . . . . . . . . . . . . . . . . . . 1-10
Safety Decal Locations . . . . . . . . . . . . . . . . . . . . . . . 1-11
Safety Decal Locations . . . . . . . . . . . . . . . . . . . . . . . 1-12
Safety Decals Care . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Information and Specications . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Two Year Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Specication Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Torque Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Standard Inch Fasteners . . . . . . . . . . . . . . . . . . . . . . . 2-6
Metric Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Determining Proper Torque . . . . . . . . . . . . . . . . . . . . . 2-8

Rosco Maximizer 4B Distributorvi
Table of Contents
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
In-Cab and Rear Controls . . . . . . . . . . . . . . . . . . . . . . 3-3
Circulating System . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Burner System. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Asphalt Spray Bar . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Machine Overview- Left Side . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Machine Overview- Right Side . . . . . . . . . . . . . . . . . . . . . . . 3-6
Pumps, Valves and Lines . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Main Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Rear Fender Controls . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Burner System Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Receiving the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Initial and Daily Inspection . . . . . . . . . . . . . . . . . . . . . . 4-5
Initial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Pre-Operating Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Spray Bar Wing Locking Pins . . . . . . . . . . . . . . . . . . . . 4-7
FLP and PTO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Distributor Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Plus +1® Control System . . . . . . . . . . . . . . . . . . . . . . . 4-8
Rear Fender Controls . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Operational Modes . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
DP700 Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Run Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Memory Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
System Faults Screen . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Mode Selection Screen . . . . . . . . . . . . . . . . . . . . . . . 4-12
Spray / Bar Circulate Screen . . . . . . . . . . . . . . . . . . . . 4-12
Hand Spray / Tank Circulate Screen . . . . . . . . . . . . . . . . . 4-12
Load Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Transfer Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Hand Spray / Unload Screen . . . . . . . . . . . . . . . . . . . . . 4-13
Reverse Suction Screen . . . . . . . . . . . . . . . . . . . . . . . 4-13
Clean-Out Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Rosco Maximizer 4B Distributor vii
Table of Contents
Set-Up Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Totals Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Flow Distance Calibration Screen . . . . . . . . . . . . . . . . . . 4-15
Bar Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Bar Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Calibration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Temperature Set-Point Screen. . . . . . . . . . . . . . . . . . . . 4-17
Hydraulic System Check . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Bar Circulate Screen. . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Hydrostatic System Check . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Automatic Valve System Check. . . . . . . . . . . . . . . . . . . . . . . 4-20
Valve Status and Material Flow . . . . . . . . . . . . . . . . . . . . . . . 4-23
Valves Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Valve Status Symbols . . . . . . . . . . . . . . . . . . . . . . . .4-24
Valve Status in Spray / Bar Circulate (Bar CLCT) Mode . . . . . . . . 4-25
Valve Status in Spray / Bar Circulate (OFF) Mode. . . . . . . . . . . 4-26
Valve Status in Spray / Tank Circulate Mode . . . . . . . . . . . . . 4-27
Valve Status in Tank Circulate Mode . . . . . . . . . . . . . . . . . 4-28
Valve Status in Hand Spray / Bar Circulate Mode. . . . . . . . . . . 4-29
Valve Status in Load Mode . . . . . . . . . . . . . . . . . . . . . . 4-30
Valve Status in Transfer Mode . . . . . . . . . . . . . . . . . . . . 4-31
Valve Status in Hand Spray / Unload Mode . . . . . . . . . . . . . . 4-32
Valve Status in Reverse Suction Mode . . . . . . . . . . . . . . . . 4-33
Valve Status in Clean-Out Mode . . . . . . . . . . . . . . . . . . . 4-34
Material Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Handling Liquid Asphalt . . . . . . . . . . . . . . . . . . . . . . .4-37
Storing Liquid Asphalt . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Asphalt Temperature Guide . . . . . . . . . . . . . . . . . . . . . 4-37
Loading the Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Top Tank Loading . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Bottom Tank Loading . . . . . . . . . . . . . . . . . . . . . . . .4-40
Heating the Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Diesel Burners. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Tank Circulate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Preparing to Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Spray Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47

Rosco Maximizer 4B Distributorviii
Table of Contents
Spray Nozzle Selection . . . . . . . . . . . . . . . . . . . . . . .4-49
Set Spray Bar Width and Height . . . . . . . . . . . . . . . . . . . 4-50
Distributor Calibration . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Spraying the Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Spray Bar Circulate . . . . . . . . . . . . . . . . . . . . . . . . .4-57
Basic Material Spraying . . . . . . . . . . . . . . . . . . . . . . . 4-58
Hand Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
Cleaning the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61
Reverse Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61
Clean-Out Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
EnviroFlush Clean-Out . . . . . . . . . . . . . . . . . . . . . . . . 4-63
Unload or Transfer Asphalt Material . . . . . . . . . . . . . . . . . . . .4-64
Unload Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-64
Transfer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-67
Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
Optional Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
GPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
Extra Toolbox Options . . . . . . . . . . . . . . . . . . . . . . . . 4-68
Full-Width Mud Flap . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
Jacketed Asphalt Pump . . . . . . . . . . . . . . . . . . . . . . . 4-68
LPG Burners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
Overnight Electric Heater . . . . . . . . . . . . . . . . . . . . . .4-72
Spray Down System . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
E-Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
Tank Hand Railing . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Loading Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Electronic Ignition (Diesel Burners). . . . . . . . . . . . . . . . . . 4-74
Remote Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
Back-Up Camera System . . . . . . . . . . . . . . . . . . . . . .4-75
Magnetic Cup Holder . . . . . . . . . . . . . . . . . . . . . . . .4-76
Spray Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76
3-Nozzle Hand Spray Wand . . . . . . . . . . . . . . . . . . . . . 4-76
Outre Burner Control . . . . . . . . . . . . . . . . . . . . . . . . 4-76
Beacon Light . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-77

Rosco Maximizer 4B Distributor ix
Table of Contents
LED Work Light Package. . . . . . . . . . . . . . . . . . . . . . . 4-77
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Routine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Preparing Machine for Maintenance . . . . . . . . . . . . . . . . . 5-4
Every 10 Hours or Daily Routine Maintenance . . . . . . . . . . . . 5-4
Every 50 Hours or Weekly Routine Maintenance . . . . . . . . . . . 5-4
Every 100 Hours or Monthly Routine Maintenance . . . . . . . . . . 5-5
Every 250 Hours or Quarterly Routine Maintenance . . . . . . . . . 5-5
Every 500 Hours or Semi-Annual Routine Maintenance . . . . . . . 5-5
Every 1000 Hours or Annual Routine Maintenance . . . . . . . . . . 5-5
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Asphalt Tank Components . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Tank Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Top Opening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Contents Gauge Packing Gland . . . . . . . . . . . . . . . . . . . 5-8
Asphalt Pump System . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Asphalt Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Asphalt Pump Packing Gland. . . . . . . . . . . . . . . . . . . . . 5-10
Pump Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
Hydraulic Pump/Motor Installation Start-Up Procedure . . . . . . . . 5-11
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Discharge Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Load Line Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Heating Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Diesel Burners. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
LPG Burners (Option) . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Spray Bar System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Check Hydraulic Oil Level and Filter . . . . . . . . . . . . . . . . . 5-18
Change Hydraulic Oil and Filter . . . . . . . . . . . . . . . . . . .5-19
Change the Fill Cap Filter and Clean Hydraulic Tank Strainer . . . . . 5-20
Automatic Valve System . . . . . . . . . . . . . . . . . . . . . . . 5-21
Hydraulic Valve Manifold . . . . . . . . . . . . . . . . . . . . . . . 5-22

Rosco Maximizer 4B Distributorx
Table of Contents
Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Replacing Hose Clamps . . . . . . . . . . . . . . . . . . . . . . . 5-23
Weldment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Winterizing for Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Spray Down Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . 5-27

Section 1Section 1
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Machine Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Hot Material Precautions. . . . . . . . . . . . . . . . . . . . . . . 1-7
Hydraulic Systems Precautions . . . . . . . . . . . . . . . . . . . 1-7
Burner Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Refueling Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Battery Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . 1-8
Parking Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Poor Visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Storage Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . 1-9
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Safety Decal Locations . . . . . . . . . . . . . . . . . . . . . . . 1-10
Safety Decals Care . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
SafetySafety
Rosco Maximizer 4B Distributor 1-1
11

Safety
NOTES
Rosco Maximizer 4B Distributor1-2

Safety
LOOK FOR THESE SYMBOLS THROUGHOUT
THIS MANUAL. THESE SAFETY NOTICES
ARE EXTREMELY IMPORTANT. READ AND
UNDERSTAND THOROUGHLY. HEED THE
WARNINGS AND FOLLOW THE INSTRUCTIONS.
Indicates a hazardous situation which,
if not avoided, will result in death or serious injury.
Indicates a hazardous situation which,
if not avoided, could result in death or serious injury.
Indicates a hazardous situation which,
if not avoided, could result in minor or moderate
injury.
Indicates a situation which can cause
damage to the equipment, personal property and/
or the environment, or cause the machine to operate
improperly.
NOTE: Indicates a procedure, practice or condition
that should be followed in order for the
machine or component to function in the
manner intended.
This manual provides important information to familiarize
you with safe operating and maintenance procedures.
Even though you may be familiar with similar equipment,
you MUST read and understand this manual before
operating the Rosco Maximizer 4B Distributor and
follow its instructions.
Safety is everyone’s business and our top concern.
Knowing the guidelines covered in this section will help
ensure your safety and the safety of those around you,
as well as proper machine operation.
Keep safety labels in good condition. If safety labels
become missing or damaged, replace them with
new matching labels. Replacement safety labels are
available from your authorized dealer (see contact
information in Section 2).
You can nd more information about occupational health
and safety in the paving industry on the internet. A few
resources are listed below:
www.osha.gov
cdc.gov
www.asphaltpavement.org
www.safety.fhwa.dot.gov/
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Safety
Safety Precautions
The safety messages that follow have CAUTION level
hazards.
Pre-Operation HazardPre-Operation Hazard
Read and understand this manual and
accompanying manuals before operating
or servicing the machine to ensure that safe
operating and maintenance procedures are
followed.
• DO NOT allow anyone to service or operate the
machine who is not properly trained. Contact your
authorized dealer for additional training if needed.
• Safety labels are important reminders for safe
operating and maintenance procedures. Ensure all
safety labels are legible. Contact your authorized
dealer to replace worn or damaged safety labels.
• Be aware and comply with all laws and regulations for
the location where the machine is operated.
• Ensure all operators have the necessary license(s) to
operate the machine.
Poor Lighting HazardPoor Lighting Hazard
• Ensure the area is well lit for safe operation and
maintenance performance.
• Always install wire cages on portable safety lights.
Tool HazardTool Hazard
Always use tools appropriate for the task. Use the
correct sized tool for loosening or tightening any
machine parts.
The safety messages that follow have DANGER level
hazards.
Power Lines HazardPower Lines Hazard
If your machine comes into contact with
electric power lines, observe the following:
• Warn others to stay away and DO NOT touch any
control or other parts of the machine.
• If contact can be broken, drive the machine away from
the danger zone. If contact cannot be broken, stay in
the operators seat until the power is off.
• Failure to observe these directions could result in
electrocution or death.
Electrocution HazardElectrocution Hazard
Disconnect the battery before welding anywhere on the
machine.
Suffocation HazardSuffocation Hazard
Carbon monoxide poisoning is a serious
condition that occurs as a result of improper
ventilation.
• Never operate the engine in an enclosed area with
poor ventilation. Ensure proper ventilation to reduce
risk of carbon monoxide poisoning or death.
Exhaust HazardExhaust Hazard
All internal combustion engines create
carbon monoxide gas during operation and
special precautions are required to avoid
carbon monoxide poisoning:
• Never block windows, vents or other means of
ventilation.
• Always ensure that all connections are tightened to
specications after repair is made to the exhaust
system.
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Safety
The safety messages that follow have WARNING
level hazards.
Crush HazardCrush Hazard
Keep bystanders away from work area before and
during operation.
Modification HazardModification Hazard
Never modify the machine without the written consent of
LeeBoy. Any modication can affect the safe operation
of the machine and may cause personal injury or even
death.
Exposure HazardExposure Hazard
Operators of the machine must be aware of
their work environment and the equipment
needed to work safely.
• Always wear personal protective equipment, including
appropriate clothing, gloves, work shoes, and
protection for eyes and ears, as required by the task
at hand.
Explosion HazardExplosion Hazard
While the engine is running or the battery is
charging, hydrogen gas is produced that
can ignite. Keep the area around the
battery well-ventilated and keep sparks,
open ame, and any other form of ignition
away from the machine.
• Always disconnect the negative (-) battery cable
before servicing the machine.
• DO NOT start the engine by “shorting” the starter
circuit or any other starting method not stated in this
manual.
• Never charge a frozen battery. Always warm the
battery slowly to room temperature before charging.
Fire and Explosion HazardFire and Explosion Hazard
• Diesel fuel is ammable and explosive under certain
conditions.
• Clean up fuel spills immediately.
• Never refuel while the engine is running.
• Store fuel containers in a well-ventilated area away
from any combustibles or sources of ignition.
Fire HazardFire Hazard
When operating machinery, there is always
a risk for re. Ensure appropriate safety
equipment is available.
• Keep a charged re extinguisher within reach at all
times.
• Ensure all re extinguishers are checked periodically
for proper operation and readiness.
• Always read and follow safety-related precautions
on hazardous substance containers like cleaners,
primers, sealants and sealant removers.
• Undersized wiring systems can cause electrical res.
Entanglement/Sever HazardEntanglement/Sever Hazard
Sound the horn as a warning and verify
there are no people, obstacles or other
equipment near the machine or in its path
before starting the engine.
If the engine must be serviced while it is
operating, remove all jewelry and tie back
long hair.
• Stay clear of moving/rotating parts.
• Always stop the engine before performing
maintenance and remove the negative battery cable.
• Verify that all guards and covers are properly attached
before starting the engine. DO NOT start the engine if
any guards or covers are not properly installed.
• If you must operate the engine during maintenance
procedures, keep bystanders clear of the area.
• Always turn the starter switch to the OFF position and
remove the key after operating the machine. Secure
the key when the machine is not operating.
• Attach a “Do Not Operate” tag near the key switch
while performing maintenance on the equipment.
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Safety
• Never operate the machine while wearing
headphones because it will be difcult to hear any
warning signals.
• Start the engine and operate the controls ONLY from
the operator seat.
Alcohol and Drug HazardAlcohol and Drug Hazard
Never operate the machine while under the
inuence of alcohol or drugs.
Piercing HazardPiercing Hazard
High-pressure hydraulic uid or fuel can
penetrate your skin and result in serious
injury. Avoid skin contact caused by a
hydraulic or diesel fuel spray caused by a
hydraulic or fuel system leak such as a
broken hydraulic hose, fuel injection or high-pressure,
common-rail engine line.
• If you are exposed to high-pressure hydraulic uid or
fuel spray, obtain prompt medical treatment.
• Never check for a hydraulic uid or fuel leak with your
hands. Always use a piece of wood or cardboard.
Contact your authorized distributor to repair damaged
parts.
Flying Object HazardFlying Object Hazard
Always wear eye protection when cleaning
the machine with compressed air or high-
pressure water.
Dust, ying debris, compressed air,
pressurized water or steam may cause eye
injury.
Coolant HazardCoolant Hazard
Coolant must be handled properly to ensure
operator safety.
• Wear eye protection and rubber gloves when handling
engine coolant.
• If eye contact occurs, ush eyes with clean water for at
least 15 minutes.
• If contact with skin occurs, wash immediately with
soap and water.
Burn HazardBurn Hazard
Some of the machine’s surfaces become
very hot during operation and may remain
hot for a few minutes after shutdown.
• Keep hands and other body parts away from hot
machine surfaces.
• Handle hot components with heat-resistant gloves.
The safety messages that follow have NOTICE level
hazards.
Any part that is found defective as a result of inspection
or any part whose measured value does not satisfy the
standard or limit must be replaced.
Always tighten components to the correct torque. (See
Section 2, Torque Tables) Loose parts can cause
improper operation and damage to the machine. Only
use replacement parts approved by LeeBoy. Other
replacement parts may affect warranty coverage.
Contact your authorized dealer for assistance.
Follow EPA and local government
guidelines for properly disposing of
hazardous materials such as engine oil,
diesel fuel, and engine coolant. Consult
local authorities or reclamation facilities
for more information. Never dispose of
hazardous materials by dumping them into a sewer, on
the ground, or into waterways.
Clean all accumulated dirt and debris away from
the body of the machine and its components before
inspecting the machine or performing repairs and
maintenance. Operating a machine with accumulated
dirt buildup will cause premature wear of machine
components and hinder effective operation.
If any alert indicator illuminates while operating, STOP
the engine immediately. Determine the cause and repair
the problem before continuing to operate the machine.
Contact your authorized dealer for service assistance.
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Safety
Machine Precautions
Hot Material PrecautionsHot Material Precautions
• ALWAYS wear protective gear for face, hands, feet,
and body when operating the machine.
• Allow machine to cool before repairing or performing
maintenance components.
• If hot asphalt emulsion or other material touches the
skin, ush area immediately with cold water. DO NOT
apply ice to the affected area. DO NOT ATTEMPT
TO REMOVE ASPHALT CEMENT with products
containing solvents or ammonia as natural separation
will occur in 48 to 72 hours. Get medical attention
immediately.
• DO NOT remove radiator cap, drain plugs, service
grease ttings, or pressure taps while engine is hot.
Add coolant to the radiator and perform other services
only when the engine is stopped and fully cooled.
Hydraulic Systems PrecautionsHydraulic Systems Precautions
• Ensure all components are in good working condition.
Replace any worn, cut, abraded, attened or crimped
hoses and metal lines.
• DO NOT attempt makeshift repairs using tape, clamps
or cements. The hydraulic system operates under
extremely high pressure and such short-term repairs
can cause serious injury.
Hydraulic oil under pressure can
cause serious personal injury. Check for oil leaks
with a piece of cardboard. DO NOT expose hands to
possible high-pressure oil. Turn off engine before
attempting to tighten oil lines and ttings.
• Escaping pressurized hydraulic uid has enough force
to penetrate the skin and cause serious personal
injury and toxic reactions. Ensure pressure is relieved
before disconnecting lines, hoses or valves. If injury
from high-pressure steam or hydraulic uid occurs,
seek medical attention immediately.
Burner PrecautionsBurner Precautions
• Never operate any part of the burner system when the
vehicle is being loaded or in transit. The ue tubes
can become exposed and cause an explosion inside
the tank or ignite material being sprayed.
• Never operate the burners if the ue tubes are
not covered with at least eight inches (20.3 cm) of
material. The ue tubes can become hot and ignite
the vapors, causing a re or explosion.
• Always park the truck so that the burners are upwind.
Some asphalt materials emit ammable vapors from
the vent that can be ignited by the burner ame and
cause an explosion.
• Never operate the burners in a conned area. Vapor
build-up is toxic and could also cause an explosion.
• DO NOT operate the burners if the tank is leaking or a
spill has occurred.
• Keep the tank vents clear to avoid a buildup of
pressure in the tank when heating. Check the vents
before starting the burners.
• Never use gasoline, alcohol or any other unapproved
fuel in a diesel burner.
• DO NOT operate the burners while the spray down
system is operating or has recently been used.
• DO NOT operate the burners with the top tank cover
open.
• Be sure to read the label, understand and follow all
precautions and instructions for using any cleaning
materials.
Refueling PrecautionsRefueling Precautions
• DO NOT overll the fuel tank as overow creates a re
hazard when spilled on hot components.
• DO NOT ll tank to capacity. Allow room for expansion
to reduce the risk of fuel expanding and spilling from
the tank.
• DO NOT smoke when refueling. Never refuel while
the engine is running. Fuel is highly ammable and
should be handled with care. Death or serious injury
can occur due to explosion and re.
• Tighten fuel cap securely. Should the fuel cap be
lost, replace it ONLY with original manufacturer’s cap.
Pressurization of the tank may result from use of non-
approved cap. Contact your authorized dealer for
replacement.
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Safety
Battery PrecautionsBattery Precautions
• Keep all sparks and ames away from batteries as gas
given off by electrolytes is explosive.
• Acid propelled by an explosion can cause blindness..
Always wear safety glasses when working near
batteries.
• If you come into contact with battery electrolyte
solution, wash it off immediately to prevent burns.
• Always disconnect the battery ground cable before
working on the electrical system to avoid injury from
sparks or short circuit.
• To avoid electrolyte loss, DO NOT tip batteries more
than 45 degrees.
Starting and StoppingStarting and Stopping
PrecautionsPrecautions
• Check all around the machine to ensure there are
no people in its path before starting. DO NOT start
until area is clear to prevent death or serious injury to
bystanders being crushed by a moving machine.
• Always check brakes, steering and other control
devices before starting the machine.
Parking PrecautionsParking Precautions
• Park the machine on level ground whenever possible
and apply the parking brake. Park the machine with
wheels securely blocked on grades.
• Remove ignition key when leaving the machine parked
or unattended.
Operating PrecautionsOperating Precautions
• Always comply with federal and local regulations for
moving equipment and industrial machinery on public
roads and highways.
• Know and use the hand signals required for a
particular job. Know who has the responsibility for
signaling.
• Make sure all lights and reectors comply with state
and local regulations. Lights must be clean, in good
working condition and clearly visible to all trafc.
• DO NOT stand between the machine and other
vehicles working at the job site. Death or serious
injury can result from being crushed between two
machines.
• Check all gauges and warning instruments for proper
operation. If malfunctions are found, shut down the
machine immediately and report the problem for
resolution. If the failure causes loss of steering,
brakes or engine power, stop immediately. Keep the
machine securely parked until the failure is corrected
or the machine can be safely moved.
• Drive the machine with care, ensuring speed is
compatible with road and climate conditions. Use
extra caution on rough ground, slopes and while
turning.
• Be alert for hazards and obstructions such as ditches,
trees, cliffs, overhead power lines, and areas where
there is danger of a slide.
• Be aware and understand job site trafc ow patterns.
• Obey agmen, road signs and trafc signals.
• Watch for bystanders. Never allow anyone near the
machine during operation.
• Operator must know how to use signaling devices and
understand which circumstances require use of each
signal. Use tail lights, slow moving vehicle signs, and
warning beacon as needed when traveling on public
roads. It is recommended that you always drive with at
least one escort vehicle to and from job sites.
• When moving the machine, adjust speed and direction
of travel for the terrain and ground conditions present.
Always consider adjusting travel speed to match
ground conditions.
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Safety
Poor VisibilityPoor Visibility
Increasingly, asphalt maintenance equipment is used
during less than ideal lighting conditions such as fog or
at night. These conditions present safety hazards for
workers, bystanders and passing trafc.
When operating under restricted light
conditions, equip the machine with special lighting to
prevent serious injury.
• Use reective tape on the sides of the machine when
working at night. Ensure all workers wear reective
safety vests.
• Use impact barriers (movable or stationary) to protect
workers and direct the trafc ow safely away from the
work site.
Contact your authorized dealer for additional lighting
packages if working under these conditions.
Storage PrecautionsStorage Precautions
• Store machine in an area away from human activity.
• DO NOT permit children to play on or around the
machine.
• Make sure the unit is stored on a surface that is rm,
level, and free from debris.
• Store the machine inside a building or cover securely
with a weather-proof tarpaulin.
Maintenance PrecautionsMaintenance Precautions
• DO NOT attempt repairs unless trained to do so.
Refer to your owner’s manuals and contact your
authorized dealer for service assistance if needed.
• Securely block the machine and any components
that may fall before performing maintenance. Block
any working components to prevent unexpected
movement while repairs are being made.
• Always wear safety glasses and other required safety
equipment when servicing or making repairs.
• Disconnect battery before working on the electrical
system.
• Avoid lubrication or mechanical adjustments while the
machine is in motion or the engine is operating.
• Never make repairs on pressurized components such
as uid lines, fuel system, or mechanical items until the
pressure has been relieved.
• When servicing or replacing hardened pins, use a
brass drift or other suitable material between the
hammer and pin.
• Keep brakes and steering system in good operating
condition.
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Safety
NOTE: It is the responsibility of the owner and
operator to make sure that all safety labels are
readable and located on the machine.
Safety Decals
It is extremely important that you replace all the
CAUTION, WARNING and DANGER safety decals in
the proper locations if they become damaged, illegible,
or you repaint the machine (see following graphics).
Contact your authorized dealer immediately to order a
replacement kit (Group Part #26422).
Part #39167-02
Part #39166-01
Part #39166-08
Part #39167-04
Safety Decal LocationsSafety Decal Locations
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