Load King Book.book - Schwarze Industries, Inc.
Contents
1. 8 4 3 STARTING THE PATCHER ra 4 3 Start Up Checklist for Daily Maintenance 2 nenn 4 3 PRE OPERATION INSTRUCTIONS 7 4 5 PREPARING OPERATE SPRAY PATCHER 4 6 SPRAY PATCHER CONTRO D P OX 3 22 a ara He nal n 4 7 MACHINE STARTING AND STOPPING PROCEDURES eee eee eee nenene 4 8 4 STEP PATCHNG 4 8 TROUBLESHOOTING GUIDE a vk o is a andes 4 10 MAINTENANCE SECTION lt lt iia 5 1 PARTS INFORMATION bars et rana dis lano 5 2 GENERAL r RR 5 2 Lubrication Filter and Maintenance Schedules 5 2 EMULSIFIER APPLICATION DO s AND DON TS sss sese 5 3 CLEAN UP AND OVERNIGHT STORAGE 5 4 SAFETY SECTION gt r LL lt Y SAFETY GENERAL SAFETY INSTRUCTIONS AND PRACTICES A careful operator is the best operator Safety is of primary importance to the manufacturer and should be to the owner operator Most accidents can be avoided by being aware of your equipment your surroundings and observing c2. 28 Safety Section 1 14 SAFETY Inspect the trailer safety tow chains to make sure they are in good condition and properly attached to the towing vehicle Do not tow the trailer unless the safety chains are attached to the towing vehicle swm 29 A DANGER Never work under the framework or any lifted component unless it is securely supported or blocked up to prevent sudden or inadvertent falling which could cause serious injury or even death swm 31p A DANGER Make sure the auxiliary electric heater and thermostat are working properly Do not use the heater if the electrical wires are damaged or the thermostat is malfunctioning Repair any damaged wires or thermostat before leaving the heater unattended Do not use spliced or damaged electrical wiring or adapters An electrical short could result in fire serious injury or death swm 32p A DANGER When recharging the Battery make sure the access door is open Connect the charger to the battery according to the battery chargers instructions and follow the chargers instructions Do not use the charger if the electrical wires are damaged Do not allow explosive gases from the charging process to accumulate in the eguipment housing An electrical spark could result in fir or an explosion causing serious injury or death swm 34p AWARNING Never use gasoline or other flammable materials to clean parts 4 gt 2 G m A Always follow these pre
3. CHWARZE INDUSTRIES SPRAY PATCHER Load King Published 10 13 OPERATOR S MANUAL FC SSP 0001 Version 1 0 10 13 Schwarze Industries Inc Ses Tet Pace 1055 Jordan Road Huntsville AL 35811 9310 1 800 879 7933 Email support schwarze com WWW Http www schwarze com ATENCI N LEA EL INSTRUCTIVO Er rh Si No Lee Ingles Pida Ayuda a Alguien Que Se Lo Lea Para Que le Traduzca Las Medidas de Seguridad 2013 Alamo Group Inc Aue OF THE KF ALAMO GROUP ALWAYS ON THE CUTTING EDGE 0 00 THE OWNER OPERATOR DEALER All equipment with moving parts are potentially hazardous There is no substitute for a cautious safe minded operator who recognizes the potential hazards and follows reasonable safety practices The manufacturer has designed this equipment to be used with all its safety equipment properly attached to minimize the chance of accidents BEFORE YOU START Read the safety messages on the implement and shown in your manual Observe the rules of safety and common sense FAILURE TO FOLLOW SAFETY MESSAGE AND OPERATOR INSTRUCTIONS CAN CAUSE SERIOUS BODILY INJURY OR EVEN DEATH TO OPERATORAND OTHERS IN THEAREA READ UNDERSTAND and FOLLOW the following INSTRUCTIONS Safety Message Serious injury or death may occur unless care is taken to follow the warnings instructions stated in the Safety Messages Always use good common sense to avoid hazards
4. Remove the keys and disable any remote starting systems Allow time for the heated fluids and components to cool to a level that is safe to handle before attempting to service the components swm 5p Never leave the Patcher unattended while the Patcher engine is running Accidental operation of the control levers or a hydraulic failure may cause a sudden movement or operation of the unit which could result in injury or death swm 6p Never crawl or work under the hopper bin while the hopper door is open Aggregate or hopper contents could fall on you resulting in serious injury or death by crushing or suffocation swm 7p Use proper protective equipment gloves safety eyewear face shield arm protection possible respirator or particle mask when handling the emulsion and heated components during filling replacement adjustment and maintenance The emulsion heated fluids and components can result in serious injury to the hands arms and or eyes if proper protective equipment is not worn sww 8p Never crawl under any raised unless the component is securely supported or blocked up and hydraulic pressure relieved Accidental operation of the lifting lever or hydraulic failure may cause a sudden drop of the unit with possible injury or death by crushing swm op Never remove the Patcher air heater or emulsion hoses to perform repairs or maintenance while the Patcher or truck engines are running Objects propelled from an open hose at
5. Watch Your Step Belt Guard Missing Lubrication Use Diesel Fuel Only Pressure Relief Keep Away from Fan No Smoking when refueling Emulsion Valve Control Use Repair Shields Hydraulic Oil Use Genuine Schwarze Parts Grease Points Tank Under Pressure Machine Can Hurt You Contents Under Pressure Rotating Fan Emulsion Control Hydraulic Fluid Only Read Service Manual 2013 Alamo Group Inc SAFETY Decal Description 110 220 VOLTS ALSAVS READ OPERATORS MANUAL BEFORE USING OR SERVICING HEATER IMPORTANT Use genuine Schwarze replacement parts 29639 USE ONLY TELLUS 68 OR EQUIVALENT HYDRAULIC OIL Safety Section 1 19 Load King 10 13 2013 Alamo Group Inc SAFETY SAFETY DIESEL FUEL ONLY Do not smoke when checking battery level Fumes from batteries are flammable and may explode Load King 10 13 Safety Section 1 20 2013 Alamo Group Inc SAFETY LUBRICATION amp MAINTENANCE SEE TRUCK MANUAL FOR ADDITIONAL MAINT DAILY OR EVERY 8 HOURS CHECK TRUCK ENGINE OIL CHECK HYDRAULIC OIL LUBRICATE CONVEYOR BEARINGS amp FEEDER CHAIN LUBRICATE BOOM FITTINGS WEEKLY OR EVERY 40 HOURS CHECK amp CLEAN BLOWER INTAKE FILTER ALSAVS MONTHLY OR EVERY 160 HOURS CHANGE TRUCK ENGINE OIL CHECK BLOWER OIL LEVEL INSPECT HOSES FOR WEAR INC HYDRAULIC ROTATE DELIVERY HOSE 1 4 TURN 6 MON
6. funnel Avoid using a funnel that has a metal screen or filter Avoid spilling fuel Fuel is expensive and can damage plastic and painted surfaces Clean up spilled fuel immediately Store fuel and all oils at a site protected from moisture dirt other contaminants swm 18p Load King 10 13 Safety Section 1 13 2013 Alamo Group Inc SAFETY gt gt 5 2 2 2 2 Q a SAFETY A DANGER AWARNING AWARNING AWARNING A DANGER AWARNING A DANGER Never run the Truck or Auxiliary engine in a closed building or without adequate ventilation The exhaust fumes can be hazardous and deadly to your health If it is necessary to run the Truck or Auxiliary engine in an enclosed area remove the exhaust fumes from the area to the outdoors with an exhaust pipe extension If you do not have an exhaust pipe extension or if it is not possible to use one open doors and circulate outside air into the area swwm 19p Engine Exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the state of California to cause cancer and birth defects or other reproductive harm swnm 20 Always read carefully and comply fully with the manufacturer s instructions when handling fuels oils solvents cleansers and any other chemical agent sww z2 Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the state of Cali
7. Always wear OSHA approved Safety Glasses Gloves Steel toed Safety shoes when operating the Road Patcher Wear full length pants and long sleeve shirts to prevent emulsion from direct contact with skin Keep Bystanders and Coworkers 25 feet away from emulsion nozzle when in use Aggregate heated fluids and debris discharged from nozzle can fly distances up to 25 feet Always shut down the Truck Engine place the transmission in the park position engage the parking brake and remove the key before dismounting the truck Never attempt to mount or dismount a moving truck or trailer Shut down both Truck and Auxiliary Engines before preforming any maintenance on the equipment Never work under raised components until they have been securely blocked up and supported D361 Load King nene Information Sheet HWARZE DELIVERY DATE Delivery Record File Copy COMPANY NAME Remove This Page Prior To Delivery To Customer ADDRESS CITY STATE ZIP PHONE PATCHER SERIAL NUMBER AUXILIARY ENGINE MODEL AUXILIARY ENGINE SERIAL NUMBER TRAILER VIN NUMBER MANUFACTURED BY Schwarze Industries Inc 1055 Jordan Road SOLD AND SERVICED BY Huntsville AL 35811 9310 1 800 879 7933 Email support schwarze com WWW Http Awww schwarze com Load King M Information Sheet INDUSTRIES IMPORTANT DELIVERY DATE 3 2 OZO OoOo CUSTOMER COMPANY INFORMATION ADDRESS It is important that all CITY w
8. Conveyor jammed or cavitated Not enough air volume Feeder jammed Operation Section 3 10 Remedy Disengage PTO and allow truck brake system to build pressure check to see that Pressure Relief Valve is closed Inspect and reset Breaker Replace Solenoid Replenish Fluids Inspect and reset Breaker Check all wiring Check Oil level in reservoir Add oil if needed If problem continues consult your dealer Adjust Boom movement flow control Replace Breaker Check Control Panel Power Line at Battery Check Oil level in Reservoir Adjust Boom movement Flow Control Open Delivery Hose at Camlock Connection and clean out Check Valve repair if needed Inspect and correct Breaker etc Tighten Conveyor Adjustment on Bearings Check Blower RPM Clean Rock from Feeder Loose Drive Chain Tighten Chain Idler 2013 Alamo Group Inc Rock Frozen Hopper Warm Up Thaw Out Break Up Aggregate or clean out Poor or uneven rock flow Conveyor jammed or cavitated Adjust Conveyor speed Delivery Hose or Feeder needs cleaning Adjust Hopper Gate Clean Rock Chute Clean Mixing Delivery Nozzle Not enough air volume Check Air Blower Air Filter Check Blower RPM Should be 1500 1600 RPM Inspect Feeder Air Blow By Dusty Delivery of Rock Dusty Rock Dry Rock Wash down Rock before loading or dampen Rock n Hopper O m gt O 2 No
9. Emulsion Not enough air pressure in Emulsion Tank Check Emulsion Tank Air Pressure Tank Gauge Check all Air Lines to Tank Disengage PTO and allow Truck Brake System to build pressure Check to see that Pressure Relief Valve is closed Line clogged Valve clogged Warm Up Thaw out Lines Clean Spray Ring in Nozzle Make sure Line was flushed after each use Poor or uneven emulsion Emulsion may be separated Drain Tank and replace emulsion Emulsion Tank level too low to draw Fill Tank Spray Ring Line or Valve clogged Warm Up Thaw out Lines Clean Spray Ring in Nozzle Make sure Line was flushed after each use Not enough air pressure Check Emulsion Air Pressure Disengage PTO and allow Truck Brake System to build pressure Check to see that Pressure Release Valve is closed on Flush Tank and Emulsion Tank Too cool for rapid set emulsion Change Emulsions Too cool for rapid set Emulsion Consult your local supplier Load King 10 13 Operation Section 3 11 2013 Alamo Group Inc MAINTENANCE SECTION Maintenance Section 4 1 MAINTENANCE MAINTENANCE 1 PARTS INFORMATION Schwarze Spray Patcher s are carefully designed and built with quality materials and should be maintained using quality parts These parts are made and tested to Schwarze specifications Non genuine will fit parts do not consistently meet these specifications The use of will fit parts may red
10. Truck and Auxiliary engines Excessive WARNING operating speeds can cause engine and component failures resulting in possible serious injury or death swo 12p Do not operate the Truck or Patcher if excessive vibration or noise exists AWARNING Shut down the Truck and Auxiliary engines Inspect the equipment to determine the source of the vibration or noise If components are loose damaged or missing replace them immediately Do not operate the equipment until all necessary repairs have been performed and the equipment operates smoothly Operating the equipment with excessive vibration can result in component failure and broken objects being thrown outward at high velocities To reduce the possibility of property damage serious injury or even death never operate the equipment with missing or damaged components swo 16p Load King 10 13 Safety Section 1 7 2013 Alamo Group Inc ALSAVS SAFETY SAFETY Piled debris loose aggregate and emulsion puddles left behind the Patcher might pose a driving hazard to vehicle traffic colliding with the debris or losing traction on the material It is recommended to post warning signs alerting drivers of the Patcher s presence and the need to reduce vehicle speed If such hazards remain the area should be swept to remove any remaining hazards swo 19p gt 2 z a A DANGER Air enters the fan housing inlet with great force Caution should be used when the
11. m gt O z OPERATION OPERATION SPRAY PATCHER PRE OPERATION Inspection Patcher ID Make Date Shift Before conducting the inspection make sure the truck engine is off all movement has stopped and the truck is in park with the parking brake engaged Make sure the Truck is parked on level ground and all movement of sweeper has stopped Condition at Specific Comments Ttem Start of Shift if not Visually inspect for general condition Check the auxiliary engine s oil level Inspect auxiliary engine air cleaner Check the hydraulic tank fluid level and fill as needed Inspect the hydraulic system for leaks and faulty lines Inspect blower intake filter Inspect the rims and wheel nuts Check the tires for wear damage and pressure Inspect and check the braking system Inspect and check the tow chains Inspect the exhaust system Check the fuel level Check the battery Inspect all engine drive belts for wear Check operation of all lights and beacons Verify that all emergency equipment is present Review daily maintenance records Be sure all lubrication schedules are current Operator s Signature DO NOT OPERATE an UNSAFE SWEEPER Load King 10 13 Operation Section 3 4 2013 Alamo Group Inc 3 PRE OPERATION INSTRUCTIONS 1 The Heating Element MU
12. or obstruction such as a vehicle building or street sign are behind the Truck or Trailer when backing up The design of the Truck and or Trailer impairs operator rear vision when backing Use extreme caution to ensure that the Equipment is not backed into the path of pedestrian or vehicle traffic Serious injury or death and property damage could result from running into being crushed by or run over by a Sweeper swo 33p AWARNING Do not start the auxiliary engine with the shields or guards missing Entanglement with A DANGER the components can result in bodily injures swo 36p Stay clear of pinch points when handling boom Serious finger or hand injuries can occur at A DANGER the pinch point of the boom when you are extending or retracting the boom Keep your hands away from the pinch point areas swo 39p O D A gt oo Safety Section 1 9 2013 Alamo Group Inc SAFETY o O a gt oo SAFETY AWARNING AWARNING AWARNING AWARNING AWARNING AWARNING AWARNING AWARNING Avoid body contact with collected debris in the hopper Use protective clothing including gloves and eye protection when servicing or working in or around hopper Aggregate and debris in the hopper can cut or puncture resulting in serious bodily injuries and the transmittal of diseases swo 42p Avoid body contact with emulsion chemicals Use protecti
13. power suction nozzle is being used To avoid being pulled into the suction nozzle do not wear loose clothes or position yourself or allow others near the suction nozzle inlet Possible serious injury could occur from being pulled into the suction nozzle swo 21p Use extreme caution when operating the pothole patcher Aggregate fluids A DANGER and debris discharge from the emulsion nozzle can fly distances up to 25 feet Be aware of bystanders vehicles or animals in the area The emulsion aggregate and debris cause serious injury to the operator bystanders and animals Stop the patching operation if any bystander comes within 25 feet of the working nozzle swo 23p Do not allow the Sweeper to come in contact with potentially dangerous and or hazardous A DANGER material Such hazards may include but are not exclusively limited to the following Fire Hazards Fuel spills burning material Chemical Hazards Chemical spills discarded chemical containers batteries Biological Hazards Decaying Carcasses Biomedical Waste Radioactive Hazards Radioactive Waste Radioactive Material Cutting Hazards Broken Glass Lumber with Protruding Nails Carcinogenic Materials Asbestos Corrosive Materials Batteries Acids and Bases In most areas these types of material require special handling requirements for safe collection and proper disposal and should not be collected by the Sweeper nor can they be disposed of in a general
14. seguridad sc 3 INSTRUCTIVO Load King 10 13 Operation Section 3 2 2013 Alamo Group Inc 1 OPERATOR REQUIREMENTS Safe operation of the sweeper the responsibility of a qualified operator A qualified operator has read and understands the Spray Patcher and Operator s Manuals and is experienced in patching operation and all associated safety practices part of the operation and safe use of this equipment is not completely understood consult an authorized dealer for a complete explanation Ifthe operator cannot read the manuals for themselves or does not completely understand the operation of the equipment it is the responsibility of the supervisor to read and explain the manuals safety practices and operating instructions to the operator 1 1 Employer Responsibilities Train the employee in the proper and safe operation of the Spray Patcher Require that the employee read and fully understand the Spray Patcher Operator s Manual Permit only qualified and properly trained employees to operate the Spray Patcher Maintain the Patcher in a safe operational condition Ensure the Truck is equipped with a functional seat belt and require that the employee operator securely fasten the safety belt at all times o Forbid the employee operator to carry additional riders in the Truck 7 Provide the required tools to maintain the Truck and Patcher in a good saf
15. sides filling the cracks and holes providing a Glue for the patch and sealing all edges to produce virtually Tack seamless patch Ops 1850 3 Aggregate is then coated with emulsion in the mixing chamber and blown at a high velocity into the hole simultaneously The air compacts from the bottom up providing a dense durable repair Ops 1851 4 Apply a thin coat of dry aggregate over the pothole to stop tire tracking Once sweeping is completed press Main Broom switch up to stop and raise broom and the conveyer The STANDBY switch can be pressed to raise all brooms to the travel position Ops 1852 Load King 10 13 Operation Section 3 9 2013 Alamo Group Inc O U m gt O z OPERATION OPERATION 8 TROUBLESHOOTING GUIDE Control Problem PTO will not engage Control Panel Dead Hydraulics No Boom Movement Poor or uneven Boom movement Rock No Rock Flow Load King 10 13 Possible Cause Not enough air pressure to engage PTO if air activated PTO Line Breaker to Main Power or PTO Switch is blown PTO Solenoid bad Transmission Fluid low Line Breaker to main power or PTO Switch blown Wire loose No or low hydraulic oil pressure Boom flow controls out of adjustment Blown Breaker or broken electrical connection Low Hydraulic Oil Boom Flow Control out of adjustment Delivery Hose jammed Valve not working PTO not engaged
16. surfaces of the engine or muffler Use gloves and eye protection when servicing hot components Contact with a hot surface or fluid can cause serious injury from burns or scalding sc 38 Always maintain the safety decals in good readable condition If the decals are missing damaged or unreadable obtain and install replacement decals immediately Consult your authorized sales representative for decal replacements sws 1 All Safety Shields Guards and other Protective Safety devices should be used and maintained in good working condition All safety devices should be inspected carefully at least daily for missing or broken components NEVER REMOVE PROTECTIVE SHIELDS AND GUARDS NEVER MODIFY OR CUT PROTECTIVE SHIELDS OR GUARDS When shields or guards are removed to access areas for maintenance they must be replaced and be in good condition before operating Missing broken or worn shields guards and other protective devices must be replaced at once and prior to operation to reduce the possibility of injury or death from thrown objects entanglement or contact sws 2 Use extreme caution when operating the Patcher in traffic To alert motorist of the Patcher s presence the Patcher is equipped with warning signals and flashing lights Optional electrical lights arrow board flashers and a warning bar light strobe or beacon may be positioned on top of the cab Use all equipped warning signals to alert motorist and pedestrians of the Patch
17. the maximum safe transport speed for you and the Truck When driving down a hill or on wet or rain slick roads the braking distance increases use extreme care and reduce your speed Do not operate the Truck with weak or faulty brakes Obey all traffic laws and regulations Never exceed the posted speed limit The Trailer has a high center of gravity that may be further increased when carrying a loaded hopper Use extreme caution when transporting at highway speeds Slow down for sharp corners to avoid tipping or turning the Truck over Only transport the Truck and Trailer at the speeds determined as safe and which allow for proper control of the machine while driving and stopping during an emergency When operating in traffic use the Truck s directional indicator or signal lights to indicate your movement Always use the Truck s flashing signal lights and other equipped warning features to alert motorist of your presence and slow moving speed when working in traffic Be Aware of Traffic Around You and Watch Out for the Other Guy swo 9p When transporting the Trailer between locations follow all local traffic laws and regulations AWARNING Before entering traffic place the cap on the emulsion nozzle lock the Patcher boom into the transport position shut off the auxiliary engine and disengage all Patcher controls Disengage all warning signals prior to entering vehicle traffic swo 10p A Do not exceed the rated operating speed for the
18. ATCHER OPERATION INSTRUCTIONS The Load King Spray Patcher is manufactured with quality material by skilled workers The unit equipped with safety warning decals and safety features to provide operator and passerby protection however no shielding is 100 accurate ALL safety equipment and safety warning decals must be maintained on the unit in good operational condition at all times It is the operator s responsibility to be knowledgeable of all potential operating hazards and to take every reasonable precaution to ensure oneself others animals and property are not injured or damaged by the unit This section of the Operator s Manual is designed to familiarize instruct and educate operators to the safe and proper use of the Spray Patcher Pictures contained in this section are intended to be used as a visual aid to assist in explaining the operation of a Unit The operator must be familiar with the Unit and operation and all safety practices before beginning operation Proper operation as detailed in this manual will help ensure years of safe and satisfactory use of the Spray Patcher READ UNDERSTAND and FOLLOW the following Safety Messages Serious injury or death may occur unless care is taken to follow the warnings and instructions stated in the un Safety Messages Always use good common sense to avoid hazards sc 2 Si no lee ingles pida ayuda alguien que si lo lea para que le traduzca las LEA EL A PELIGRO medidas de
19. ION Pressure release valve on the top of the tank must be opened before opening the emulsion tank Damage to Equipment or bodily injury can result from failure to release the emulsion tank DANGER pressure Pressure Release Valve Emulsion Tank Op 1847 The asphalt will cool during the day s operation and must be plugged into a 110 volt power source overnight to be reheated The operator should check with the local asphalt supplier as to what grades and type of emulsion are available throughout the year The manufacturer suggest using a rapid set Rs2 or CRS2 for warm weathering patching Different emulsions must be used when the temperature begins to dip below 40 degrees Fahrenheit There are several possibilities depending on what your local supplier is able to offer AE150 or AE300 asphalt has been used successfully for winter work The emulsion tank must be cleaned thoroughly before switching emulsion Consult your local CAUTION suppliers for compatibility Load King 10 13 Operation Section 3 6 2013 Alamo Group Inc 5 SPRAY CONTROL BOX O U m gt O 2 1854 Load King 10 13 Operation Section 3 7 2013 Alamo Group Inc 6 MACHINE STARTING AND STOPPING PROCEDURES 1 Remove the nozzle cap 2 Start the engine 3 Run the engine at 1200 to 1500 rpm until the nozzle is hot to the touch or th
20. Inc SAFETY Decal Location NOTE Schwarze supplies safety decals on this product to promote safe operation Damage to the decals may occur while in shipping use or reconditioning Schwarze cares about the safety of its customers operators and bystanders and will replace the safety decals on this product in the field free of charge Some shipping and handling charges may apply Contact your Schwarze dealer to order replacement decals ALJJVS ji 8 DL SSP 001 Load King 10 13 Safety Section 1 17 O 2013 Alamo Group Inc SAFETY SAFETY ITEM PART NO 1 29716 2 29718 3 29722 4 21078 5 29708 6 21074 7 29711 8 29709 9 22891 10 29717 11 29713 12 29729 13 22533 14 29639 15 29714 16 21090 17 29710 18 29730 19 29712 20 29719 21 29715 22 21077 Load King 10 13 TYPE WARNING WARNING INSTRUCT CAUTION WARNING INSTRUCT CAUTION CAUTION WARNING WARNING INSTRUCT WARNING CAUTION IMPORTANT INSTRUCT WARNING DANGER WARNING DANGER INSTRUCT INSTRUCT CAUTION lt Safety Section 1 18 DESCRIPTION No Smoking when Checking Battery 110 220 Volts Patching Procedures
21. Operator Regulations U S Public Law 91 596 The Williams Steiger Occupational and Health Act of 1970 OSHA This Act Seeks 10 assure so far as possible every working man and woman in the nation safe and healthful working conditions and to preserve our human resources DUTIES Sec 5 a Each employer 1 shall furnish to each of his employees employment and a place of employment which are free from recognized hazards that are causing or are likely to cause death or serious physical harm to his employees 2 shall comply with occupational safety and health standards promulgated under this Act b Each employee shall comply with occupational safety and health standards and all rules regulations and orders issued pursuant to this Act which are applicable to his own actions and conduct OSHA Regulations OSHA regulations state in part At the time of initial assignment and at least annually thereafter the employer shall instruct every employee in the safe operation and servicing of all equipment with which the employee is or will be involved Employer Responsibilities To ensure employee safety during Truck and Patcher operation it is the employer s responsibility to 1 Train the employee in the proper and safe operation of the Truck Patcher 2 Require that the employee read and fully understand the Truck and Patcher Operator s manual 3 Permit only qualified and properly trained employees to operate the Truck and Pa
22. ST be covered by the Emulsion level BEFORE PLUGGING IN THE ELEMENT 2 The pressure in the Emulsion or Flushed Tank MUST be Emulsion or Flushed Tank MUST be released BEFORE CHECKNG OR FILING THE TANK by opening the Pressure Relief Valve 3 The Emulsion Consult your Emulsion Supplier on Line MUST be flushed at the END OF EACH DAY or before any extended break between patching 4 Consult your Emulsion Supplier BEFORE MIXING OR SWITCHING EMULSION BATCHES Never operate the Machine without all Guards in place If during the patching operation The Rock flow stops due to delivery hose jamming the operator must click the OFF Rock Switch and allow the Blower to clear the hose or manually clear it if necessary O 5 m gt O z FC SSP 0001 Load King 10 13 Operation Section 3 5 2013 Alamo Group Inc OPERATION OPERATION 4 PREPARING TO OPERATE SPRAY PATCHER The aggregate hopper should be filled with a relatively clean 1 4 or 3 8 diameter rock Larger rock or excessive dust in the aggregate will adversely affect the patching process Therefore 1 2 or larger aggregate is not acceptable for this equipment The screen in the hopper will catch the occasional over sized rock The asphalt tank must be filled with high quality emulsified asphalt The asphalt should be heated at approximately 165 degrees Fahrenheit Consult your local distributor compatible products and availability CAUT
23. THS OR 1000 HOURS REPLACE HYDRAULIC OIL FILTER YEARLY OR 2000 HOURS REPLACE HYDRAULIC OIL REPLACE BLOWER OIL Load King 10 13 Safety Section 1 21 2013 Alamo Group Inc SAFETY A WARNING SAFETY Do not place body parts or foreign objects in fan intake SCHWARZE 22891 Do not operate without belt guards in place 44 WARNING Do Not Smoke when refueling Safety Section 1 22 Load King 10 13 2013 Alamo Group Inc SAFETY DO NOT OPERATE WITHOUT GUARDS IN PLACE A WARNING ALSAVS TANK UNDER 75 P S I PRESSURE READ SERVICE MANUAL BEFORE REMOVING CAP Load King 10 13 Safety Section 1 23 Alamo Group Inc SAFETY SAFETY Machine can hurt you when running Keep Away Remove Radiator Cap slowly Contents under pressure Do Not stick hand into rotating Engine Fan Load King 10 13 Safety Section 1 24 2013 Alamo Group Inc SAFETY Load King 10 13 Safety Section 1 25 2013 Alamo Group Inc ALSAVS SAFETY SAFETY Federal Laws and Regulations This section is intended to explain in broad terms the concept and effect of federal laws and regulations concerning employer and employee equipment operators This section is not intended as a legal interpretation of the law and should not be considered as such Employer Employee
24. a high velocity could cause serious injury Always shut down the Truck and Auxiliary engines completely and wait for all motion to come to a complete stop before working on any Patcher component Allow sufficient time for the heated fluids and components to cool before attempting to service them swm 10p Safety Section 1 12 SAFETY Escaping pressurized hydraulic oil generated by hydraulic pumps has the potential to inflict serious injury and possible death Never attempt to repair a pump or hose or tighten a connection while the system is pressurized Always shut down the Truck and Auxiliary engines and relieve hydraulic oil pressure before performing any repairs to the hydraulic system swm 11p A DANGER Water pressure generated by the water pump has the potential to inflict serious injury Never attempt to repair a pump or hose or tighten a connection while the system is pressurized Always shut down the Truck and Auxiliary engines and relieve water pressure before performing any repairs to the high pressure water system Allow sufficient time for the water to cool be attempting repairs swM 13p AWARNING NEVER work on or near any engine component that has generated heat until it has cooled down Use extra caution around the exhaust manifold near the water valve and the turbo charger manifold tubes NEVER check or replenish the fluid levels of the Truck and Auxiliary engine coolant or hydraulic circuit oil level
25. and emulsion and can be towed with a one ton pickup 2 0 cubic yard aggregate hopper eliminated need for dump truck Durable unibody construction for years of operation Optional vacuum feature allows removal of water and debris from pothole before making repair Auxiliary Engine Manufacturer Isuzu Model 4LE1 Number of Cylinders 4 water cooled Horsepower 49 6 2600 RPM Starting System Electric Charging System 12 volt 35 amp Fuel Tank 40 gallons Blower System Type Lobe Type Air Blower Drive Direct Drive Output 435 CFM Dimensions 4 x6 102 mm X 152 4 mm Load King 10 13 SPECIFICATIONS FEATURES Heating Element Air Cleaner Aggregate Delivery Hose Type Rubber lined abrasion resistant spiral reinforced non kinking hose Inner Diameter 3 Hose Length 19 Aggregate Hopper Body Capacity 2 0 Cubic Yards 1 529 m3 Fill Opening Length 53 Fill Opening Width 53 Aggregate Cover Nylon Neoprene Tarp Aggregate Conveyance Gravity fed with vibration assist Construction 10 Gauge Steel Emulsion Storage amp Delivery Emulsion Capacity Delivery System Pressure Heating Element 100 gallons 70 PSI 110 volt 2 000 watt thermostatically controlled Delivery Nozzle Temp 160 F Flush Tank Capacity 30 gallon Safety Equipment Lighting Amber beacon light Signage Slow moving vehicle emblem warning triangle Optional directional arrow board Alarm backup alarm Fire 5 lb fire extinguisher Introd
26. angerous or hazardous material is being swept by or cleaned swo 4p Load King 10 13 Safety Section 1 3 2013 Alamo Group Inc SAFETY SAFETY A CAUTION A CAUTION A DANGER AWARNING Load King 10 13 Prolonged operation of the Truck and Patcher may cause operator boredom and or fatigue affecting the safe operation of the Truck and Equipment It is recommended that the operator take scheduled work breaks to help prevent these potentially impaired operating conditions If possible completely shut down the Truck and Patcher exit the cab and move around stretching your arms and legs Never operate the Truck and Patcher in a fatigued or bored mental state that impairs proper and safe operation swo sp PROLONGED EXPOSURE TO LOUD NOISE MAY CAUSE PERMANENT HEARING LOSS Patching operation can often be noisy enough to cause permanent hearing loss We recommend that you always wear hearing protection if the noise in the Operator s position exceeds 80db Noise over 85db over an extended period of time will cause severe hearing loss Noise over 90db adjacent to the Operator over an extended period of time will cause permanent or total hearing loss Note Hearing loss from loud noise from patcher s chain saws radios and other such sources close to the ear is cumulative over a lifetime without hope of natural recovery swo sp Do not operate or perform maintenance to the Equipment while wearing loose fitti
27. area in daylight or with adequate artificial lighting Never work in darkness of foggy conditions where you cannot clearly see at least 300 feet in front and to the sides of the Equipment Make sure that you can clearly see and identify passersby steep slopes ditches drop offs overhead obstructions power lines oversized debris and foreign objects If you are unable to see these types of items discontinue sweeping until visibility improves If drivers of passing vehicles do not have enough light to clearly see you or co workers for a least 300 feet discontinue work until visibility improves swo 8p Safety Section 1 6 2013 Alamo Group Inc SAFETY Transport the Truck only at safe speeds Serious accidents injuries can result from WARNING driving this Truck at unsafe speeds Become familiar with the driving characteristics of the Truck and how it handles before operating or transporting on streets and highways Make sure the Truck s steering brakes and wheels are in good condition and operate properly Before transporting the Truck and Trailer determine the safe transport speeds for you and the machine Make sure you abide by the following rules Test the Truck and Trailer at a slow speed and increase the speed slowly Apply the brakes smoothly to determine the stopping characteristics of the Truck equipped with the Patcher As you increase the speed of the Truck the stopping distance increases Determine
28. arranty forms for the chassis sweeper and STATE 2 auxiliary engine be filled out and sent to the appropriate PHONE component manufacturer Failure to do so may result in costly delay or denial should a warranty claim be made PATCHER SERIAL NUMBER AUXILIARY ENGINE MODEL AUXILIARY ENGINE SERIAL NUMBER TRAILER VIN NUMBER MANUFACTURED BY Schwarze Industries Inc 1055 Jordan Road Huntsville AL 35811 9310 1 800 879 7933 Email support schwarze com WWW Http www schwarze com SOLD AND SERVICED BY TABLE OF CONTENTS SAFETY SECTION 0 a 1 1 GENERAL SAFETY INSTRUCTIONS AND PRACTICES 1 2 DRIVER SAFETY INSTRUCTIONS AND PRACTICES 1 3 OPERATION SAFETY INSTRUCTIONS AND 8707777 1 4 MAINTENANCE AND SERVICE SAFETY INSTRUCTIONS AND PRACTICES 1 11 PARTS INFORMATION di 1 16 A AA A gad to AAA 1 17 Decal Description A 1 19 Federal Laws and Regulations 1 26 INTRODUCTION SECTION sees sees esse asien 2 1 SPECIFICATIONS REATURES Vla n ae ade iii A Vl ana e ela 2 4 OPERATION SECTION sarria 4 1 OPERATOR REQUIREMENTS een 4 3 Employer
29. cautions to reduce the dangers involved in cleaning parts Completely shut down the Truck and Auxiliary Engines Let hot and heated parts cool before cleaning Do Not Smoke Use only nonflammable cleaning solvents Dispose of cleaning solvents properly swm 35p Load King 10 13 Safety Section 1 15 2013 Alamo Group Inc ALSAVS SAFETY SAFETY PARTS INFORMATION In addition to the design and configuration of this Patcher including Safety Signs and Safety Equipment hazard control and accident prevention are dependent upon the awareness concern prudence and proper training of personnel involved in the operation transport maintenance and storage of the machine Refer also to Safety Messages and operation instruction in each of the appropriate sections of the Truck and Auxiliary Engine Manuals Pay close attention to the Safety Signs affixed to the Patcher swe 5p PARTS INFORMATION Schwarze uses balanced and matched system components for Patcher These parts are made and tested to Schwarze specifications Non genuine or will fit parts do not consistently meet these specifications The use of non genuine or will fit parts may reduce Patcher performance void Patcher warranties and present a safety hazard Use genuine Schwarze Patcher parts for economy and safety swc 06p SEE YOUR LOCAL SCHWARZE DEALER Schwarze Web Page Load King 10 13 Safety Section 1 16 2013 Alamo Group
30. e emulsion is heated to 165 degrees 4 Unfold the boom on the rear of the machine 5 Turn the emulsion valve located on the top of the machine from the OFF position to the emulsion position 6 TURN OFF ENGINE 7 Using the 5 gallon pail provided with the machine flush out the line until the emulsion starts to come out of the nozzle and into the pail 8 START THE ENGINE You are now ready to start patching 9 When you are finished patching for the day TURN OFF ENGINE turn the emulsion valve from the emulsion position to the flush position Place a 5 gallon pail under the nozzle and flush the line until you no longer see black emulsion coming out of the nozzle The contents should be clear or white in color 10 Turn the emulsion valve from flush position to the off position for overnight storage 11 The above instructions must be done to ensure the life of the machine and components Any emulsion left inside the tank must be heated continuously drained or flushed Emulsion Temperatures Storage 2 weeks or longer 120 Degrees Operation 165 Degrees 7 4 STEP PATCHNG OPERATION 1 The Spray Patcher s articulating hydraulic boom is positioned over the pothole Dust dirt and debris are removed with hight velocity air Ops 1849 Load King 10 13 Operation Section 3 8 2013 Alamo Group Inc 2 emulsion of liquid asphalt is blown into the clean hole lining the
31. e working condition and provide the necessary support devices to secure the equipment safely while performing repairs and service 8 Require that the employee operator stop patching if bystanders or passersby come within 25 yards Child Labor under 16 Years of Age Some regulations specify that no one under the age of 16 may operate power machinery It is your responsibility to know what these regulations are in your own area or situation Refer to U S Dept of Labor Employment Standard Administration Wage amp Home Division Child Labor Bulletin 102 2 STARTING THE PATCHER Before operating the Schwarze Load King ensure the unit s equipment is working properly and that you are prepared for patching operations by 1 completing the Start Up Checklist and 2 testing patcher operations 2 1 Start Up Checklist for Daily Maintenance The following PRE OPERATION Inspection sheet names specific items and areas deserving special attention when you inspect the Spray Patcher It is not a complete list however so you should always complete a PRE TRIP inspection as required by U S Department of Transportation DOT regulations We suggest that your remove the master copy from this manual and make copies that can be used for regular inspections and the completed forms can be compiled in a notebook to give you a comprehensive inspection record of your sweeper Load King 10 13 Operation Section 3 3 2013 Alamo Group Inc O
32. er s presence and relatively slow speed Serious injury or death and property damage may occur if a vehicle collides with the Patcher or workers sws 3p Before starting a patching operation make sure all the warning signal lights are connected visible and working Routinely inspect the Equipment s headlights brake lights backup lights and turn signal lights for operational condition Immediately repair non functioning lighting Always follow all local traffic regulations while operating the Patcher sws 4p Always turn on all safety lights and flashers when you operate the Patcher It is recommended that you preset the beacon strobe light switches to ON so lights go on whenever the auxiliary engine is ON and lights go OFF whenever the auxiliary engine is turned OFF This presetting action has the additional benefit of alerting the operator if the auxiliary engine is inadvertently left ON sws 5p The Patcher must be eguipped with a fire extinguisher rated for all fires in an accessible and visible area The fire extinguisher should be inspected routinely by a certified inspector for operational use and replaced as needed Never obstruct access to the fire extinguisher SWS 6p Use available handholds and steps to board or exit the truck Make sure you have solid footing before stepping down Be careful of your step and use extra caution when mud ice snow or other matter has accumulated on the steps or handrails Never rush to exi
33. ernight delivery is available To speak with our parts team representatives call 1 800 879 7934 To assure prompt delivery and processing of your parts order please have the following information ready before calling and serial numbers for the chassis power module engine and the sweeping unit This information is also located on the Sweeper Information Sheet in the front of this manual part number s description s and the quantity desired Please indicate any relevant particulars such as whether the part is for the right or left front or rear Shipping instructions Tell us how you want you order shipped e g next day air second day air truck freight etc When left unspecified orders are shipped UPS Truck freight is used when weight restrictions apply Every effort is made to ship all in stock parts on the same day the order is placed when received before 12 00 noon Central Time Orders received after noon are shipped on the following business day For customer convenience orders may be faxed to the Schwarze factory 24 hours per day The parts department s fax number is 1 256 851 1199 Schwarze Warranty Information When a Schwarze Load King Spray Patcher is purchased it is important that all warranty forms for the chassis sweeper and auxiliary engine be filled out and sent to the appropriate component manufacturer Failure to do so may result in costly delay or denial should a warranty claim be
34. ertain precautions The first section of this manual includes a list of Safety Messages that if followed will help protect the operator and bystanders from injury or death Read and understand these Safety Messages before assembling operating or servicing this Implement This equipment should only be operated by those persons who have read the manual who are responsible and trained and who know how to do so responsibly The Safety Alert Symbol combined with a Signal Word as seen below is used throughout this manual and on decals which are attached to the equipment The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED The Symbol and Signal Word are intended to warn the owner operator of impending hazards and the degree of possible injury faced when operating this equipment Practice all usual and customary safe working precautions and above all remember safety is up to YOU Only YOU can prevent serious injury or death from unsafe practices Indicates an imminently hazardous situation that if not avoided WILL result in DEATH OR A DANGER VERY SERIOUS INJURY A Indicates an imminently hazardous situation that if not avoided COULD result in DEATH WARNING OR SERIOUS INJURY Indicates an imminently hazardous situation that if not avoided MAY result in MINOR A CAUTION JURY Identifies special instructions or procedures that if not strictly observed could result in damage to or destruction of
35. fornia to cause cancer and birth defects or other reproductive harm Wash Hands after handling sww 23 Avoid contact with hot surfaces on the emulsion nozzle and heated components Use gloves and eye protection when servicing hot components Contact with a hot surface can cause serious injury from burns or scalding sww 24p Remove the negative battery cable from the battery before performing any maintenance on the electrical system to prevent an accidental circuit shorting and sparks Sparks can result in wiring damage fire or personal injury 25 Use caution when working around the hopper doors Do not let the doors fall uncontrolled onto bystanders or coworkers Use the door locks to hold the doors open while cleaning or performing maintenance swm 26p Before conducting maintenance on the Patcher stop the truck place the transmission in park and set the parking brake Turn the Truck engine and the auxiliary engine off and remove the keys and disengage any remote starting systems to prevent inadvertent or accidental starting of the engines Unexpected engine start up or truck movement can result in serious bodily injuries or death swm 27p Do not inspect or approach the engine fans while they are rotating Serious bodily injury including dismemberment can result Shut down the Truck and Auxiliary engines and wait for all rotating motion to stop completely before attempting to inspect or perform maintenance on or near the fans
36. hing functions to be controlled without leaving the boom The 100 Gallon Emulsion Tank means fewer refills during the day for better productivity Mix on demand eliminates the end users dependency of commercially premixed materials in the 2 0 Cubic Yard Aggregate Hopper 2 hoppers for rock per 1 tank of emulsion on average There are no butt connectors All connections are soldered which increases uptime with the use of severe duty wiring that eliminates shorts caused by poor connections Custom made to order Hydraulic Hoses reduce the opportunity for contamination in the Hydraulic System Computer controlled cutting and forming process guarantees a consistent cut part every time Hydraulic leveling boom produces ease of operation and reduces physical stress on the operator This unit uses a high mount Strobe Light which alerts oncoming traffic of patching operation LED Lighting increases visibility on the streets and reduced cost of ownership Come to the people you know for the products you trust Schwarze people are on duty to support you and your equipment Call toll free 1 800 879 7933 Load King 10 13 Introduction Section 2 3 2013 Alamo Group Inc A O o O INTRODUCTION INTRODUCTION The People You Know The Products You Trust Repairs Potholes Alligator Cracks e Utility Cuts Shoulder Work e Depressions General Self contained unit carries its own aggregate
37. ic roadways Contact your local State Department of Public Safety office for special licensing requirements to operate the Truck in your area swo 2p NEVER use drugs or alcohol immediately before or while driving or operating the Truck Drugs and alcohol will affect an operator s alertness and coordination and therefore affect the operator s ability to operate the Truck safely Before operating the Truck or Patcher an operator on prescription or over the counter medication must consult a medical professional regarding any side effects of the medication that would hinder their ability to operate the Truck and Patcher safely NEVER knowingly allow anyone to operate this Equipment when their alertness or coordination is impaired Serious injury or death to the operator or others could result if the operator is under the influence of drugs or alcohol swo 3p o gt TI m lt Always wear OSHA approved Personal Protective Eguipment PPE while operating WARNING servicing repairing and or cleaning the Truck or Patcher PPE is designed to provide bodily protection during such activities Personal Protective Eguipment includes e Protective Eye Wear Steel Toed Safety Footwear e Gloves e Hearing Protection e Close Fitted Clothing Hat When working around a raised hopper e Respirator Depending on conditions and material being swept or cleaned Specialized protective equipment may be required if d
38. ing in fire or explosion Always wear protective clothing including gloves and eye protection when servicing or working in or around the diesel tank swo 4sp Keep co workers and bystanders 25 feet away from the hopper when aggregate is being loaded into the hopper Falling aggregate and debris can cause serious injury if it falls on to a person swo 47p Make sure you are using the correct voltage and adapter when connection the external electrical power to the auxiliary electric heater Only use the proper size electrical cords to power the heater Do not use spliced or damaged electrical cords or adapters An electrical short could result in fire serious injury or death swo 48p Before disconnecting the trailer from the truck place blocks or wheel chocks between the trailer to prevent inadvertent movement of the trailer while it is disconnect Do not remove the blocks until the trailer is reattached to a towing vehicle Serious injury or death can result from sudden movement of an unrestrained trailer swo sop Safety Section 1 10 N U gt B o a a o SAFETY Do not overfill hopper with aggregate Over filling can cause aggregate to fall on co workers AWARNING BERN VA and bystanders Falling aggregate and debris can cause serious injury if it falls on to a person Spilled aggregate can result in the operator or co workers slipping tripping or falling resulting in
39. ion level in the tank must cover the heating element before heating The Manufacturer suggests keeping the element thermostat at 165 degrees Fahrenheit If the emulsion will be stored for two or more weeks turn the temperature down to 130 degrees Fahrenheit Load King 10 13 Maintenance Section 4 4 2013 Alamo Group Inc LOAD KING LOAD KING 10 13 Version 1 0 10 13 Printed U S A
40. ity service Our goal at Schwarze Industries is always 100 customer satisfaction We re confident you ll find this new patcher to be the best built on the market and it s backed by a company with a service commitment that s second to none If you need help don t hesitate to call Many ideas for improvements to previous models have come from users in the field If you have an idea or suggestion on how we might make our product even better please let us know by calling toll free 1 800 879 7933 Load King 10 13 Introduction Section 2 2 2013 Alamo Group Inc INTRODUCTION FC SSP 0001 The Schwarze Load King Spray Patcher is Self contained Road and Asphalt Repair Schwarze Web Page Patcher which does not require the use of special tow vehicles over 1 ton The Schwarze Spray Patcher Load King unibody enclosure protects the components from the elements but allows easy maintenance access through the large access doors During operation the Emulsion Heating System engine coolant keeps the emulsion at or near 150 degrees which allows cold temperature operation The optional vacuum feature allows removal of water and debris from potholes before patching to achieve a longer lasting and more durable repair The Load King achieves a 95 compaction rate without the use of compactors based on the Strategic Highway Initiative Testing and allow for immediate traffic flow Controls are boom mounted which allows all patc
41. landfill site like most swept waste Contact the appropriate authority for the collection and disposal requirements of such dangerous and or hazardous material swo 25 Always wear required OSHA approved Personal Protective Equipment PPE when coming in contact with and removing potentially dangerous and hazardous material used in the process of patching Pay close attention to dangerous and hazardous material including but not exclusively limited to chemicals and aggregate Review the Material Safety Data Sheet MSDS for any chemical or materials used in the patching process Always comply with all handling and PPE requirements listed for the materials being used swo 26p A DANGER Load King 10 13 Safety Section 1 8 2013 Alamo Group Inc SAFETY Use extreme care when flushing the emulsion hoses with the pressurized diesel Any burning object even as small as a lit cigarette has the potential of igniting the diesel and possibly destroying the equipment and inflicting serious injury or death to the operator or passersby Never allow any open flame or anyone to smoke near equipment when using the patcher When flushing the emulsion hoses Never allow the diesel or emulsion to be spayed onto a heated surface smoldering substance or near any open flames swo 27p A DANGER Verbal communication near the Equipment may be difficult and dangerous while near traffic or with the engines running Operating instructio
42. lly understand and comply with their responsibilities for the handling and proper disposal of any hazardous waste materials involved with the use of the Patcher ALSAVS Load King 10 13 Safety Section 1 27 2013 Alamo Group Inc INTRODUCTION SECTION Introduction Section 2 1 INTRODUCTION INTRODUCTION We pleased to have you as an Schwarze customer Your Load King Spray Patcher has been carefully designed with care and built with quality materials by skilled workers to give maximum service with minimum down time This manual is provided to give you the necessary operating and maintenance instructions for keeping your patcher in top operating condition Careful use and timely service saves extensive repairs and costly downtime losses The purpose of this manual is to familiarize instruct and train Please read this manual thoroughly The Operations and Maintenance sections of the manual trains the owner operator how to work the Spray Patcher correctly and attend to appropriate maintenance The Trouble Shooting Guide helps diagnose difficulties with the patcher and offers solutions to the problems Safety is of primary importance to the owner operator and to the manufacturer Observe all safety precautions decaled on the machine and noted throughout the manual for safe operation of implement If any assistance or additional information is needed contact your authorized Schwarze dealer The ow
43. made Warranty claims are handled by our parts department Before any warranted parts may be returned for warranty credit however authorization by a Schwarze representative must first be obtained Also once the authorization has been granted the defective part MUST be returned to us This policy allows for efficient parts shipping and account crediting For your convenience we accept MasterCard and Visa If credit card payment is not used orders will be shipped C O D unless prior arrangements have been made with our accounting department Once received shipments should be examined immediately Any shortage or damage should be noted on the freight bill or express receipt BEFORE the parts are accepted from the carrier Immediate notification to us of such shortage or damage is also required If you still have questions with the service or operation of your sweeper after consulting the maintenance and troubleshooting sections of this manual call us toll free and we will provide you with additional instruction At Schwarze Industries we are truly committed to your complete satisfaction with our products and services If you have any suggestions please call our toll free number 1 800 879 7933 We are only a toll free phone call away Load King 10 13 Introduction Section 2 5 2013 Alamo Group Inc NOILONGOULNI OPERATION SECTION Operation Section 3 1 OPERATION OPERATION LOAD KING SPRAY P
44. ner operator dealer should know and understand the Safety Messages before assembly and be aware of the hazards of operating this patcher during assembly use and maintenance The Safety Alert Symbol combined with a Signal Word as seen below is intended to warn the owner operator of impending hazards and the degree of possible injury faced when operating this machine Indicates an imminently hazardous situation that if not avoided WILL result in DEATH OR A DANGER VERY SERIOUS INJURY Indicates an imminently hazardous situation that if not avoided COULD result in DEATH AWARNING OR SERIOUS INJURY Indicates an imminently hazardous situation that if not avoided MAY result in MINOR A CAUTION JURY Identifies special instructions or procedures that if not strictly observed could result in damage to or destruction of the machine attachments or the environment To obtain the best use of the patcher s equipment we strongly recommend that the operator be required to thoroughly read understand and follow all of the applicable information in this Manual prior to and during the operation of this patcher Daily cleaning and strict adherence to other unit s routine maintenance schedules are major factors in keeping your unit in like new condition Ensuring that service personnel and operators become familiar with the information unique to this make and model of patcher will greatly contribute to cost effective operation and many years of qual
45. ng clothing Entanglement of loose clothing with the rotating elements can result in serious injury or death Stay clear of all rotating elements at all times swo 7p Do not operate this Equipment with hydraulic oil or fuel leaking Oil and fuel are explosive and their presence could present a hazard Do not check for leaks with your hand High pressure oil streams from breaks in the line could penetrate the skin and cause tissue damage including gangrene To check for a hose leak SHUT the unit ENGINE OFF and remove all hydraulic pressure Wear oil impenetrable gloves safety glasses and use Cardboard to check for evidence of oil leaks If you suspect a leak REMOVE the HOSE and have it tested at a Dealer If oil does penetrate the skin have the injury treated immediately by a physician knowledgeable and skilled in this procedure swc 15p OPERATION SAFETY INSTRUCTIONS AND PRACTICES Perform service repairs and lubrication according to the maintenance section Ensure the unit is properly lubricated as specified in the lubrication schedule and all bolts and nuts are properly torqued Failure to properly service repair and maintain this Implement in good operating condition could cause component failure and possible serious injury or even death sc 35 Safety Section 1 4 2013 Alamo Group Inc SAFETY ES 2 a 5 A DANGER AWARNING AWARNING AWARNING AWARNING Load King 10 13 Avoid contact with hot
46. ns and directions should be made prior to starting the Equipment Unclear and misunderstood communication may lead to operator and bystander injury or death and equipment damage lf communication to the bystander by the operator is necessary completely shutdown the Equipment Never allow anyone to approach the Equipment while in operation swo 28p AWARNING ALSAVS Never allow children to play on under or around the Equipment nor allow children to operate Equipment controls Children can slip or fall off the Equipment and be injured or killed Children can cause the components to shift or fall crushing themselves or others SWO 29p A DANGER Allow passengers only in situations where their presence is involved in the Equipment operation operator training supervision maintenance inspection Never carry passengers whose presence distracts from the safe operation or transport of the Sweeper Passengers must be seated securely and belted in the Truck cab s passenger seat Never allow any person to ride on any other location of the Equipment during operation or transport swo 30p AWARNING Extreme caution should be used by the operator when operating near passersby Stop patching if anyone comes within 25 feet of the emulsion nozzle to prevent possible passerby injury or death from being struck from a thrown object contact with the heated emulsion or run over swo 31p AWARNING Make sure that no co worker bystander animal
47. ood shape Make sure all fluid levels are full and replenish as necessary sure fuel oil and coolant caps are replaced and tightened e sure that the emulsion tank cap is securely in place e Check tire condition for tread wear and tire pressure at the rated PSI e sure that all safety shields and guards are attached and in good condition e sure the warning light s are functioning properly Make sure all scheduled maintenance is up to date swm 2p Load King 10 13 Safety Section 1 11 2013 Alamo Group Inc ALSAVS SAFETY SAFETY AWARNING A DANGER A DANGER A DANGER A DANGER AWARNING A DANGER AWARNING Do not modify or alter this Patcher Do not permit anyone to modify or alter this Patcher any of its components or any Patcher function swm 3p Use extreme care when climbing onto the Equipment to perform repairs maintenance and cleaning Use proper stands and ladders to access areas that cannot be reached from ground level Slipping and falling off the Equipment can cause serious injury or death SWM 4p Never attempt to repair lubricate adjust clean remove obstructions or perform any other type of service to any component while the Auxiliary and or Truck engine is running Completely shut down the Patching components and the Truck and Auxiliary engines and wait for all motion to come to a complete stop before servicing the Patcher
48. r Fittings Table 5 Maintenance Every 1 000 Hours ITEM TYYPE OF SERVICE Blower Oil Replace Oil 3 EMULSIFIER APPLICATION DO s AND DON Ts DO s 1 Determine if you have a light or heavy build up of asphalt road oils Heavy is more than 1 4 A Light Build Up Mist on a medium amount of emulsifier and let sit for approximately 5 minutes Rinse thoroughly with water or wipe away if using a non painted surface B Heavy Build Up Mist on a medium amount of emulsifier and let set for approximately 15 20 minutes Rinse with water Repeat until clean Super heavy build up may take 2 3 applications to reach bare metal 2 Sometimes hot pressure wash helps to flush away loosened deposits more thoroughly 3 To reduce usage of emulsifier always apply a light coat prior to your paving activity This greatly reduces the ability of the asphalt to stick and cure on your paving equipment demanding much less product to clean the equipment after your paving activity 4 Hand Tools A Use above process to clean hand tools B Once you have a clean tool and are ready to start using mist on a light coating of emulsifier to help prevent sticking C When alight build up starts to occur stop and mist again then continue shoveling or raking 5 Do realize that the reason diesel fuel cannot be used is not only due to E P A regulations but that we all should be concerned with the future availability of water on ou
49. r planet Diesel fuel ends up in our ground water and streams killing wildlife and eventually making our water undrinkable DONTs 1 Don t wait until you have an inch or two of build up to use emulsifier then expect it to clean off immediately 2 Don t use emulsifier on a painted surface it testing it on a small area first Always rinse painted surfaces thoroughly with water after use 3 Don t apply an excessive amount of emulsifier on the first application Apply until you first see the asphalt begin to run The waiting period and repeating the application is much more important than the amount you apply initially 4 Don t rinse emulsifier of too quickly It needs time to penetrate asphalt deposits thoroughly so it can be flushed away Load King 10 13 Maintenance Section 4 3 2013 Alamo Group Inc JDONVNALNIVN MAINTENANCE MAINTENANCE 4 CLEAN UP AND OVERNIGHT STORAGE At the end of the day and before any prolonged break in patching during the day the emulsion line must be flushed This is accomplished by switching the emulsion valve to FLUSH The emulsion valve in the cab is opened and the flushed material is allowed to flow through the nozzle until it is clean The flush is left in the line overnight but it must be cleared out before the patching operation resumes Overnight the emulsion tank must be plugged into a 110 volt single phase power source to maintain operating temperature The emuls
50. s until sufficient time has passed up to 2 hours to allow the system to cool down Contact with a hot engine component or operating fluid may result in serious injury from burns scalding and possible death sww 14p A DANGER ALSAVS Use extreme care when attempting to remove debris from or unclog jams in the air amp aggregate hoses Always wear PPE including safety glasses when removing or unclogging the hoses Serious injury may occur if aggregate or debris is suddenly thrown from the end of the hose or a hose rupture sww 15p AWARNING Use extreme caution when working in confined areas of the hopper bin or emulsion tank for an extended period of time Confined work areas may pose a danger because of the physical constraints imposed on the body Routinely exit the confine to stretch and correct posture to prevent physical stress imposed on the body before bodily injury occurs swm 16p AWARNING Use extreme caution when refueling Diesel fuel is highly combustible and explosive if not handled safely Always follow these precautions to reduce the dangers involved in refueling 4 gt 2 Q m A Completely shut down the Truck and Auxiliary Engines before refueling Do Nat refuel while smoking or near an open flame Do Not store Patcher with fuel in the tank a building where fumes can reach an ignition source To prevent a fire and explosion caused by static electric discharge while filling the tank use a plastic
51. serious injuries swo 51p A Never unhitch the Trailer without using the Tongue Jack The Tongue is very heavy Attempting to lift the Tongue without using the Tongue Jack could cause strains or other injury Allowing the tongue to fall suddenly and unexpectedly could result in crushing injury Use the Tongue Jack for lifting the Trailer only Overloading the Tongue Jack can cause failure with possible serious bodily injury or even death swo 52p AWARNING Only tow the Trailer behind a properly sized and equipped Truck which exceeds the weight of the loaded trailer by at least 20 and is equipped with appropriate trailer brake controls SWO 53p MAINTENANCE AND SERVICE SAFETY INSTRUCTIONS AND PRACTICES Periodically inspect all moving parts for wear and replace when AWARNING i necessary with authorized service parts Look for loose fasteners worn or broken parts and leaky or loose fittings Make sure all pins have cotter pins and washers Serious injury may occur from not maintaining this Patcher in good working order sww 1p AWARNING Inspect the entire Sweeper before each use Accidents may occur or damage to the Patcher may result if the Patcher is not maintained in good mechanical working order e Check for loose bolts worn or broken parts pinched hydraulic hoses and leaky or loose fittings sure all pins are secure and safety pins equipped Make sure hose covers are in place and the insulation is in g
52. t or jump off the Truck swo 2p Safety Section 1 5 O 2013 Alamo Group Inc ALSAVS SAFETY SAFETY A DANGER A DANGER AWARNING A DANGER A DANGER Load King 10 13 Do not attempt to mount the Equipment or Truck while the machine is moving Never attempt to mount a runaway Truck or Trailer Serious injury or death may occur from being run over by moving Equipment swo 3p BEFORE leaving the Truck s seat always engage the parking brake and or set the Truck s transmission in parking gear stop the engine remove the key and wait for all moving parts to stop Never dismount a Truck that is moving or while the Truck and Auxiliary engines are running Operate the Equipment controls from the Truck seat only swo 4p Always wear a seat belt while driving the Truck during operation and transport Serious injury or even death could result from falling out of the Truck or from being involved in a collision swo sp Start the Truck engine only when seated and belted in the Truck s operator seat Operate the Engine controls only while properly seated with the seat belt secured around you Inadvertent movement of the Truck and or Patcher components may cause serious injury or death to the operator and passersby Read the Truck and Auxiliary Engine operator s manuals for proper starting instructions swo 6p Operate the equipment only in conditions where you have clear visibility of the immediate
53. tcher 4 Maintain the Truck and Patcher in a safe operational condition and maintain all shields and guards on the equipment 5 Ensure the Truck is equipped with a functional seat belt and require that the employee operator securely fasten the safety belt at all times 6 Provide the required tools to maintain the Truck and Patcher in a good safe working condition and provide the necessary support devices to secure the equipment safely while performing repairs and service OSHA 1910 147 c 1 Energy Control Program The employer shall establish a program consisting of energy control procedures employee training and periodic inspections to ensure that before any employee performs any servicing or maintenance on a machine or equipment where the unexpected energizing startup or release of stored energy could occur and cause injury the machine or equipment shall be isolated from the energy source and rendered inoperative OSHA 1926 417 Lockout and Tagging a Controls Controls that are to be deactivated during the course of work on energized or de energized equipment or circuits shall be tagged b Equipment and Circuits Equipment or circuits that are de energized shall be rendered inoperative and shall have tags attached at all points where such equipment or circuits can be energized OSHA 1926 600 a 3 ii Whenever the equipment is parked the parking brake shall be set Equipment parked on inclines shall have the wheels chocked and
54. the machine attachments or the environment NOTE dentifies points of particular interest for more efficient and convenient operation or repair sG 1 READ UNDERSTAND and FOLLOW the following Safety Messages Serious injury or death may occur unless care is taken to follow the warnings and instructions stated in the eee Safety Messages Always use good common sense to avoid hazards sc 2 Si no lee ingles pida ayuda a alguien que si lo lea para que le traduzca las LEA EL A PELIGRO medidas de seguridad INSTRUCTIVO REAN Load King 10 13 Safety Section 1 2 2013 Alamo Group Inc SAFETY DRIVER SAFETY INSTRUCTIONS AND PRACTICES The operator of the Truck and Patcher must be trained in the operation and safe use of this machine The operator must read and completely understand the operator s manuals of the Patcher Truck and Auxiliary engine manufacturers New operators should be trained in an open area clear of obstructions before operating on public roadways operation of the entire Patcher unit Truck Auxiliary engine and Patcher Components is not completely understood consult your authorized sales representative for a detailed explanation Never allow an untrained or unqualified driver to operate the Truck Patcher swo o1p The Truck driver must meet the requirements and possess a Motor Vehicle License as determined by the state in which the Truck is operated if used on publ
55. the parking brake set Employee s Responsibilities Remove the truck keys and keep them in your pocket before performing any service maintenance cleaning or before any person enters into equipment hopper The Truck engine controls must be shut off and prevented from accidental activation 1 Follow all safety rules and regulations 2 Use all safety equipment as prescribed in Operators Manual 3 Report any unsafe conditions 4 Be aware of and protect the safety of coworkers or others in vicinity Load King 10 13 Safety Section 1 26 2013 Alamo Group Inc SAFETY Hazard Communication and MSDS Information OSHA requires the employer to inform the employee of the potential hazards associated with the chemicals and materials that the employee may contact This includes but is not limited to the diesel fuel emulsion chemicals hydraulic oil radiator coolant and treated aggregate The Employer must provide annual training for the employee in Material Safety Data Sheets MSDS the location of the MSDS sheets how to read and understand the MSDS information and the PPE requirements when using the chemicals Proper Disposal of Hazardous Waste Materials EPA regulations require the proper disposal of any hazardous chemicals and waste material This includes but is not limited to the diesel fuel emulsion chemicals hydraulic oil radiator coolant and treated aggregate Ensure that the employees and operators fu
56. uce the sweepers performance void warranties and present a safety hazard Use genuine Schwarze sweeper parts for economy and safety 2 GENERAL MAINTENANCE Before operating your Spray Patcher make sure it is properly lubricated and thoroughly inspected Only a minimum of time and effort is required to regularly lubricate and maintain this machine to provide long life and trouble free operation 2 1 Lubrication Filter and Maintenance Schedules The following table tells you where to look in the manual to find procedures for specific maintenance tasks Table 1 Lubrication Filter and Maintenance Daily or Every 10 Hours TYPE OF SERVICE Engine Crankcase Check Oil Level Table 2 Weekly Maintenance Weekly or Every 40 Hours ITEM TYPE OF SERVICE Air Intake Filter Check and Clean Replace if necessary Machinery Bearings Lubricate all Fittings Boom Bracket Lubricate and Grease Table 3 Weekly Maintenance Monthly or Every 160 Hours ITEM TYPE OF SERVICE Engine Oil Change Oil Air Blower Oil Check Oil Level Hoses Check for Wear Delivery Hose Check for Wear and Rotate quarter turn Rock Feeder Grease 2 Grease Load King 10 13 Maintenance Section 4 2 2013 Alamo Group Inc MAINTENANCE Lubrication Filter and Maintenance Schedules Con t Table 4 Maintenance Every 500 Hours ITEM TYPE OF SERVICE Air Blower Grease Blowe
57. uction Section 2 4 Paint Application one coat sealer primer two coats polyurethane Brand DuPont Imron Color Standard Yellow Warranty The Spray Patcher Load King road patching system is guaranteed to be free from defects due to faulty materials and or workmanship for a period of 12 months or 1200 hours The auxiliary engine is guaranteed to be free from defects due to faulty materials and or workmanship for a period of 24 months or 2000 hours whichever occurs first from date of delivery Liability is limited to replacement of defective parts at factory or authorized dealer INTR SSP 0001 2013 Alamo Group Inc INTRODUCTION Customer Assistance Schwarze Industries is noted for its commitment to customer satisfaction In addition to many Authorized Dealers located throughout the country Schwarze Industries also maintains a fully stocked factory service center in Huntsville Alabama In the event you need parts or service call your nearest Authorized Dealer Their name and number can be found on the Spray Patcher Information Sheet located in the front of this manual In the unlikely event that your local dealer is unable to provide the assistance you require call us at our home office in Huntsville Alabama We have a state of the art fabrication and production facility and a complete service and refurbishing center with an inventory of over 500 000 in spare parts In most cases same day shipping and ov
58. ve clothing including gloves and eye protection when servicing or working in or around the emulsion tank or emulsion nozzle Contact with Heated Emulsion can result in serious bodily injuries swo 43p Relieve pressure in emulsion tank before attempting to open the lid for inspection or filling Failure to release pressure before removing the emulsion tank lid could result in heated emulsion chemicals escaping under pressure toward the individual attempting to remove the lid Always wear protective clothing including gloves and eye protection when servicing or working in or around the emulsion tank Contact with heated emulsion under pressure can result in serious bodily injuries swo 44p Relieve the pressure in Diesel flushing tank before attempting to open the tank cap for inspection or filling Failure to release pressure before removing the cap could result in diesel fuel being sprayed in the air and toward the operator Fire or explosion can result from diesel sprayed on to hot surfaces Always wear protective clothing including gloves and eye protection when servicing or working in or around the diesel tank swo 45p Do not disable the diesel tank cap block lever located on the Diesel flushing tank The cap lock lever requires the operator to relieve the air pressure in the tank before the cap can be removed Failure to release pressure before removing the cap could result in diesel fuel being sprayed in the air and toward the operator result
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