Falcon RME Series Operation, Parts And Repair Manual
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Falcon RME Series Operation, Parts And Repair Manual

Diesel asphalt hot patchers
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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 (989) 495-9332
Fax (989) 495-9342
www.falconrme.com
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  • Page 1 FALCON RME DIESEL ASPHALT HOT PATCHERS OPERATION, PARTS AND REPAIR MANUAL FALCON ROAD MAINTENANCE EQUIPMENT, INC. 2600 W Salzburg Rd FREELAND, MI 48623 Phone (989) 495-9332 Fax (989) 495-9342 www.falconrme.com...

  • Page 2: Table Of Contents

    Axle Bolts, Frame, Suspension and Structure ..... 18 Lug Nuts (Bolts) ..............19 Wheel Rims ................19 Falcon RME Asphalt Hot Patcher Limited Warranty ......Inspection, Service and Preparation BEFORE EACH USE ..... Inspection, Service and Preparation TWO TIMES PER MONTH ..22 Inspection, Service and Preparation MONTHLY ......
  • Page 3 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 ............
  • Page 4 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 ............

  • Page 5: Safety Alert Symbols And Signal Words

    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. Danger DANGER - Immediate hazards which WILL result in severe personal injury or death if the warning is...

  • Page 6: Operator Warnings (Read Before Using Equipment)

    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 (989) 495-9332 AND REPLACEMENTS WILL BE PROVIDED AT NO CHARGE. General Warnings DANGER: NEVER USE FLAMMABLE MATERIAL IN OR NEAR THE HOPPER.
  • Page 7 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.
  • Page 8 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.
  • Page 9 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.
  • Page 10 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.

  • Page 11: General Trailer Safety Information

    National Highway Traffic Safety Administration (NHTSA) in addition to notifying Falcon RME at 120 Waldo Ave., Midland, MI 48642 Phone (989) 495-9332. 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.

  • Page 12: Major Hazards

    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.

  • Page 13: Trailer Not Properly Coupled To The Hitch

    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. Warning Proper selection and condition of the coupler and hitch are essential to safely towing your trailer.

  • Page 14: Incorrect Use Of Breakaway Brake

    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.

  • Page 15: Mismatch Of Trailer And Hitch

    Mismatch of Trailer and Hitch Danger 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.
  • Page 16 Lugnuts on trailer wheels are prone to loosen. Before each tow, check to make sure they are tight. Warning 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.

  • Page 17: Do Not Exceed Gvwr

    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. Warning An overloaded trailer can result in loss of control of the trailer, leading to death or serious injury.

  • Page 19: Lug Nuts (Bolts)

    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. FIGURE 1 LUG NUT SEQUENCE OF TIGHTENING 5-BOLT 8-BOLT...

  • Page 20: Falcon Rme Asphalt Hot Patcher Limited Warranty

    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.

  • Page 21: Inspection, Service And Preparation Before Each Use

    DAILY AND PERIODIC INSPECTION, SERVICE & MAINTENANCE Inspection, Service and Preparation BEFORE EACH USE Item Inspection / Service Use diesel fuel recommended by diesel burner manufacturer (#1 and #2 diesel fuel and B5 bio-diesel fuel). Fill fuel tank daily or at the beginning of each shift and do not allow fuel tank to run out of fuel.

  • Page 22: Inspection, Service And Preparation Two Times Per Month

    Secure all equipment to trailer -- plate compactor, vibratory roller, tools, hoses, et al. before moving the patcher. FALCON RME is not Detachable Equipment responsible for accidents resulting from operator's failure to secure equipment to the patcher. Raise jack stand before moving.

  • Page 23: Inspection, Service And Preparation Every Three Months

    Burner Tune-up Kit - Falcon Part KT 31303 / KT 31217 Diesel Burner Nozzles Replace - Burner Tune-up Kit - Falcon Part KT 31303 / KT 31217 CAD Cell Replace - Burner Tune-up Kit - Falcon Part KT 31303 / KT 31217...

  • Page 24: Lubrication Schedule

    LUBRICATION SCHEDULE ITEM FREQUENCY LUBRICANT Material door linkages Daily Spray lubricant like WD40 Material door finger / pin Daily Spray lubricant like WD40 Dump box pivot blocks (located at Grease generously with clean back of patcher -- block, spacer Two Times per month grease until grease runs clear and pin) High temperature wheel bearing...

  • Page 25: Recommended Fluid Maintenance Schedule

    4) the 50/550 thermometer (option) on the rear hopper wall. Falcon recommends using one of the heat transfer oils listed in the table below. The use of any grade oil not specifically recommended by Falcon RME shall be cause for the voidance of the warranty on the tack tank.

  • Page 26: Attaching Patcher To Tow Vehicle

    ATTACHING PATCHER TO TOW VEHICLE 1. Back tow vehicle hitch directly under the asphalt hot patcher coupling device. 2. Lower the trailer onto the tow vehicle by turning the jack handle in a counter-clockwise motion until the pintle eye rests on the coupler. Read and follow the receiver manufacturer's instructions to ensure that the patcher is properly secured to the towing vehicle.

  • Page 27: Loading Slip-In Patcher Into Tow Vehicle

    LOADING SLIP-IN PATCHER INTO TOW VEHICLE WARNING: TO AVOID SERIOUS INJURY, ENSURE THAT ONLY TRAINED PERSONNEL LOAD AND SECURE THE SLIP-IN UNIT TO THE TOWING VEHICLE PER ORGANIZATION PROCEDURES. WARNING: REMOVE ALL ASPHALT FROM PATCHER BEFORE LOADING OR UNLOADING SLIP-IN UNIT. WARNING: ENSURE LOADING/UNLOADING EQUIPMENT (I.E.

  • Page 28: Filling Hopper And Loading Door Instructions

    FILLING HOPPER AND LOADING DOOR INSTRUCTIONS CAUTION: STANDING TOO CLOSE TO THE PATCHER WHILE CLOSING THE LOADING DOORS OR NOT KEEPING THE LOADING DOOR HANDLES FULLY EXTENDED WHILE CLOSING LOADING DOORS COULD CAUSE OPERATOR INJURY. CAUTION: DUMP BOX MUST BE IN THE "DOWN" POSITION BEFORE OPERATING MANUAL LOADING DOORS.
  • Page 29 FILLING HOPPER AND LOADING DOOR INSTRUCTIONS (CONTINUED) 6. OPEN HYDRAULIC LOADING DOORS NOTICE: MAKE SURE THERE IS CLEARANCE ABOVE AND AROUND THE ENTIRE PERIMETER OF THE PATCHER WHILE HYDRAULIC LOADING DOORS ARE OPEN/OPENING. CAUTION: ALWAYS TURN TOW VEHICLE OFF AFTER HYDRAULIC LOADING DOORS ARE OPEN.

  • Page 31: Operation Of Hydraulic Material Metering Door

    OPERATION OF HYDRAULIC MATERIAL DOOR DANGER: TO AVOID INJURY OR DEATH FROM HOT ASPHALT BURNS, STAND BACK WHEN ASPHALT IS FLOWING FROM A TILTED DUMP BOX. CAUTION: TO AVOID SERIOUS INJURY, DO NOT PUT HANDS NEAR THE MATERIAL DOOR WHEN LIFTING OR LOWERING. To open the material door, lift the left lever of the spool valve and release when door is open to desired height.

  • Page 32: Starting The Main Hopper Diesel Burner And

    STARTING THE MAIN HOPPER DIESEL BURNER AND SETTING THE TEMPERATURE CONTROLLER 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. REFER TO PAGES 74 - 87 IN THIS MANUAL FOR DETAILED INFORMATION ON MAINTAINING THE DIESEL BURNER.
  • Page 33 See the DIESEL FUEL PRE-HEATER OPTION section of this manual for instructions on using the diesel fuel pre-heating system. NOTICE: Falcon asphalt recyclers/hot patchers are designed to allow the diesel burner to run while being towed.
  • Page 34 The on and off cycling of the burner is by design. If the green light is not visible when the temperature displayed on the controller is lower than the "set temperature", there may be a problem with the controller. Contact Falcon at (989) 495-9332 for technical assistance.
  • Page 35 STARTING THE MAIN HOPPER DIESEL BURNER AND SETTING THE TEMPERATURE CONTROLLER (CONTINUED) 3. TROUBLESHOOTING a) Check the diesel burner CAD cell to confirm the eye is clean. To clean the CAD cell, wipe the eye with a clean cloth or a cotton swab. If the CAD cell eye was dirty, attempt to start the burner by turning the HOPPER toggle switch off/down and on/up and waiting 30 seconds to see if cleaning the CAD cell allows the burner to ignite.
  • Page 36 Turn hopper switch off/down. Clean the blower wheel, air inlet, air guide and retention head of any dirt, asphalt or other material. Inspect igniter spring contacts and clean or replace if corroded. Turn hopper switch on/up and attempt to ignite diesel burner. If burner still does not light, contact Falcon at (989) 495-9332.

  • Page 37: Dump Box Operating Instructions

    DUMP BOX OPERATING INSTRUCTIONS READ THESE INSTRUCTIONS BEFORE USING THE ASPHALT HOT PATCHER DUMP BOX WARNING: STAND BACK 10 FEET FROM PATCHER ANYTIME THE DUMP BOX HOPPER IS IN MOTION. CAUTION: PROTECT THE REMOTE HOPPER CONTROL FROM BEING DAMAGED AT ALL TIMES.
  • Page 38 DUMP BOX OPERATING INSTRUCTIONS (CONTINUED) WARNING: BEFORE THE DUMP BOX HOPPER IS RAISED, LOWER BOTH OUTRIGGERS AND INSERT RETENTION PIN INTO POSITION SUCH THAT THE BASE OF THE OUTRIGGER IS ON THE GROUND OR AS CLOSE TO THE GROUND AS POSSIBLE. SHOULD THE PATCHER ACCIDENTALLY UNCOUPLE FROM THE TOW VEHICLE, THE OUTRIGGERS WILL PREVENT THE PATCHER FROM TIPPING...

  • Page 39: Lowering Dump Box Instructions

    LOWERING DUMP BOX INSTRUCTIONS 1) Place cylinder guard in storage location and engage retention pin. 2) Ensure that no one is within 10 feet of the entire trailer and that the remote cord will not be pinched when the hopper is lowered. Using the hopper remote control, depress and hold the "down"...

  • Page 40: Patcher Shutdown

    PATCHER SHUTDOWN 1. Open the electrical enclosure box and turn all toggle switches to the OFF position. 2. Remove unused asphalt and clean hopper floor with an environmental-friendly asphalt release agent to prevent a build-up of asphalt that could result in heat loss to the hopper contents.
  • Page 41 PATCHER SHUTDOWN (CONTINUED) 7. If tack tank has a spray system, ensure that all tack material has been flushed through the spray system and no liquid remains in the spray system hose. 8. Remove unused tack material from the tack tank at the end of each workday. The tank is not designed to be a storage reservoir and must be emptied at the end of a workday.

  • Page 42: Replacement Parts And Numbers

    REPLACEMENT PARTS AND NUMBERS Item Description Falcon Part Number Beckett Burner (Main Burner) FS10072 Burner Nozzle (.75) FS10075 Burner Nozzle (.5) FS11543 Igniter Assembly FS10322 Motor FS10323 Primary Burner Control FS10331 Fuel Unit Pump FS10324 Solenoid Valve FS10701 Cad Cell...
  • Page 43 REPLACEMENT PARTS AND NUMBERS (CONTINUED) Item Description Falcon Part Number Flange Bearing DO10115 CAM Roller DO31125 Loading Door Handle Grips DO10144 Material Door Pin DO32171 8-Bolt Axle Hub Caps SU11512 3/8" Midlink TR10117 3/8" Grab Hook TR10101 Lanyard and Pin...

  • Page 44: Non-Heated Tack Tank Instructions

    NON-HEATED TACK TANK INSTRUCTIONS CAUTION: NEVER FILL THE TOP CYLINDER OF THE TACK TANK WITH TACK MATERIAL. ! ! 1 . Open the door of the tack fill spout. 2. Fill tack tank with the amount of material that will be used in a day. NOTICE: The tank is not designed to be a storage reservoir and must be emptied at the end of a workday.

  • Page 45: Heated Tack Tank Operation

    HEATED TACK TANK OPERATION CAUTION: Falcon recommends wearing protective clothing while operating the asphalt hot patcher or tack tank. The tack tank burner will heat the tack material to the temperature set by the operator. Never set the controller temperature for an air- jacketed tack tank above 150 degrees Fahrenheit or an oil-jacketed tack tank above 275 degrees Fahrenheit.
  • Page 46 HEATED TACK TANK OPERATION (CONTINUED) 9. Place tack bucket under the tack tank spout. 10. Lift up on the material supply valve located at the base of the tack tank. 11. Close the material supply valve on the bottom of the tack tank when the appropriate level of tack has been drawn.

  • Page 47: Tack Tank Spray System Operation

    TACK TANK SPRAY SYSTEM OPERATION CAUTION: Falcon RME recommends wearing protective clothing while operating the asphalt hot patcher or tack tank. The tack tank burner will heat the tack material to the temperature set by the operator. Never set the controller for the tack tank to a temperature above 150 degrees Fahrenheit.
  • Page 48 TACK TANK SPRAY SYSTEM OPERATION (Continued) 9. Depress handle and spray tack material as needed by the application. 10. When complete, replace hose and spray wand in storage locations and turn off tack tank burner by flipping the “TACK” toggle switch OFF/DOWN. 11.

  • Page 49: Flush Spray System Procedure

    FLUSH SPRAY SYSTEM PROCEDURE NOTICE: 1) Never adjust ball valves when motor is running. 2) Spray System hose must be flushed after each use. 3) Either yellow ball valves or red ball valves must be closed when running the motor or the tack will mix with the release agent. 1.

  • Page 50: Two-Burner Recycling Option Instructions

    TWO-BURNER RECYCLER OPTION INSTRUCTIONS Both RAP and stockpiled virgin hot mix asphalt that has been broken into large pieces can be placed in the hopper, and broken down into a reusable form through a heating process. By surrounding the material with heat, the chunks of material can be converted to a malleable form and used to fill potholes.
  • Page 51 TWO-BURNER RECYCLER OPTION INSTRUCTIONS (CONTINUED) 8. Hook up asphalt hot patcher battery to a battery charger ensuring that battery charger is plugged into building power that has a 120VAC ground fault circuit interrupt. Using a heavy-duty UL approved extension cord, plug extension cord into building power LAST. 9.

  • Page 52: Battery Charging Instructions

    BATTERY CHARGING INSTRUCTIONS If the asphalt hot patcher is equipped with an on-board battery charger and male receptacle, connect a heavy-duty UL-approved extension cord to the patcher's male receptacle before plugging the male end of the extension cord into a 120VAC building ground fault circuit interrupt outlet.

  • Page 53: Electric Overnight Heat Option Instructions

    OPERATING STEPS 1) TURN THE DISCONNECT TO THE OFF POSITION 2) FALCON OFFERS BOTH 110V and 240V ELECTRIC HEAT SYSTEMS. THE VOLTAGE IS IDENTIFIED ON THE DISCONNECT BOX AS WELL AS THE CORD CAP. IDENTIFY AN APPROPRIATE POWER OUTLET WITH A GROUND FAULT RECEPTACLE FOR USE IN CONNECTING AN EXTENSION CORD TO THE CORD CAP OF THE EQUIPMENT.

  • Page 54: Manual Hoist Option Instructions

    MANUAL HOIST OPTION INSTRUCTIONS NOTE: The lift capacity of the manual hoist is 1,000 pounds / Cable Length 25 Feet. WARNING: Never exceed weight capacity of lift. Make sure vehicle brakes are locked before using the hoist. Use grab hook at the end of the wire line to attach the item to be lifted. Never stand underneath or in close proximity to the load being lifted.

  • Page 55: Diesel Fuel Pre-Heater Option Instructions

    2) open the ball valve at the base of the filter and allow liquid to drain 3) close the ball valve at the base of the filter 4) replace the protective steel covering Change the diesel fuel pre-heater's filter annually. Falcon part number FS11633.

  • Page 56: Wiring Color Code

    WIRING COLOR CODE WARNING: REWIRING THE PATCHER IMPROPERLY MAY CAUSE COMPONENT FAILURE. NOTICE: REWIRING THE PATCHER WITHOUT PRIOR AUTHORIZATION VOIDS THE WARRANTY. STROBE / WARNING LIGHT Orange RUNNING Brown FUEL SENDING UNIT (option) Violet ELECTRIC BRAKES Blue LEFT TURN Yellow RIGHT TURN Green BURNER COMMAND WIRE...

  • Page 57: Tire Safety Information

    Tire Safety Information This portion of the User’s Manual contains tire safety information as required by 49 CFR 575.6. Section 2.1 contains “Steps for Determining Correct Load Limit - Trailer”. Section 2.2 contains “Steps for Determining Correct Load Limit – Tow Vehic le”. Section 2.3 contains a Glossary of Tire Terminology, inc luding “cold inflation pressure”, “maximum inflation pressure”, “recommended inflation pressure”, and other non-technical terms.
  • Page 58 1.1.1. Trailers 10,000 Pounds GVWR or Less Tire and Loading Information Placard – Figure 1-1 1. Locate the statement, “The weight of cargo should never exceed XXX kg or XXX lbs.,” on your vehicle placard. See figure 1-1. 2. This figure equals the available amount of cargo and luggage load capac ity. 3.
  • Page 59 Carcass The tire structure, except tread and sidewall rubber which, when inflated, bears the load. Chunking The breaking away of pieces of the tread or sidewall. Cold inflation pressure The pressure in the tire before you drive. Cord The strands forming the plies in the tire. Cord separation The parting of cords from adjacent rubber compounds.
  • Page 60 Load rating The maximum load that a tire is rated to carry for a given inflation pressure. Maximum load rating The load rating for a tire at the maximum permissible inflation pressure for that tire. Maximum permissible inflation pressure The maximum cold inflation pressure to which a tire may be inflated. Maximum loaded vehicle weight The sum of curb weight, accessory weight, vehic le capacity weight, and production options weight.
  • Page 61 Pneumatic tire A mechanical device made of rubber, chemicals, fabric and steel or other materials, that, when mounted on an automotive wheel, provides the traction and contains the gas or fluid that sustains the load. Production options weight The combined weight of those installed regular production options weighing over 2.3 kilograms (5 lbs.) in excess of those standard items which they replace, not previously considered in curb weight or accessory weight, including heavy duty brakes, ride levelers, roof rack, heavy duty battery, and special trim.
  • Page 62 Vehicle capacity weight The rated cargo and luggage load plus 68 kilograms (150 lbs.) times the vehicle’s designated seating capacity. Vehicle maximum load on the tire The load on an individual tire that is determined by distributing to each axle its share of the maximum loaded vehic le weight and dividing by two.
  • Page 63 Underinflated tires and overloaded vehicles are a major cause of tire failure. Therefore, as mentioned above, to avoid flat tires and other types of tire failure, you should maintain proper tire pressure, observe tire and vehic le load limits, avoid road hazards, and regularly inspect your tires. 1.5.1.
  • Page 64 Step 5: At a service station, add the missing pounds of air pressure to each tire that is underinflated. • Step 6: Check all the tires to make sure they have the same air pressure (except in cases in whic h •...
  • Page 65 Next number This two-digit number, known as the aspect ratio, gives the tire's ratio of height to width. Numbers of 70 or lower indicate a short sidewall for improved steering response and better overall handling on dry pavement. R The "R" stands for radial. Radial ply construction of tires has been the industry standard for the past 20 years. Next number This two-digit number is the wheel or rim diameter in inches.
  • Page 66 Max. Load Dual kg (lbs) at kPa (psi) Cold This information indicates the maximum load and tire pressure when the tire is used as a dual, that is, when four tires are put on each rear axle (a total of six or more tires on the vehic le).
  • Page 67 WHAT DO I NEED TO DO BEFORE PUTTING ASPHALT IN THE HOPPER FOR THE FIRST TIME? 1) FALCON RME RECOMMENDS WEARING PROTECTIVE CLOTHING WHILE OPERATING THE ASPHALT HOT PATCHER OR TACK TANK. 2) Coat the inside hopper walls with a non-flammable, environmentally-friendly asphalt release agent before filling the hopper to facilitate cleaning at the end of the day.
  • Page 68 WILL I VOID THE WARRANTY ON THE DIESEL BURNER IF I USE BIO-DIESEL? Use of bio-diesel fuel exceeding B5 will void the warranty on the burner and related failure(s). The burners are designed to run on B5 bio-diesel fuel or #1 and #2 diesel fuel. SHOULD I BE CONCERNED ABOUT ASPHALT MATERIAL OVERSPILL ON THE TOP CAPS OF THE HOPPER WALLS? Yes, Asphalt must be cleared away from top of hopper walls before closing loading doors.
  • Page 69 ARE THERE ANY INDICATORS THAT THE HOPPER TEMPERATURE IS TOO HOT? 1) If you can see the asphalt cement (from hot mix) dripping onto the shoveling apron from beneath the material metering door, it is an indicator that the material temperature is too hot. The operator should lower the temperature on the controller.
  • Page 70 It is critical to keep the battery fully charged at 12.8 volts or the burner(s) will not light. A low battery, anything below 12.8 volts, may be the reason for a burner failing to light. Falcon RME recommends hooking up the towing vehicle battery to the patcher battery to keep it charged throughout the day. The battery may also be hooked up to a battery charger overnight.
  • Page 71 HOW DO I OPERATE THE MATERIAL METERING DOOR? Read the operator's manual for instructions on adjusting material metering door. Damage will result if weight is not removed from pin/finger of manual metering door before adjusting the opening height. WHAT HAPPENS IF I FAIL TO FLUSH THE TACK TANK SPRAY SYSTEM AFTER EACH USE? The tack material will build up in the spray system hose and pump and you will not be able to spray tack.
  • Page 72 IF YOU HAVE QUESTIONS OR CONCERNS ABOUT YOUR ASPHALT HOT PATCHER, YOU MAY CALL FALCON RME DIRECTLY FOR ASSISTANCE AT (989) 495-9332. WHAT ARE SOME IMPORTANT ONGOING MAINTENANCE ITEMS? Lugnuts must be kept at 100 foot pounds of torque and tires inflated to pressure on sidewall of tire.
  • Page 73 SUMMARY ALWAYS KEEP BATTERIES CHARGED TO 12.8 VOLTS. CLEAN HOPPER FLOOR AT THE END OF THE DAY (UNLESS KEEPING HOT MIX WARM OVERNIGHT) TURN OFF TOP BURNER AFTER RECYCLED ASPHALT IS THOROUGHLY HEATED OR ICE IS NOT VISIBLE ON COLD MIX. PERFORM FLUSH THE TACK TANK SPRAY SYSTEM AFTER EACH USE.
  • Page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
  • Page 75 !"#$%#$& 8'9'+1)S$! )%&#&"%3 B%1&D'#$3)')5'9'+1">3)3&#>'#&"%-) F>+%$+)244(&D'#&"%).D"4$)'%1)B%#$%1$1)G3$)HHHHHHHHHHH I ;5&D5-)&*)%"#)'C"&1$1-);&(()+$3>(#) &%)1$'#5)"+)3$+&">3)&%\>+6H !+$4'+$)F$*"+$)B%3#'((&%E)HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH J D2$*0! !*%10.)&! 9 99999999999999999999999999999999999999999999999999999999999999999999L F.10*$!D2$*0%#!>$8,0'$5$)1&999999999999999999999999999999999999999999999L K$%$+'()B%*"+/'#&"%)HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH L B%1&D'#$3)')5'9'+1">3)3&#>'#&"%-) @9!?8,025$)1!M.*%1$(!0)!:.)! !)$(!D2%*$!9999999999999999999999999N ;5&D5-)&*)%"#)'C"&1$1-)D">(1) O9!?P4%,&1!J%)&!%)(!H14$'!@0'<G&0)6!A$30*$&9! 9 999999999999999999999 N +$3>(#)&%)1$'#5)"+)3$+&">3)&%\>+6H :9!:#$%'%)*$&!1.!O,')$'!%)(!?8,025$)1!999999999999999999999999999N A9!?P4%,&10)6!C%Q%'(.,&!J,5$&!99999999999999999999999999999999999999N ?9!M./!J0'0)6!>%1$!O%+" !$9!99999999999999999999999999999999999999999999999999R M"99($)233$/N(6)O'&%#$%'%D$)HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH P B%1&D'#$3)')5'9'+1">3)3&#>'#&"%-) @9!>$2#%*$!14$!O,')$'!F.QQ#$99999999999999999999999999999999999999999999R ;5&D5-)&*)%"#)'C"&1$1-)D">(1) O9!:4$*=S@(K,&1!?#$*1'.($&!99999999999999999999999999999999999999999999999T +$3>(#)&%)/&%"+)"+)/"1$+'#$)&%\>+6H) :9!E6)01$'!U%0)1$)%)*$! 9 999999999999999999999999999999999999999999999999999999T A9!D$'30*0)6!F.QQ#$!M0)$!@&&$57#-!99999999999999999999999999999999999T ?9!:4$*=S@(K,&1!VWX!A05$)&0.)! 9 99999999999999999999999999999999999999999T \0140)! 14$! 7.,)(%'0$&! .+! 14$! 4%Q%'(! /%')0)6;! 14$'$! /0##!
  • Page 76 !"#$%&'()*+",-+")."/&+")0'1$-22%'3 5)%,0)%*'%6")%*3#&$0--.#7 .4$D&! )D'#&"%3 ?;%$+]3)Y$34"%3&N&(&#6 T'4'D&#6 456)7"-8 !"#$%%&#'( )"*'+,,+')$"-( +./0*'1&"'-( +".( 5%+%'3)9-$"(!_9YR!<!a9R_!f"C 0*&($2('3)*(40%"&%(#$0,.(%&*0,'()"(*&5&%&( 0',:$(!^_R;___!<!LR_;___!O1,S4 6&%*$"+,( )"/0%7-( .&+'3-( $%( *04*'+"')+,( 6%$6&%'7( .+1+8&( 2%$1( ! (%&-( #+%4$"( ,>$(3 ;!<(!!F.9!^!.'!F.9!a!(0$&$#!+,$#!.'!=$'.&$)$g! F.9^!.'!F.9!a!4$%10)6!.0#!Z@DBU!AL]T[ 1$"$:).&(6$)*$")"8-(*$$'($%(&:6,$*)$"9 :.)1%*1!%!2'.+$&&0.)%#;!8,%#0! !$(!&$'30*$!%6$)*-!+.'!14$! !!S?)M?:)G.<)K2.^ 0)&1%##%10.);! %(K,&15$)1! %)(! &$'30*$! .+! -.,'! .0#! 4$%10)6! ?ZBM<-)TY2M_T2.<)?BZ-)?Y)2M`) &-&1$59! ! B40&! /.'=! '$8,0'$&! 1$*4)0*%#! 1'%0)0)6;! 1'%($! ?BZ)T?M:2BMBMK)K2.?ZBM<H...
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  • Page 78 !"#$%&'()V&YY2")<11"OU2>)A-%'$"'-'#" <H)Z";),&+&%E)Y'#$)F'*" )$H a9! "#%*$!%!LSNX!.2$)<$)(!/'$)*4!.)!14$!).QQ#$!%(%21$'9! E)&$'1!14$!).QQ#$!0)1.!14$!%(%21$'!%)(!! !)6$'!10641$)9! B4$!#./!! !'0)6!'%1$!7%+" !$!ZD$$!MJ>O!0)!>$2#%*$5$)1!"%'1&[! J0)0&4!10641$)0)6!/014!%!RSbX!.2$)<$)(!/'$)*49 '$(,*$&!14$!%0'!" !./!%)(!2'$&&,'$9!B4$!MJ>O!0&!&.5$105$&! ,&$(!+.'!! !'0)6!'%1$&!,)($'!^9__!624!%&!#0&1$(!0)!>+4,&(@9! L9! E+!14$!).QQ#$!0&!%#'$%(-!0)&1%##$(;!'$5.3$!14$!).QQ#$! >$+$'! 1.! 14$! $8,025$)1! 5%),+%*1,'$'`&! 0)&1',*10.)&9! A.! #0)$!%&&$57#-!1.!3$'0+-!14%1!14$!).QQ#$!&0Q$!%)(!&2'%-! ).1! .501! 14$! MJ>O! /4$)! &2$*0! !$(9! H50110)6! 14$! 7%+" !$! 2%11$')!%'$!*.''$*1!+.'!14$!%22#0*%10.)!Z2$'!$8,025$)1! /4$)!&2$*0! !$(!.'!0)&1%##0)6!14$!7%+" !$!/4$)!).1!&2$*0! !$(! 5%),+%*1,'$'`&!0)+.'5%10.)[9!I$'0+-!14%1!14$!$#$*1'.($! *.,#(!'$&,#1!0)!2..'!7,')$'!2$'+.'5%)*$9! 102!&$110)6&!*.52#-!/014!?)80%&(E9...
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  • Page 80 !"#$%&'()5:"2)!:,,2> TH),>$().>44(6)F$(";)Z$C$()"*)F>+%$+ B4$!O$*=$11!W!6%,6$!Z2%'1!),57$'!W< a___[!0&!%3%0#%7#$!1.!2$'501!*4$*=0)6! \4$)!14$!+,$#!&,22#-!0&!5.'$!14%)!$0641!+$$1!7$#./!14$!#$3$#! 14$!J!4$%(!VWX!(05$)&0.)!/014.,1!'$5.30)6!14$!7,')$'9 .+!14$!7,')$';!%!1/.<202$!+,$#!&,22#-!&-&1$5!0&!'$8,0'$(9! A$2$)(0)6! .)! 14$! +,$#! #0)$! (0%5$1$'! %)(! 14$! 4.'0Q.)1%#! %)(! 3$'10*%#! #$)614;! 14$! 0)&1%##%10.)! 5%-! %#&.! '$8,0'$! %! ?(%-*1(,,-= 1/.<&1%6$! 2,529! :.)&,#1! 14$! +,$#! ,)01! 5%),+%*1,'$'`&! #01$'%1,'$!+.'!#0+1!%)(!3%*,,5!*%2%70#01-9! 2H)T"%%$D#),>$()Z&%$3 SH),>$()Z&%$)Y$4('D$/$%#)aY$/"#$):'%0)?%(6b S")M"#)B%3#'(()F64'33)!(>E) \4$)! '$2#%*0)6! +,$#! #0)$&;! *.)10),.,&! #$)614&! .+! 4$%3-! ;&#5)W^!&4$).63#$/ /%##! *.22$'! 1,70)6! 0&! '$*.55$)($(9! B.! $)&,'$! %! 10641! &$%#;! %#/%-&! ,&$! "...
  • Page 81 !"#$%&'().:+'"+)S%+%'3 ?)80%&([F9(>76)#+,(\)%)"8(?$%(G$"*'+"'(;0'7(!8")')$"(M(\)'3(<$(]%)1+%7(G$"'%$, 0H<MQS'H16 =9M8HQ+1! G+(+Q'7=1Q8=G0 7=1Q8=G0 <P0M <P0M <P0M 0=G+6 @GPM'?+QV X+=GMQTYU =8H1!M ?V+QM '?V+QM'0Q8+9M SMGG=? +!1+QM8 XHGXM (=Q=8 7H99M6 T1=Q'P0M6U @GH7[ ?V+QMTZU @GH7[ F.1$&c ^9!\0'$&!%'$!1.!7$!&0Q$(!1.!2'$3$)1!%!3.#1%6$!('.2!7$1/$$)!7%11$'-!%)(!7,')$'!/014!7,')$'!',))0)6!%1!+,##!#.%(9 <8=('RL'Z'RN>W'X*4 a9!U.1.'!',)&!*.)10),.,&#-!0)!).'5%#!*.)! !!6,'%10.)9 9=?M8'0P99GS L9!C%'(</0'$!7,')$'!6'.,)(!1.!7%11$'-9!AH!FHB!GD?!:C@DDED!f>HGFA!DeDB?U9 0[ROO\] ?)80%&([A9(>76)#+,(\)%)"8(?$%(!"'&%%06'&.(!8")')$"(M(\)'3(<$(]%)1+%7(G$"'%$, 0H<MQS'H16 =9M8HQ+1! G+(+Q'7=1Q8=G0 7=1Q8=G0 <P0M <P0M <P0M 0=G+6 @GPM'?^ X+=GMQTYU...
  • Page 82 !"#$%&'()T+%Z")[&O,&'"'$)A-%'$"'-'#" ?)80%&([G9(>76)#+,(\)%)"8(C)'3(^RR[(]%)1+%7(Q+2&'7(G$"'%$, F.1$&c ^9! \0'$&! %'$! 1.! 7$! &0Q$(! 1.! 2'$3$)1! %! 3.#1%6$! ('.2!7$1/$$)!14$!7%11$'-!%)(!14$!7,')$'!/014!14$! XHGXM 7,')$'!',))0)6!%1!+,##!#.%(9 HGH8( a9!J,&$!D0Q$&!Z0)&0($!*.)1'.#[c U.1.'!n!L_!@52 XHGXM E6)01$';!:.)1'.#;!I%#3$;!s!@#%'5!n!^_!@52 !16'TXGXU L9! C%'(</0'$! 7,')$'! 6'.,)(! 1.! 7%11$'-9! A.! FHB! +!1+QM8 ,&$!*4%&&0&!6'.,)(!&-&1$59 N9!E)2,1!2./$'!1.!14$!*.)1'.#`&!i^a!I.#1!/0'$!&4%##! +!1+QM8 7$!2'.30($(!+'.5!%!+,&$(!&$'30*$!&/01*4;!'%1$(!%1! F.1$!Y !16'T+!1U R_!%52&!.'!#$&&9 F.1$!b R9! U.1.'<.++! ($#%-! .)! %! YRRT"! /0##! 7$! (0&%7#$(! 0+! 14$! &%+$1-! %)(! .2$'%10)6! #0501&! %&! &4./)! 0)! (=Q=8 ?)80%&( [G! 0)1$'',21! 2./$'! 1.! 14$! *.)1'.#`&! '$(!
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  • Page 87 !"#$%&'()]+&:U2"1J&&$%'3 >+4,&(T9(>%$04,&*3$$')"8(G3+%' .6/4#"/ !"33&N($)T'>3$ B*)#5$)N>+%$+)&3)%"#)&E%&#&%E-)#5$)N>+%$+)/"#"+-)1+&C$)D">4(&%E-)'%1)"&()4>/4)'+$)"4$+'#&%E)'%1)"&()&3) " )";&%E)#")#5$)%"99($)#5+">E5)#5$)3"($%"&1)C'(C$-)D5$D0)#5$)*"((";&%E)4"33&N&(&#&$3H ^9!:4$*=!14$!%0'!&4,11$'!%(K,&15$)19!E+!14$!%0'!&4,11$'!0&!.2$)$(!1..!+%';!14$!" !./!.+!%0'!5%-!2'$3$)1!14$!%'*!+'.5! '$%*40)6!14$!.0#!&2'%-9!B40&!5%-!%22$%'!%&!%!/401$!3%2.'!$P4%,&1!+'.5!14$!4$%1$'9!!!!t>$+$'!1.!&$*10.)!^!$-+$) H0#!F.1! :,)U:+'"+)-'8)1"$)#&OU:1$%&'_u E6)010)6 a9!B4$!06)010.)!&-&1$5!5%-!4%3$!+%0#$(!1.!&,22#-!%)!%($8,%1$!%'*!1.!06)01$!14$!.0#9!:4$*=!14$!7%11$'-!%)(! *4%'60)6!&-&1$5!1.!0)&,'$!%!*.)10),.,&!&,22#-!.+!^^!1.!^T!3.#1&!A:!Z^R!%52&[9!!!!t>$+$'!1.!&$*10.)!^V&YY2") <11"OU2>)A-%'$"'-'#"_u L9!:4$*=!14$!$#$*1'.($&!+.'!/$%'!%)(!(%5%6$9!E)&,'$!14%1!14$!$#$*1'.($&!%'$!%(K,&1$(!2'.2$'#-9!!!!t>$+$'!1.! &$*10.)!^V&YY2")<11"OU2>)A-%'$"'-'#"_u B*)#5$+$)&3)%")" )'/$-)#5$)N>+%$+)/"#"+)'%1)&E%&#$+)"4$+'#$)D"%#&%>">3(6)'%1)#5$)"&()3"($%"&1)C'(C$)&3) *>%D#&"%'(-)D5$D0)#5$)*"((";&%E)4"33&N&(&#&$3H ^9!:4$*=!+.'!%!2#,66$(!.0#!).QQ#$9!t>$+$'!1.!&$*10.)!Lu a9!E+!14$!*.0#!.)!14$!&.#$).0(!3%#3$!0&!%*1,%10)6;!0)&,'$!14%1!14$!3%#3$!0&!.2$)0)6!.'!*#.&0)6!2'.2$'#-9!!!!t>$+$'!1.! &$*10.)!^5:"2)!:,,2>_u F.!J#%5$ L9!:4$*=!+.'!&,+! !*0$)1!+,$#!2'$&&,'$9!"'$&&,'$!0&!^__!2&06!/014!3%#3$!$)$'60Q$(;!,)#$&&!.14$'/0&$!).1$(9!!!! t>$+$'!1.!&$*10.)!^T+%Z")[&O,&'"'$)A-%'$"'-'#"_u N9!:4$*=!14$!2,52!2'$&&,'$9!:4$*=!+.'!%0'!0)!+,$#!#0)$&9 R9!:4$*=!7,')$'!+.'!7'.=$)!5.1.'!*.,2#0)69!E+!14$!*.,2#0)6!0&!7'.=$)!*4$*=!2,52!'.1%10.)!2'0.'!1.!'$2#%*0)6!14$! *.,2#0)69!!!!t>$+$'!1.!&$*10.)!^T+%Z")[&O,&'"'$)A-%'$"'-'#"_u T9!:4$*=!+.'!*.)1%50)%1$(!+,$#!%)(S.'!2%'10%##-!2#,66$(!+,$#!! !#1$'9!!!!t>$+$'!1.!&$*10.)!^5:"2)!:,,2>_u B*)#5$)N(";$+)/"#"+)&3)%"#)"4$+'#&%E-)D5$D0)#5$)*"((";&%E)4"33&N&(&#&$3H ^9!:4$*=!3.#1%6$!%1!14$!5.1.'!1.!0)&,'$!14%1!&/01*4$&!%)(!'$#%-&;!0)!#0)$!/014!14$!5.1.';!%'$!.2$'%10)6!2'.2$'#-9! U.1.'!F.1! t>$+$'!1.!&$*10.)!^.:+'"+)S%+%'3_u H2$'%10)6 a9!:4$*=!2,52!%)(!5.1.'!&4%+1!.2$'%10.)9!B4$-!&4.,#(!/.'=!+'$$#-!/014.,1!70)(0)69!!!!t>$+$'!1.!&$*10.)!^T+%Z") [&O,&'"'$)A-%'$"'-'#"_u B*)#5$)N(";$+)/"#"+)&3)"4$+'#&%E-)#5$+$)&3)*>$()&%)#5$)#'%0-)N>#)"&()1"$3)%"#)34+'6)">#)#5$)$%1)"*)#5$) %"99($-)D5$D0)#5$)*"((";&%E)4"33&N&(&#&$3H ^9!:4$*=!+.'!%!7'.=$)!.'!&1'022$(!*.,2#0)6!7$1/$$)!14$!2,52!%)(!14$!5.1.'9!!!!t>$+$'!1.!&$*10.)!^T+%Z")
  • Page 88 !"#$%&'()9",2-#"O"'$)*-+$1 F%,-0/%9%#$*50)$& "! "* "# "" !& !" " & !" B((>3#+'#&"% B((>3#+'#&"% S$3D+&4#&"% !'+#d S$3D+&4#&"% !'+#d ?&*,1*4$.)!"#%1$ LN]L A:!U.1.' ?#$*1'.($!o01!.3$'!L< RSb X RYbYL^ O#./$'!\4$$# a]]]G :%(!:$##!A$1$*1.' YN]aSY__TG :.,2#0)6 a^N_R_^ E6)01$'!f%&=$1!o01 R^N^^ @0'!f,0($ L^aL^G NlN!\0'0)6!O.P!o01 RYY_ O,')$'!C.,&0)6!<!O#%*= RbYNOoG :.)1'.#!o01 YRRTP<PPPPGm @0'!O%)(! R^R^R_^ @0'!D4,11$'!<!N!D#.1...

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