Falcon RME Series Operation, Parts And Repair Manual Download

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Summary of Contents for RME Series

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 co...

Page 2: ...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...

Page 3: ...ump 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 T...

Page 4: ...er 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 Part...

Page 5: ...the safety and operational considerations of the equipment 1 DANGER Immediate hazards which WILL result in severe personal injury or death if the warning is ignored 1 WARNING Hazards or unsafe practi...

Page 6: ...OOR 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 SERIO...

Page 7: ...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 TH...

Page 8: ...HE 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...

Page 9: ...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...

Page 10: ...mperature 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...

Page 11: ...ctions given by the tow vehicle and trailer hitch manufacturers as well as the instructions in this manual Reporting Safety Defects If you believe that your vehicle has a defect that could cause a cra...

Page 12: ...wer acceleration and increased length Be alert for slippery conditions You are more likely to be affected by slippery road surfaces when driving a tow vehicle with a trailer Anticipate the trailer swa...

Page 13: ...racks before coupling Replace worn corroded or cracked hitch components before coupling the trailer to the tow vehicle Be sure the hitch components are tight before coupling the trailer to the tow veh...

Page 14: ...part of the trailer hitch 2 Cross chains underneath hitch and couple with enough slack to permit turning and to hold tongue up should the trailer come loose 1 An ineffective or inoperative breakaway...

Page 15: ...checking tire pressure NOTE Tire pressure identified on VIN tag is the tire pressure at the time the equipment was delivered Check the pressure rating on the tire to determine the pressure requirement...

Page 16: ...rious injury 1 2 8 Overload 1 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...

Page 17: ...t hot patcher may ignite a flammable liquid 1 2 11 Inoperable Brakes and Lights 1 An overloaded trailer can result in loss of control of the trailer leading to death or serious injury Do not exceed th...

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Page 19: ...k a curb inspect the rims for damage i e being out of round and replace any damaged wheel Inspect the wheels for damage every year even if no obvious impact has occurred FIGURE 1 LUG NUT SEQUENCE OF T...

Page 20: ...ility to the original purchaser in excess of the price paid by the original purchaser for the product in question This warranty shall extend only to the original purchaser and is non transferable IMPL...

Page 21: ...component failure Charge a low voltage battery before proceeding Breakaway Brakes Electric Hydraulic Check Operation and Connect Electric Breakaway see page 14 Check Brake Fluid Level in actuator and...

Page 22: ...Hydraulic Hookup to Tow Vehicle if applicable It is the end user s responsibility to 1 supply the asphalt hot patcher with hydraulic fluid from the tow vehicle and 2 adjust the flow rate of hydraulic...

Page 23: ...iesel burner on 2 Slowly loosen the 3 8 bleeder screw on the diesel burner pump 3 Let fuel flow until a steady stream of diesel runs with no spurts of air Burner Tune up Kit Falcon Part KT 31303 KT 31...

Page 24: ...nually remove bearings from axles clean thoroughly and reinstall with fresh grease Grease with high temperature wheel bearing grease 6 10 pumps Heat Transfer Oil Oil Jacketed Hopper or Oil Jacketed Ta...

Page 25: ...peratures deteriorate with time and lose many of their characteristics For best results and safety the heat transfer oil in this machine must be drained and replace with any of the oils listed above a...

Page 26: ...ctions to ensure that the patcher is properly secured to the towing vehicle Secure the jack stand in the raised position before moving the tow vehicle WARNING Failure to raise the jack when trailer is...

Page 27: ...cle 2 MOVE PATCHER INTO VEHICLE WITH FORK TRUCK NEVER LIFT WITH CORNER EYES CAUTION Do not attempt to transport slip in unit with a fork truck without using fork pockets A Insert forks into pockets lo...

Page 28: ...S PERFORM STEPS 6 and 7 1 Remove all four positive locking pins from top of loading doors and hopper walls 2 Open loading doors by a grabbing both loading door handles b pulling handles out until they...

Page 29: ...OFF AFTER HYDRAULIC LOADING DOORS ARE OPEN Make sure that tow vehicle power is on Open loading doors by lifting the spool valve right spool on a 2 position spool valve center position on a 3 position...

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Page 31: ...M 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 d...

Page 32: ...firm and change if necessary the desired hopper temperature before operating the equipment To change the desired hopper temperature the operator holds the left green scroll button down while pressing...

Page 33: ...el exceeding B5 will cause burner component failure and void the warranty on the burner NOTICE The most common reasons for the diesel burner failing to light are 1 a low voltage battery and 2 gelled d...

Page 34: ...ed attempt to start the diesel burner by flipping the HOPPER toggle switch OFF DOWN then ON UP If the burner still wont start after 30 seconds and it has been determined that the fuse is good and the...

Page 35: ...tio of 1 1 in cold weather conditions Poor quality fuel can prevent the burner from running properly and CAUSE BURNER COMPONENT FAILURE Clues that fuel is not within the ASTM specs might be a sudden r...

Page 36: ...tter adjustment helps the burner ignite If the burner ignites with the outer air shutter is at a point less than a setting of 4 the nozzle needs to be replaced Turn off down the HOPPER toggle switch r...

Page 37: ...BOX HOPPER IS IN MOTION CAUTION PROTECT THE REMOTE HOPPER CONTROL FROM BEING DAMAGED AT ALL TIMES IF CONTROLLER IS EVER DAMAGED REPAIR OR REPLACE BY AN AUTHORIZED SERVICE TECHNICIAN WARNING ALWAYS USE...

Page 38: ...S OUTRIGGERS WARNING NEVER LEAVE OUTRIGGERS DOWN WHEN THE TRAILER IS IN MOTION SERIOUS INJURY COULD OCCUR IF OUTRIGGERS ARE NOT RAISED TO PROVIDE ADEQUATE CLEARANCE OVER ROADWAYS AND POTENTIAL OBSTRUC...

Page 39: ...rd will not be pinched when the hopper is lowered Using the hopper remote control depress and hold the down button until the hopper is returned to cradle 3 Replace the remote operating control in the...

Page 40: ...UL approved extension cord 4 Leave HOPPER toggle switch ON UP and set automatic temperature controller setting to 180 degrees Fahrenheit Patcher burner will cycle on and off throughout the night keepi...

Page 41: ...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...

Page 42: ...cess Controller digital HT10133 Thermocouple 36 HT10184 Thermocouple 24 HT10325 Thermocouple 18 HT11714 12 Volt Relay EL10031 Battery SRM 24 EL10026 Battery Box SRM 24 EL10217 Battery Terminal End EL1...

Page 43: ...OP11642 Main Hopper Burner Tune up Kit KT31217 Tack Tank Burner Tune up Kit KT31303 Recycling Burner Tune up Kit KT31303 Diesel Burner Maintenance Kit KT31218 Environmentally Friendly Release Agent F...

Page 44: ...t DANGER NEVER USE A FLAMMABLE MATERIAL TO CLEAN NEAR THE PATCHER 4 Close tack tank door 5 Place tack bucket under the tack tank spout 6 Lift up on the material supply valve located at the base of the...

Page 45: ...out lid 5 If tack tank is oil jacketed check level of heat transfer oil when equipment is level and add to fill line if low See page 25 for a list of recommended heat transfer oils 6 Obtain the proper...

Page 46: ...e tack tank when the appropriate level of tack has been drawn 12 Apply tack material based on organization s procedures 13 Remove all visible tack material with an environmental friendly tack release...

Page 47: ...only two positions fully closed perpendicular to the plumbing or fully open parallel to the plumbing Red handled ball valves are for the tack tank Yellow handled ball valves are for the flush tank 1...

Page 48: ...off tack tank burner by flipping the TACK toggle switch OFF DOWN 11 Turn off tack tank spray system motor see manual for instructions 12 Close Tack Tank ball valves coated with RED 13 Perform Flush Sp...

Page 49: ...id coming out of the wand is the color of the release agent used in the flush tank This means that the tack material has been cleared from the hose and wand 6 Close the two flush tank ball valves YELL...

Page 50: ...ture of the machine will keep the material at the appropriate temperature until street crews are ready to begin patching After the material reaches the temperature set on the controller the burner shu...

Page 51: ...operating instructions If using a 7 day timer make sure to set the timer to the correct weekday a Set the current time b Move the pin on the outside of the timer dial to the calculated start time usi...

Page 52: ...are hard wired to the on board battery charger and will be charged at the same time If the asphalt hot patcher does not have a male receptacle that is hard wired to an on board battery charger connect...

Page 53: ...NDITION NOTICE THE DISCONNECT USES 30 AMP TIME DELAY FUSES OPERATING STEPS 1 TURN THE DISCONNECT TO THE OFF POSITION 2 FALCON OFFERS BOTH 110V and 240V ELECTRIC HEAT SYSTEMS THE VOLTAGE IS IDENTIFIED...

Page 54: ...ke 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: ...y ensure that the system is turned off by turning the FUEL toggle switch OFF DOWN It is possible to run this system overnight by leaving the FUEL switch in the UP ON position however the patcher must...

Page 56: ...MPONENT 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 Yell...

Page 57: ...This is the most a particular axle can weigh If there are multiple axles the GAWR of each axle will be provided If your trailer has a GVWR of 10 000 pounds or less there is a vehicle placard located i...

Page 58: ...bined weight of the driver and passengers who will be riding in your vehicle 3 Subtract the combined weight of the driver and passengers from XXX kilograms or XXX pounds 4 The resulting figure equals...

Page 59: ...Gross Axle Weight Rating The maximum weight that any axle can support as published on the Certification VIN label on the front left side of the trailer Actual weight determined by weighing each axle o...

Page 60: ...ith the requirements of this standard Non pneumatic tire A mechanical device which transmits either directly or through a wheel or wheel center member the vertical load and tractive forces from the ro...

Page 61: ...tire or a tire and tube assembly upon which the tire beads are seated Rim diameter This means the nominal diameter of the bead seat Rim size designation This means the rim diameter and width Rim type...

Page 62: ...s published a brochure DOT HS 809 361 that discusses all aspects of Tire Safety as required by CFR 575 6 This brochure is reproduced in part below It can be obtained and downloaded from NHTSA free of...

Page 63: ...ommended tire pressure if your tires are not cold Because tires are designed to be used on more than one type of vehicle tire manufacturers list the maximum permissible inflation pressure on the tire...

Page 64: ...tions spaced intermittently in the bottom of the tread grooves When they appear even with the outside of the tread it is time to replace your tires Another method for checking tread depth is to place...

Page 65: ...ers 3197 means the 31st week of 1997 The other numbers are marketing codes used at the manufacturer s discretion This information is used to contact consumers if a tire defect requires a recall Tire P...

Page 66: ...nting Tire Damage Slow down if you have to go over a pothole or other object in the road Do not run over curbs or other foreign objects in the roadway and try not to strike the curb when parking Tire...

Page 67: ...ay WHEN THE WEATHER IS COLD 40 degrees Fahrenheit and below WHAT DO I NEED TO DO DIFFRENTLY TO GET THE DIESEL BURNER TO IGNITE Use the diesel fuel pre heater if asphalt hot patcher includes this optio...

Page 68: ...like a melted CAD cell Once the material has reached the set temperature of the controller the burner cycles on and off periodically as the temperature of the material inside the hopper drops 10 degr...

Page 69: ...the lower end of the manufacturer s recommended temperature range when setting the temperature on the controller WHEN SHOULD I USE THE TOP BURNER LABELED RECYCLE The top hopper burner with the label R...

Page 70: ...pical temperatures ranges are COLD MIX 100 degrees Fahrenheit HOT MIX 240 270 degrees Fahrenheit Follow the recommendations of your particular brand supplier of asphalt WHAT IS THE PROCESS TO KEEP MAT...

Page 71: ...e burner component failure If the burner toggle switch es has have been turned on and off several times adequate time should be given to allow excessive diesel fuel to evaporate before attempting to t...

Page 72: ...olts Every 1 000 hours inspect the combustion chamber flange gasket to ensure a good seal Check water separator located on the bottom of the fuel filter regularly and empty water as needed CAUTION Bad...

Page 73: ...RIDES LEVEL DO PERFORM ONGOING MAINTENANCE DO REMOVE WEIGHT FROM PIN FINGER OF MATERIAL METERING DOOR BEFORE ADJUSTING DO NOT CLOSE LOADING DOORS IF ASPHALT MATERIAL IS ON CAPS OF HOPPER WALLS DO NOT...

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