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Falcon RME Series User Manual

Falcon RME Series
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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

Table of Contents

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Falcon RME Series Specifications

General IconGeneral
BrandFalcon
ModelRME Series
CategoryConstruction Equipment
LanguageEnglish

Summary

SAFETY ALERT SYMBOLS AND SIGNAL WORDS

Danger

Immediate hazards that will result in severe personal injury or death if ignored.

Warning

Hazards or unsafe practices that could result in severe personal injury or death if ignored.

Caution

Hazards or unsafe practices that could result in minor or moderate injury if ignored.

OPERATOR WARNINGS

General Warnings

General safety instructions for operating the asphalt hot patcher.

Dump Trailers

Specific safety warnings related to dump trailer operation.

Slip-In Units

Specific safety warnings for slip-in unit operation.

Hydraulic Operated Units

Specific safety warnings for hydraulic unit operation.

Tack Tanks

Specific safety warnings for tack tank operation.

Oil Jacketed Tack Tank and/or Hopper

Safety warnings for oil-jacketed tack tanks and hoppers.

GENERAL TRAILER SAFETY INFORMATION

Reporting Safety Defects

Procedure for reporting vehicle safety defects to NHTSA and Falcon RME.

MAJOR HAZARDS

Driving Too Fast

Risks associated with exceeding safe towing speeds.

Failure to Adjust Handling While Towing a Trailer

Handling adjustments needed when towing a trailer.

Trailer Not Properly Coupled to the Hitch

Critical safety regarding trailer coupling and chains.

Incorrect Use of Breakaway Brake

Proper use and function of the breakaway brake system.

Mismatch of Trailer and Hitch

Risks of incompatible trailer and hitch ratings.

Unsafe Tires, Lug Nuts or Wheels

Hazards from improper tire condition, pressure, and lug nuts.

Lug Nuts (Bolts)

Safety procedures for tightening trailer lug nuts.

Do Not Exceed GVWR

Consequences of overloading the trailer beyond its GVWR.

No Riders

Prohibition of riding on the hot patcher.

Keep Flammable Liquids Away From Trailer

Risks of fire ignition from flammable liquids near the patcher.

Check electrical components

Ensuring proper electrical connections for brakes and lights.

Hazards From Modifying Your Trailer

Risks and warranty implications of trailer modifications.

Axle Bolts, Frame, Suspension and Structure

Hazards associated with worn or broken suspension parts.

Wheel Rims

Inspection of wheel rims for damage.

FALCON RME ASPHALT HOT PATCHER LIMITED WARRANTY

INSPECTION AND MAINTENANCE SCHEDULE

Inspection, Service and Preparation BEFORE EACH USE

Pre-operation checks for the asphalt hot patcher.

Inspection and Service Twice a Month

Scheduled inspection and service tasks performed bi-monthly.

Monthly Inspection and Service

Scheduled inspection and service tasks performed monthly.

Quarterly Inspection and Service

Scheduled inspection and service tasks performed quarterly.

Semi-Annual Inspection and Service

Scheduled inspection and service tasks performed semi-annually.

Annual Inspection and Service

Scheduled inspection and service tasks performed annually.

LUBRICATION SCHEDULE

Door & Linkage Lubrication

Lubrication points for doors, fingers, pins, and linkages.

Pivot & Bearing Lubrication

Lubrication for pivot points and bearings on various components.

Fluid System Lubrication

Refilling the hydraulic pump reservoir and checking heat transfer oil.

Hydraulic Components Lubrication

Lubrication for hydraulic cylinders and jack stand gears.

RECOMMENDED FLUID MAINTENANCE SCHEDULE FOR HEAT TRANSFER OIL

ATTACHING PATCHER TO TOW VEHICLE

LOADING SLIP-IN PATCHER INTO TOW VEHICLE

FILLING HOPPER AND LOADING DOOR INSTRUCTIONS

Manual Loading Doors Operation

Instructions for operating manual loading doors.

Hydraulic Loading Doors Operation

Instructions for operating hydraulic loading doors.

OPERATION OF MANUAL MATERIAL METERING DOOR

Material Door Operation with Finger

Steps for operating the material door using the finger mechanism.

Material Door Operation with Pin

Steps for operating the material door using the pin mechanism.

OPERATION OF HYDRAULIC MATERIAL DOOR

STARTING THE MAIN HOPPER DIESEL BURNER AND SETTING THE TEMPERATURE CONTROLLER

Preparation of Fuel for Cold-Weather Operation

Guidelines for fuel preparation in cold weather conditions.

Diesel Fuel Usage and Warranty

Information on using bio-diesel fuel and its warranty implications.

Diesel Burner Ignition Issues

Common reasons for diesel burner failure to ignite.

Troubleshooting

Steps for troubleshooting burner ignition and fuel system issues.

DUMP BOX OPERATING INSTRUCTIONS

LOWERING DUMP BOX INSTRUCTIONS

PATCHER SHUTDOWN

Keeping Hot Mix Overnight

Procedure for maintaining hot mix asphalt temperature overnight.

REPLACEMENT PARTS AND NUMBERS

NON-HEATED TACK TANK INSTRUCTIONS

HEATED TACK TANK OPERATION

TACK TANK SPRAY SYSTEM OPERATION

FLUSH SPRAY SYSTEM PROCEDURE

REFILLING TACK TANK

Procedure for refilling the tack tank.

TWO-BURNER RECYCLER OPTION INSTRUCTIONS

INSTRUCTIONS TO RECYCLE ASPHALT

Steps for recycling asphalt using the two-burner system.

BATTERY CHARGING INSTRUCTIONS

ELECTRIC OVERNIGHT HEAT OPTION INSTRUCTIONS

OPERATING STEPS

Step-by-step guide for using the electric overnight heat option.

MANUAL HOIST OPTION INSTRUCTIONS

DIESEL FUEL PRE-HEATER OPTION INSTRUCTIONS

ONGOING MAINTENANCE TIPS

Maintenance recommendations for the diesel fuel pre-heater.

WIRING COLOR CODE

TIRE SAFETY INFORMATION

Steps for Determining Load Limits

Guide to determining trailer and tow vehicle load limits.

Glossary Of Tire Terminology

Definitions of common tire-related terms.

Tire Safety Overview

General overview of tire safety and its benefits.

Basic Tire Maintenance

Essential tire maintenance practices for vehicle safety.

COMMONLY ASKED QUESTIONS

Burner Operation and Safety

Q&A on burner cleaning, cold weather ignition, and bio-diesel fuel.

Hopper and Material Handling

Q&A on asphalt overspill, hopper floor cleanliness, and hot empty hoppers.

Temperature Control and Indicators

Q&A on hopper temperature, gauges, and controller settings.

Troubleshooting and Maintenance Q&A

Q&A on battery charging, starting issues, and tack spray system maintenance.

IMPORTANT ONGOING MAINTENANCE ITEMS

SPRAY SYSTEM HELPFUL HINTS

Helpful tips for operating and maintaining the spray system.

ADC 12Vdc Oil Burner Manual

Critical Safety Warnings

General warnings for burner installation, misuse, and safety.

Hazard Definitions

DANGER

Definition of DANGER hazard level.

WARNING

Definition of WARNING hazard level.

Burner Application Scope and Intended Use

Prepare Before Installing

Owner's Responsibility

Owner's responsibilities for burner installation and use.

Specifications

Technical specifications for the oil burner.

Notice Special Requirements

Special requirements for burner installation.

General Information

Equipment Located in Confined Space

Requirements for installing equipment in confined spaces.

Exhaust Fans and Other Air-Using Devices

Considerations for air openings and exhaust systems.

Clearances to Burner and Equipment

Minimum clearances for service and maintenance.

Exhausting Hazardous Fumes

Ensuring adequate ventilation to exhaust fumes.

Nozzle Assembly Maintenance

Nozzle and Electrode Adjustment

Procedures for adjusting nozzle size, flow rate, and electrodes.

Igniter and Line Assembly Service

Maintenance for the igniter and nozzle line assembly.

Z-Dimension Check/Adjustment

Checking and adjusting the Z-dimension for nozzle alignment.

Fuel Supply

Fuel Line Connections

Guidelines for connecting fuel lines and installing bypass plugs.

Fuel Supply & Level Considerations

Fuel supply level requirements and two-pipe systems.

Fuel Line Maintenance

Fuel line replacement, valves, and filter usage.

Burner Wiring

Burner installed on equipment

Referencing appliance manufacturer's wiring diagrams.

Burner Replacement

Information on burner wiring variations and replacement.

Drive Component Maintenance

Motor, Blower Wheel, and Coupling Replacement

Steps for replacing the motor, blower wheel, and coupling.

Pump Maintenance

Valve Coil and Stem Replacement

Start Up Burner & Set Combustion

Basic Burner Operation

Overview of burner operation, motor, pump, and igniter.

Combustion Set-up

Steps for setting combustion using air adjustments.

Set Combustion with Instruments

Adjusting combustion levels with CO2/O2 measurements.

Maintain & Service Burner

Owner's Information

General information for burner owners regarding service.

Owner Service and Maintenance

Owner's responsibilities for burner maintenance.

Troubleshooting

Replacement Parts

SECTION 2 FUNCTIONS MENU AND PROGRAM MODE GUIDE

BREAKAWAY SWITCH INSTALLATION INSTRUCTIONS

Installation Guide

Steps for securely mounting and wiring the breakaway switch.

HYDRAULIC CIRCUIT: 103