KM ASPHALT RECYCLER T2 C1M2 User manual

MODEL KM T2 C1M2 ASPHALT RECYCLER TM

ORIGINAL INSTRUCTIONS

THE CHOICE OF ASPHALT PROFESSIONALS WORLWIDE

KM INTERNATI0NAL

6561 Bernie Kohler Drive, North Branch, Michigan

Tel 1-810-688-1234 Toll Free 800-492-1757 Fax 1-810-688-8765

www.kminternatinal.com

all other KM names and symbols are Trademarks owned by KM International

KM T-2 C1M2 –v.Apr.15.4 Page 1

Phone: 810-688-1234 Toll Free: 800-492-1757  Fax: 810-688-8765

www.KMINTERNATIONAL.com

Contents

INTRODUCTION ..................................................................................................................................... 2

SAFETY AND WARNING INFORMATION...................................................................................... 3

THE KM T2 IS A TRAILER UNIT..................................................................................................... 5

KM T2 ASPHALT RECYCLER ........................................................................................................... 7

HOW DOES THE KM T2 ASPHALT RECYCLER WORK.......................................................... 7

PRE-OPERATION INSPECTION CHECK LIST ............................................................................ 8

T-2 OPERATION ...................................................................................................................................10

CLEANING, STORAGE and TRAVEL............................................................................................16

MAINTENANCE.....................................................................................................................................17

TROUBLE SHOOTING ........................................................................................................................20

TECHNICAL DRAWINGS ...................................................................................................................22

PARTS LIST ........................................................................................................................................... 24

TRAINING POLICY ..............................................................................................................................32

LIMITED WARRANTY......................................................................................................................... 33

EQUIPMENT INFORMATION & NOTES ...................................................................................... 36

TIRE SAFETY INFORMATION........................................................................................................37

names and symbols are Trademarks owned by KM International.

KM T-2 C1M2 –v.Apr.15.4 Page 2

Phone: 810-688-1234 Toll Free: 800-492-1757  Fax: 810-688-8765

www.KMINTERNATIONAL.com

INTRODUCTION

The KM International Team would like to take this opportunity to THANK YOU for your

purchase of the KM T-2 ASPHALT RECYCLER. We at KMI are confident that the newest

addition to the KM International product offering will provide you with years of safe,

reliable and cost effective use. We are sure that the KM T-2 will begin paying for itself

in the form of savings with the first batch of recycled asphalt that it produces. In

January 2009 the Michigan Department of Transportation (MDOT) engaged KM

International, Inc. (KMI) to come up with a feasible plan to recycle the mountains of

millings and asphalt product that was building up in equipment yards all over the State

of Michigan. KMI was up to the challenge. The challenge though was not to just recycle

and be “Green” just for the sake of being “Green” but to do it responsibly. The goal for

KMI has always included a product offering that provides cost savings, purchase

justification and profitability for our customers.

KM International, Inc. has acquired and developed a number of strengths that has

fostered KMI’s worldwide reputation in the asphalt industry as the “Gold” and “Green”

standards. We are the preeminent authority on the “infrared process” of in place asphalt

recycle and repair. We have fostered an ongoing industry standard of quality and

excellence that continually exceeds our customers’ expectations in all of our product

offerings including our “Infrared” line of equipment, crack maintenance and “Hot Box”

Reclaimers.

Our commitment to the design and manufacture of the highest quality asphalt

maintenance equipment in the market is not just a “quote on the wall” but rather the

driving force for the entire KMI team.

KM T-2 C1M2 –v.Apr.15.4 Page 3

Phone: 810-688-1234 Toll Free: 800-492-1757  Fax: 810-688-8765

www.KMINTERNATIONAL.com

SAFETY AND WARNING INFORMATION

NOTICE: This unit is not ATEX Certified. Do Not use in any explosive

environment.

NOTICE: Operation of the T-2 Asphalt Recycler requires qualified trained

personnel to be present at all times during operation.

WARNING: READ and UNDERSTAND all instructions carefully before starting the

KM T-2 ASPHALT RECYCLER. FAILURE TO FOLLOW these instructions may result

in a possible fire hazard and will void the warranty.

WARNING: Always wear protective clothing, including eye and ear protection,

leather protective gloves, long sleeved protective shirt, long pants, and leather

protective boots when operating this or any other equipment.

WARNING: Any safety screen or guard removed for servicing must be replaced before

operating the KM T-2 ASPHALT RECYCLER. DO NOT USE the KM T-2 ASPHALT

RECYCLER if any part has been damaged or placed under water. Immediately CALL a

qualified service technician to inspect the appliance and to replace any part of the

control system which has been damaged.

NOTICE: Maintenance or repair should be performed by a qualified service person.

NOTICE: The KM T-2 ASPHALT RECYCLER system should be INSPECTED before

initial use and annually by a professional KMI service person. It is IMPERATIVE that

the unit’s control compartment, burners, and circulating air passageways ARE KEPT

CLEAN to provide for adequate combustion and ventilation air.

WARNING: Always keep the KM T-2 ASPHALT RECYCLER clear and free from

combustible materials, gasoline, and other flammable vapors and liquids.

NOTICE: Never obstruct the flow of combustion and ventilation air. Keep the front

of the KM T-2 ASPHALT RECYCLER CLEAR of all obstacles and materials for servicing

and proper operation.

NOTICE: Children and adults should be alerted to the hazards of high surface

temperature and should STAY AWAY to avoid burns or clothing ignition.

KM T-2 C1M2 –v.Apr.15.4 Page 4

Phone: 810-688-1234 Toll Free: 800-492-1757  Fax: 810-688-8765

www.KMINTERNATIONAL.com

IT IS HIGHLY RECOMMENDED THAT YOU HAVE A FIRE EXTINGUISHER ON

YOUR JOB SITE AT ALL TIMES.

NOTICE: The KM T-2 ASPHALT RECYCLER is designed to heat asphalt to a

working temperature that should not exceed 350 degrees Fahrenheit. The heated

asphalt and the unit will become DANGEROUSLY hot quickly; care and caution must

be observed at all times. Be aware of your surroundings. Use caution around buildings,

utility wires, combustibles, landscaping, etc. to prevent damage.

WARNING: Inspect all fuel lines and connections daily before using the KM T-2

Asphalt Recycler. DO NOT use if damaged in any way.

NOTICE: The T-2 Asphalt Recycler is intended to heat up to 2500 lbs. of asphalt

millings or chunked asphalt (12” size and smaller) per drum load. It is not intended

for any other use.

NOTICE: This unit is trailer mounted and allows for transportation from jobsite to

jobsite but is intended for stationary operation on level ground only. Operation during

travel or transporting Hot Mix Asphalt in the drum may cause component failure and

will void all warranties.

NOTICE: READ and UNDERSTAND all instructions carefully before starting the KM

T-2 ASPHALT RECYCLER. The KM T-2 ASPHALT RECYCLER requires the presence

of an operator at all times. The machine should never be left unattended.

WARNING: FAILURE TO FOLLOW these instructions may result in a possible FIRE

HAZARD, BURN HAZARD AND POSSIBLE DEATH and will void the warranty.

KM T-2 C1M2 –v.Apr.15.4 Page 5

Phone: 810-688-1234 Toll Free: 800-492-1757  Fax: 810-688-8765

www.KMINTERNATIONAL.com

Reporting Safety Defects

If you believe that your vehicle has a defect that could cause a crash or could cause

injury or death, you should immediately inform the National Highway Traffic Safety

Administration (NHTSA) in addition to notifying KM International Inc.

If the NHTSA receives similar complaints, it may open an investigation, and if it finds that

a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.

However, the NHTSA cannot become involved in individual problems between you, your

dealer, or KM International, Inc.

To contact the NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1-888-

327-4236 (TTY:1-800-424-9153), go to http://www.safercar.gov; or write to: NHTSA,

1200 New Jersey Ave SE, Washington, DC 20590. You can also obtain other

information about motor vehicle safety from http:www.safercar.gov.

THE KM T2 IS A TRAILER UNIT

NOTICE: It is necessary to learn and know all applicable Department of

Transportation regulations prior to towing this vehicle.

AXLE RATING: 7,000 LBS. (EACH)

GVWR: 14,000 LBS.

TIRES: 3,520 LBS. capacity each (load range E)

TIRE PRESSURE: 80 PSI cold inflation

BRAKES: 12V Electric; all four tires; safety breakaway feature

Optional: Hydraulic brakes; all four tires

WARNING: Use of a tow vehicle with a towing capacity less than the load rating of

the trailer can result in loss of control, and may lead to death or serious injury. Ensure

your hitch and tow vehicle are rated for the Gross Vehicle Weight Rating identified on

the VIN tag of your trailer.

WARNING: Be sure that the tow hitch load rating meets or exceeds the GVWR of the

trailer. Inspect the tow hitch for wear. Replace if worn, cracked, or corrosion exists.

Inspect and ensure that all connecting hardware is tightened and serviceable.

NOTICE: When connecting the tow vehicle to the trailer ensure to match the tow

hitch and trailer hitch size. Inspect that the hitch is securely coupled and safety chains

are properly attached before travel.

KM T-2 C1M2 –v.Apr.15.4 Page 6

Phone: 810-688-1234 Toll Free: 800-492-1757  Fax: 810-688-8765

www.KMINTERNATIONAL.com

WARNING: Inspect and test the safety chains and safety breakaway system before

travel. The safety breakaway cable must connect to the vehicle, never connect to the

hitch.

LIGHTS & BRAKES

NOTICE: Inspect all trailer lighting prior to travel. Inspect rear running tail lights,

marker lights, turn signals and brake lights. Ensure that trailer light plug is properly

connected to the tow vehicle.

WARNING: For electric brakes it is necessary for the tow vehicle to signal the trailer

electric brakes. Inspect the trailer brakes for operation before travel. Failed trailer

brakes can result in a hazardous accident causing injury, or death.

WARNING: For hydraulic actuated brake systems it is necessary to inspect the hitch

actuator, hydraulic tube lines and connections. Inspect for leaks. Inspect the hydraulic

fluid level in the brake actuator. . Inspect the trailer brakes for operation before travel.

Failed trailer brakes can result in a hazardous accident causing injury, or death.

NOTICE: A qualified mechanic should inspect the brakes and braking system for

proper service and wear.

WHEELS & TIRES

WARNING: Improper tire pressure can result in loss of control which can lead to

death or serious injury. Ensure tires are inflated to the pressure indicated on the side

wall of the tire before towing the trailer.

WARNING: Be sure lug nuts are tight before each trip. Lug nuts can loosen after

initial installation. Check lug nuts for tightness after new tire installation at intervals of

the first 10, 25 and 50 miles of travel.

NOTICE: Tighten the lug nuts to 100 ft/lbs. torque. Over tightening will result in

breaking the lugs or cause permanent damage resulting in possible wheel failure. Use a

calibrated torque wrench to tighten the lug nuts.

The Trailer Handbook, A Guide to Understanding Trailers & Towing Safely, can be

purchased through the National Association of Trailer Manufactures, available at

www.natm.com.

KM T-2 C1M2 –v.Apr.15.4 Page 7

Phone: 810-688-1234 Toll Free: 800-492-1757  Fax: 810-688-8765

www.KMINTERNATIONAL.com

KM T2 ASPHALT RECYCLER

The KM T2 Asphalt Recycler is designed to recycle milled or chunked hot mix asphalt to

working temperature. The KM T2 Asphalt Recycler will safely recycle up to four tons of

material per hour using either pure asphalt cement, CRF, and/or shingles to bring life

back to the material. The solid welded construction and straight forward design is simple

to use and requires little maintenance.

NOTICE: Safety is always a concern when working with any fuel combustion system

and the KM T2 Asphalt Recycler diesel fuel burner system is no exception. WARNING:

DIESEL FUEL LEAKS PRESENT A DANGER and must be corrected prior to operating

the burner. Fuel spills should be properly cleaned up prior to system operation.

The burner is designed to burn No.1 or No.2 Heating Oil (ASTM D396) ONLY.

DANGER: NEVER USE GASOLINE in the burner as an explosion could result.

NEVER use crankcase or waste oil in this burner; contamination could cause burner

malfunction.

HOW DOES THE KM T2 ASPHALT RECYCLER WORK

The KM T2 Asphalt Recycler uses a 700,000 BTU, 12 VDC powered fuel oil combustion

burner to produce heat inside of the drum. The material tumbles throughout the drum

area while being heated from the burner.

Once the material being recycled has nearly reached the optimum temperature, asphalt

cement, CRF, and/or shingles should be added to revitalize the asphalt. Once the

additive has been thoroughly mixed the load can by discharged and transferred to a KM

Hotbox Reclaimer to maintain the load temperature during transport to the job site(s).

WARNING: Never clean the drum with a combustible solvent. Doing so will result in

fire or explosion.

Daily cleaning with a shovel or the tumbling of stone is the best maintenance for the

interior of the KM T2 Asphalt Recycler.

KM T-2 C1M2 –v.Apr.15.4 Page 8

Phone: 810-688-1234 Toll Free: 800-492-1757  Fax: 810-688-8765

www.KMINTERNATIONAL.com

PRE-OPERATION INSPECTION CHECK LIST

NOTICE: Before operation of this unit, there should be an inspection of key

components to ensure that the machine is operating safely and efficiently. Always turn

off the engine, remove the engine key and remove the 12v DC burner power key

prior to performing any repairs or maintenance to the T-2 unit.

1. VISUAL INSPECTION. The T-2 Asphalt Recycler should always be visually

inspected for damage, signs of abuse, missing components, loose or missing bolts

and fittings and fuel or oil leaks prior to operation.

2. OPERATE ON LEVEL GROUND. The T-2 Asphalt Recycler must always be level

during operation. Unleveled operation may cause premature component failures.

3. INSPECT INTERIOR COMPARMENT. Open both access panels on either side of

the T-2 to ensure that the compartment area has not been used for storage

purposes. Remove all items from compartment prior to operation. Both doors

must be closed during operation.

4. INSPECT DRIVE CHAIN. Visually inspect the drive chain for excessive wear or

obstructions. The chain tension is maintained by an automatic, spring loaded

chain tensioner.

5. EXHAUST FAN. KM T-2 recyclers are fitted with a 12v DC exhaust fan to aid the

flow of heat thru the drum. Fan will power on when engine key is turned to the

“RUN” position. When possible, position the Recycler so the burner is up-wind

and the fan is down-wind.

6. FUEL CAPACITY. The diesel tank capacity is 80 gallons and allows you to

operate all day without refueling. Top off each day before use with No.1 or No.2

Heating Oil (ASTM D396) ONLY.

KM T-2 C1M2 –v.Apr.15.4 Page 9

Phone: 810-688-1234 Toll Free: 800-492-1757  Fax: 810-688-8765

www.KMINTERNATIONAL.com

7. BATTERY VOLTAGE. Check the battery for the proper voltage. The burner

ignition key will need to be inserted and turned to the on position. The volt meter

should read at least 12 volts. Low voltage may cause premature component

failure.

8. SHUT OFF VALVES. Diesel fuel shut-off valve must be in the full open position

prior to starting the unit.

9. HYDRAULIC FLUID. Check Hydraulic Fluid Level in 28 gallon Hydraulic Tank.

Level should be approximately mid-range on the sight glass. If necessary, fill with

hydraulic fluid, TYPE AW 32, to proper level.

10. HYDRAULIC CONTROLS. Hydraulic Control Valves, located on the rear

passenger side fender, must all be in the neutral (Center) position before

operation.

11. ENGINE PRE-OPERATION. Consult the engine manufacturer manual for engine

specifications including proper starting, operating and maintenance.

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