KM 4-40 C1M1 User manual

MODEL KM 4-40 C1M1
ORIGINAL INSTRUCTIONS
TM
THE CHOICE OF ASPHALT PROFESSIONALS WORLWIDE
KM INTERNATI0NAL
6561 Bernie Kohler Drive, North Branch, Michigan
Tel [phone] Toll Free (USA) 1-800-492-1757 Fax [phone]
www.kminnternational.com
© 2010 Keizer-Morris International. All Rights Reserved. Keizer-Morris, Crack Jet, the KM Emblem, and
all other KM names and symbols are Trademarks owned by KM International

TM
KM 4-40C1M1 Infrared Asphalt Recycler Manual –v.5.25.21 Page 1
Phone: [phone] Toll Free: 800-492-1757 Fax: [phone]
www.kminternational.com
© 2010 Keizer-Morris International. All Rights Reserved.
TABLE of CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
SAFETY and WARNING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4
THE KM 4-40 IS A TRAILER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6
HOW THE HEATING SYSTEM WORKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
SET UP / UNFOLDING THE 4-40 FOR WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10
OPERATING THE KM 4-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-13
MAINTENANCE - ADJUSTING THE ZONES - BASIC MAINTENANCE -REFERENCE.
14-15
HELPFUL HINTS . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16-19
SELECTING THE ZONES . . . CHANGING BOTTLES . . . . . . . . . . . . . . . . . . . . . . . . .
16
REGULATOR OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
WIND SKIRT USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
ASPHALT REPAIR STEPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
BLANKET REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-23
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24-26
TRAINING POLICY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
EQUIPMENT INFORMATION AND NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
TIRE SAFETY . . . 49 CFR 575.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31-41
TM
THE CHOICE OF ASPHALT PROFESSIONALS WORLWIDE
© 2010 Keizer-Morris International. All Rights Reserved. Keizer-Morris, Crack Jet, the KM Emblem, and
all other KM names and symbols are Trademarks owned by KM International.

TM
KM 4-40C1M1 Infrared Asphalt Recycler Manual –v.5.25.21 Page 2
Phone: [phone] Toll Free: 800-492-1757 Fax: [phone]
www.kminternational.com
© 2010 Keizer-Morris International. All Rights Reserved.
INTRODUCTION
The KM International Team would like to take this opportunity to THANK YOU for
your purchase of the KM 4-40 Infrared Asphalt Recycler (KM 4-40 IR). We at KMI are
confident that your newest Infrared asphalt surface heater will offer years of safe,
reliable and cost effective “IN PLACE ASPHALT RECYCLE and REPAIR.” KM
International, Inc. has acquired and developed a number of strengths that has
fostered KMI’s worldwide reputation as the “INFRARED PROCESS EXPERTS”. We have
designed, developed and set the “Gold” and “Green” standards for Infrared use. We are
the preeminent authority on the “Infrared Process” of in place “asphalt surface
heating” and “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 repair equipment, Hot Box Asphalt Reclaimers and Asphalt Recyclers.
Our commitment to the design and manufacture of the highest quality asphalt surface
maintenance and repair equipment on the market is not just a “quote on the wall” but
rather the driving force for the entire KMI team. Our 26 years in the Infrared and
asphalt maintenance industries has provided KM INTERNATIONAL the necessary
experience and knowledge of “IN PLACE ASPHALT RECYCLE and REPAIR” to give our
customers the “peace of mind” that only experience and knowledge can provide;
experience and knowledge that our customers have come to rely on. The Management
Team at KM INTERNATIONAL is confident that YOUR purchase of the KM 4-40 IR will
be the basis for a long standing and mutually profitable relationship. The Goal at KM
INTERNATIONAL has and will always be to manufacture infrared heaters that provide
our customers cost savings, purchase justification and profitability.
The KM 4-40 Infrared Asphalt Recyclers are designed to give years of dependable
high performance service. Their solid welded construction stands up well to
commercial use. The simple, straight forward design has little to go wrong and can be
maintained easily. Its patented fold up design makes the 4-40 IR easy to use,
transport and store.
The KM 4-40 Infrared Asphalt Recycler provides two (2) 2 foot x 4 foot (.6m x 1.2m)
and two (2) 3 foot x 4 foot (.9m x 1.2m) independently controlled infrared zones for a
total coverage of 8 foot x 5 (2.4 m x 1.5 m) foot (3.6 sq. meters), as the name indicates
four (4) zones for 40 sq. feet (3.6 sq m) hence the name KM 4-40 IR. It is designed to
be used to heat and repair asphalt of varying sizes and shapes making it the most
versatile and efficient Infrared Asphalt Recycler on the market.
The serial number for this machine is located on a serial tag on the front of the
machine. Please be sure to retain this manual. It is a convenient information source
that should be consulted regularly.

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KM 4-40C1M1 Infrared Asphalt Recycler Manual –v.5.25.21 Page 3
Phone: [phone] Toll Free: 800-492-1757 Fax: [phone]
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© 2010 Keizer-Morris International. All Rights Reserved.
SAFETY
NOTICE: This unit is not ATEX Certified. Do Not use in any explosive environment.
NOTICE: Only properly trained personnel should operate this equipment.
WARNING: Always wear protective clothing, safety glasses, ear protection, leather protective
gloves, and leather protective work boots when operating this or any other equipment. This
equipment uses an open flame and requires the proper protection to avoid operator injury.
READ and UNDERSTAND these operating instructions carefully PRIOR TO ATTEMPTING TO
OPERATE the KM 4-40 Infrared Asphalt Recycler. FAILURE TO FOLLOW these instructions and the safety
warnings on the KM 4-40 IR may result in a possible FIRE HAZZARD and will void the warranty. Any
safety screen or guard removed for servicing must be replaced before operating the KM 4-40 Infrared
Asphalt Recycler.
WARNING: DO NOT USE the KM 4-40 Infrared Asphalt Recycler if any part(s) has been damaged or
placed under water.
NOTICE: DO NOT OPERATE if the ceramic refractory blanket is wet or damaged.
NOTICE: DO NOT OPERATE if the side safety panels have been removed.
If the 4-40 IR is not working or has been damaged in any way IMMEDIATELY CALL a qualified service
technician to inspect the infrared heater and/or to replace any part of the control system and any gas
control, which has been damaged.
THIS UNIT REQUIRES PROPANE GAS. Maintenance must be PERFORMED by a qualified service
person. The KM 4-40 Infrared Asphalt Recycler system should be INSPECTED before initial use and every
use thereafter only by a qualified service technician.
WARNING: 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. Always keep the
KM 4-40 IR clear and free from combustible materials, gasoline, and other flammable vapors and liquids.
NEVER OBSTRUCT the flow of combustion and ventilation air. Keep the front of the KM 4-40 IR CLEAR of
all obstacles and materials for servicing and proper operation. Children and adults should be ALERTED to
the hazards of high surface temperature and should STAY AWAY to avoid burns or clothing ignition.
NOTICE: The KM 4-40 IR is intended for OUTDOOR USE ONLY.

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KM 4-40C1M1 Infrared Asphalt Recycler Manual –v.5.25.21 Page 4
Phone: [phone] Toll Free: 800-492-1757 Fax: [phone]
www.kminternational.com
© 2010 Keizer-Morris International. All Rights Reserved.
SAFETY
NOTICE: Safety is a serious concern when working with any fuel combustion system and the KM
4-40 propane system is no exception. Gas leaks present a danger and should be tested for daily. Use a
strong soap solution around fittings, bottles and hoses, watching for bubbles. NEVER use a flame to
locate a suspected leak.
The KM 4-40 Infrared Asphalt Recycler is designed to heat asphalt to a working temperature in
excess of three hundred 300 degrees Fahrenheit (149 Celsius). The desired surface temperature can be a
hazard and requires all necessary caution. The heat can and will get DANGEROUSLY HOT very quickly;
care and caution must be observed at all times.
WARNING: Explosions can occur if gas is present!
NOTICE: Be aware of your surroundings. Use caution around buildings, utility wires, combustibles,
excess seal coat, flammable gasses from manhole covers, landscaping material, dry weeds and grasses,
or buried utilities, etc. to prevent damage from heat or fire.
Whenever heating on or around manholes and other underground utilities, always check with the
local utility company for presence of gas or combustibles. Use a gas sniffer or detector to determine
flammable hazards. Do not ever use an open flame to check for flammable gases.
CAUTION: When heating asphalt where rubber crack fill exists, take extreme care as the rubber may
catch fire. It may be necessary to manually cycle the heating sequence in order to heat the surface
more slowly. A slower heating process minimizes the potential to flash ignite the rubber. The same
procedure may also be necessary while heating over fresh or excessive sealcoat.
WARNING: Inspect all fuel lines and connections daily before using the KM 4-40 Infrared. DO NOT
use if damaged in any way. DO NOT allow the fuel line to lie against the bottom of the machine or on
any hot surface during use. DO NOT expose the hose in any way to heat or physical abuse during
operation.
NOTICE: Whenever heating on or around manholes and other underground utilities, always check
with the local utility company for presence of gas or combustibles. Use a gas sniffer or detector to
determine flammable hazards. Do not ever use an open flame to check for flammable gases.
IT IS HIGHLY RECOMMENDED THAT YOU HAVE A FIRE EXTINGUISHER ON YOUR JOB SITE AT ALL
TIMES.

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KM 4-40C1M1 Infrared Asphalt Recycler Manual –v.5.25.21 Page 5
Phone: [phone] Toll Free: 800-492-1757 Fax: [phone]
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© 2010 Keizer-Morris International. All Rights Reserved.
THE KM 4-40 IS A TRAILER UNIT
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 call the Vehicle Safety Hotline toll-free at 1-888-327-4236 (TTY:
1800-424-9153), go to http://www.safercar.gov; or write to: NHTSA, US Department of
Transportation, 1200 New Jersey Ave SE, Washington, DC 20590. You can also obtain other
information about motor vehicle safety from http://www.safercar.gov.
NOTICE: It is necessary to learn and know all applicable Department of
Transportation regulations prior to towing this vehicle.
AXLE RATING: 2,000 Lbs. (900 kg)
GVWR: 1,180 Lbs. (531 kg)
TIRES: 590 Lbs. (268 kg) capacity each (load range B)
TIRE PRESSURE: 60 PSI (410 kpa) cold inflation
BRAKES: N/A
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.
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.

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KM 4-40C1M1 Infrared Asphalt Recycler Manual –v.5.25.21 Page 6
Phone: [phone] Toll Free: 800-492-1757 Fax: [phone]
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© 2010 Keizer-Morris International. All Rights Reserved.
THE KM 4-40 IS A TRAILER UNIT
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 breaks and breaking 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.

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KM 4-40C1M1 Infrared Asphalt Recycler Manual –v.5.25.21 Page 7
Phone: [phone] Toll Free: 800-492-1757 Fax: [phone]
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© 2010 Keizer-Morris International. All Rights Reserved.
HOW the HEATING SYSTEM WORKS
The blower constantly forces air through the micro-spaces in the ceramic refractory
fiber blanket. When the control valves are opened, propane gas is mixed with this air.
The pilot light then ignites as shown in Figure 2. This results in the combustible
mixture, at the lower surface of the blanket, to ignite on the surface of the ceramic
blanket as shown in Figure 1. Flame is never present behind the blanket. The flame
spreads evenly across this lower surface and quickly turns red-orange hot. The long
wave radiant energy or Infrared that is developed then penetrates the asphalt surface.
The KMI Infrared heating process is the only one of its kind in the industry. The heater
utilizes automatically timed cycles that turn the heater on and off during use. The
process was specifically designed by the KMI Team to allow for deeper penetration of
the asphalt without burning or scorching the surface. The KM International Infrared
Process allows the heated asphalt to be reused and provides a better longer lasting
seamless repair.
WARNING: Heat escaping from under the KM 4-40 Infrared causes the bottom
sides of the unit to get very hot. Be sure that the blower has gone through its final
cooling cycle. Depending on ambient conditions, the heaters may still be hot enough to
cause serious injury. SHOW CARE & CAUTION when loading and transporting.
WARNING: Always wear protective clothing, safety glasses, ear protection, leather
protective gloves, and leather protective work boots when operating this or any other
equipment. This equipment uses an open flame and requires the proper protection to avoid
operator injury.
Figure 1 Figure 2
CAUTION: When heating asphalt where rubber crack fill exists, take extreme care as the
rubber may catch fire. It may be necessary to manually cycle the heating sequence in order to
heat the surface more slowly. A slower heating process minimizes the potential to flash ignite
the rubber. The same procedure may also be necessary while heating over fresh or excessive
sealcoat.

TM
KM 4-40C1M1 Infrared Asphalt Recycler Manual –v.5.25.21 Page 8
Phone: [phone] Toll Free: 800-492-1757 Fax: [phone]
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© 2010 Keizer-Morris International. All Rights Reserved.
SET UP / UNFOLDING THE 4-40 FOR WORK
The KM 4-40 Infrared must be removed from the transporting vehicle and put into the “unfolded” open
position to be operated. The KM 4-40 Infrared Asphalt Recycler was designed for easy use and transport.
Its unique folding design accomplishes that goal.
Figure 3
FOLDING (CLOSING) AND UNFOLDING(OPENING) the INFRARED ASPHALT RECYCLER
1. Remove the corresponding removable lift pipe handle bars located in their respective
holders directly adjacent to the propane bottles. Place one of the lift pipe handle bars in
the slot located on the trailer tongue for easy lift and maneuvering. (Figure 4.)
2. Remove the unit from the trailer hitch of the transporting vehicle. The trailer hitch ball
lock lever MUST be lowered to the down position to avoid damage to the surface of the
KM 4-40.
Figures 4 and 5
3. Place the lift pipe handle bars into the fold/unfold slots under the front edge of the
Infrared Recycler, (as shown in Figure 6.)
Figure 6
Lift pipe handle bars in
fold unfold slots
Fully Closed Position
Fully OPENED Position
Ball lock lever MUST be in
the full down position prior
to opening the unit.
TOW Mode

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SET UP / UNFOLDING THE 4-40 FOR WORK
4. While holding onto the lift pipe handle bars slowly walk the front edge backwards
toward the rear of the KM 4-40. Please NOTE: the rear casters must be in the rear
facing position and locked into position using the caster locking “U” pin (Figure 12),
(not side maneuvering position) to prevent the bottom of the 4-40 from directly
touching the surface, (as shown in Figures 7 & 8.)
Figure 7 Figure 8
5. The 4-40 should then be slowly lowered until resting entirely on the deck surface. (As
shown in Figures 9 & 10)
Figure 9 Figure 10
6. When the KM 4-40 is completely unfolded the lift pipe handles should be placed in the
axle side corner holsters for easy maneuvering of the infrared machine. (Figure 11) The
casters may then be placed in the side maneuvering position to avoid heating surfaces
depending upon the application or repair configuration.
Figure 11 Figure 12

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SET UP / UNFOLDING THE 4-40 FOR WORK
7. TO FOLD/CLOSE: Remove the corresponding removable lift pipe handle bars located in
their respective holders and place the lift pipe handle bars back into the fold/unfold
slots under the front edge of the Infrared Recycler, (as shown in Figure 13.)
Figure 13 Figure 14 Figure 15
8. PRIOR TO FOLDING the rear casters must be placed back into the rear facing and locked
position (Figure 12.).The KM 4-40 Infrared can then be returned to the closed position.
9. Two Crew members will then slowly lift the unit straight up avoiding back or strain
injury, (Figure 13.)
10. The unit should then be lifted to the maximum height (approximately 4’) and
immediately walked backwards slowly in a single motion until the unit is closed and
resting on the tow tires in the fully closed “towing” position. (See Figures 14, 15 and 6.)

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KM 4-40C1M1 Infrared Asphalt Recycler Manual –v.5.25.21 Page 11
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OPERATING THE KM 4-40-C1
Once unfolded the KM infrared heater can be moved to the area for repair
by pushing on the removable lift pipe handles inserted at the axle side of the
unit as well as the handle bar across the control panel side of the unit.
Helpful hint: Consider wind direction, caster location, and repair size when
positioning the unit.
Remove the U-pin on zone casters #1 and #2 when positioning the unit over
an area for repair.
WARNING: Always wear protective clothing, safety glasses, ear
protection, leather protective gloves, and leather protective work boots when
operating this or any other equipment. This equipment uses an open flame
and requires the proper protection to avoid operator injury.
All four independent casters can be positioned to allow the operator to
straddle most repairs with the casters. Remove the hitch pin from the S-arm
pin on the bracket, reposition the caster and re-install the hitch pin.
To begin heating a repair area:
1.Slowly open all propane cylinders.
NOTE: Opening a propane cylinder valve too quickly will activate the safety flow control valve
which minimizes the amount of propane allowed to leave the bottle.
2. Gently twist and pull the Emergency Stop button up.
NOTICE: Push the E-stop button at any time to stop the KM infrared
heater. The blower will continue to operate for one minute after stopping the
unit. This allows for all combustible mixture to be purged from the blanket.
3. Turn the keyed switch On. The blower will operate.
The Volt gauge will indicate voltage. The optimum operating range is 12 Volts. A fully charged
battery might indicate higher at the beginning of operations. As a work time continues the
battery voltage will drop and show approximately 11.5 Volts, this is normal. Once the battery
voltage drops below 11 Volts, the unit's electronic controls will begin to malfunction and the
blower will turn slower causing inefficient heating. Do not depend on solar panel for charging,
solar panel is only capable of being a maintaine.
Volt Gauge

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OPERATING THE KM 4-40-C1
4. Push the Green Start button to begin the automatic heat cycling.
The light will indicate that the unit is operating. The infrared heater will cycle
automatically for ten minutes then stop. It is necessary to re-start the next
heating cycle.
Push the Red Stop button to stop automatic heat cycling when desired. This
will reset the 10 minute time cycle.
The Low Pressure Gauge will indicate fuel supply during On cycles.
Note: The High Pressure Gauge indicates vapor pressure from the fuel cylinders. Vapor
pressure is dependent on temperature. Warmer temperatures will offer higher pressures from
the fuel cylinders. It may be necessary to replace fuel cylinders often when working in cold
temperatures due to propane bottle freeze up and a drop in fuel pressure.
5. Select the Zones desired for heating.
The ball valves 1 -4 correspond with the quadrants of the unit 1-4.
All four zones have been selected in this picture. The entire 5' x 8' (1.5 m x
2.4 m) of the unit is heating.
By selecting only Zone 3 and Zone 4 the operator can heat half of the unit.
In this picture the bottom half of the unit is heating equaling 5' x 4' (1.5 m x
1.2m) of repair area.
NOTE: Other configurations can be used. An experienced operator will find the optimum
heating configurations per jobsite application.
6. Reposition the machine for the next repair.
The operator will determine when the asphalt is softened to the desired
depth for repair.
Push the red stop button and then re-start to begin a full heat cycle.
7. Close the propane cylinders to begin shut down of the unit.
Allow the unit to consume all fuel within the combustion system. Both
pressure gauges will indicate Zero psi (kpa).

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OPERATING THE KM 4-40-C1
8. Turn the keyed switch off.
The blower will continue to operate for 90 seconds. Allow the unit to
complete this delay cycle before proceeding to the "fold-up" sequence.
9. Reposition and install the U-pin locks on Casters #1 and #2.
Follow the Set up, folding and unfolding, procedures to return the unit to
travel position.
Casters #1 and #2 (corresponding with Zone #1 and Zone #2) will be in the
rear position of the unit and locked.
Casters #3 and #4 (corresponding with Zone #3 and Zone #4 will be at the
side position of the unit for folding and unfolding the machine.

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MAINTENANCE
ADJUSTING THE HEATING ZONES
CAUTION: VIEW FROM AT LEAST 8 FEET (2.5 METERS) AWAY!
From time to time it may be necessary to re-adjust the gas/air ratio of a zone. Adjustment of the improperly
heating zone is best done in dim light. The KM 4-40 should be raised up off of the ground and level with a hoist, or
lifted onto nonflammable blocks so that the underside may be viewed during adjustment.
There are five (5) mixture adjustment valves located under the control panel. Four are connected to their
corresponding control valves above. The fifth is located toward the middle and is the mixture adjustment valve for
the pilot light. The mixture adjustment valves have round handles, which should move stiffly when turned by
hand. If any handles move loosely, gently tighten the packing nut that is on the shaft beneath the handle.
Clockwise rotation closes the adjustment valve, leaning the mixture to that zone. Counterclockwise richens it.
Turn slowly because a small adjustment can make a big difference. If a blue flame layer is visible a distance below
the blanket, the mixture is too rich. A patchy blue dancing flame close to blanket means the mixture is too lean.
Try several positions as you zero in on the optimum adjustment. Compare the zone to the ones around it.
The ideal heating zone adjustment turns the blanket red/orange hot.
Zone adjustment needle
valves (4 valves).
Pilot adjustment needle
valve.
The Zone adjustment Needle
Valves are located within the
control panel.

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KM 4-40C1M1 Infrared Asphalt Recycler Manual –v.5.25.21 Page 15
Phone: [phone] Toll Free: 800-492-1757 Fax: [phone]
www.kminternational.com
© 2010 Keizer-Morris International. All Rights Reserved.
BASIC MAINTENANCE - Quick Reference
THIS UNIT REQUIRES PROPANE GAS. Maintenance must be PERFORMED by a qualified service person. The
KM 4-40 Infrared Asphalt Recycler system should be INSPECTED before initial use and every use thereafter only by
a qualified service technician.
WARNING: Inspect all fuel lines and connections daily before using the KM 4-40 Infrared. DO NOT use if
damaged in any way. DO NOT allow the fuel line to lie against the bottom of the machine or on any hot surface
during use. DO NOT expose the hose in any way to heat or physical abuse during operation.
DAILY
Charge battery. Solar panel
only provides 125mA of charge,
this is for a maintainer and
should not be relied on for
charging.
Grease all casters.
Inspect tires and wheels.
Inspect propane cylinders.
Secure before travel.
Test & inspect lighting
before travel.
Inspect hitch and trailer
light connections.
Inspect blanket retainer
hardware & blanket
condition.
Clean spark plug.
WEEKLY
Inspect pilot flame. Adjust if
necessary.
Consult Maintenance Adjusting
the Zones section in Manual.
Inspect heating zones.
Observe from a safe distance -
minimum 8' (2.4 m).
Example: Block machine
with cement block.
Adjust heating zones if
necessary.
Consult Maintenance Adjusting
the Zones section in Manual.
MONTHLY,
SEASONAL
Inspect blanket thoroughly.
Inspect interior of blanket.
Inspect air distribution
Adjust heating zones after

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KM 4-40C1M1 Infrared Asphalt Recycler Manual –v.5.25.21 Page 16
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© 2010 Keizer-Morris International. All Rights Reserved.
Replace if needed.
manifolds. Replace if
needed.
new blanket installation.
HELPFUL HINTS
SELECTING HEATING ZONES
CHOOSING HEATING ZONES
When you have positioned the unit over the area you would like to heat, you must then choose which
zones to use. You have the choice of any of the four zones independently or in any combination. It does
not hurt to heat a margin of asphalt larger than the actual repair area. For example, a pothole that
measures 22 inches (56 cm) across would best be done with Zone #3 -3' x 4' (.9 m x 1.2 m). A 2' x 4' -
(.6m x 1.2m) Zone 4 zone would suffice, but would probably not give the best results.
HEATING SEQUENCE
If the repair area is larger than the infrared's area, you will have to decide the sequence of areas to heat.
Long narrow repairs are easy to figure. Heating an adjoining series of areas with the appropriate zones
you can do 2, 3, 6, and 8-foot (.6 m, .9 m, 1.8 m, 2.4 m) width strips. Move with the wind so that the
smoke blows away from the work area. Helpful Hint: use a chalk line as a guide on long repairs to make
attractive straight edges.
Wider and oddly shaped areas may require more planning. The general guidelines to follow are:
1. Heat the widest strips possible to maximize hot to hot adjoining edges.
2. Never start a repair in the middle, always work from an edge.
3. Step back periodically and look across the repair from a viewpoint close to the ground, this
helps you to make a level repair.
CHANGING the BOTTLES
During the course of a day propane bottle pressure may drop below acceptable operating pressure.
They may have run out of propane or on cold days with extensive use they may “freeze up,” leaving
some amount of cold liquid propane in them. It is necessary to replace these bottles with full ones.
Simply turn off all the propane valves, turn off the toggle switch and remove the POL fittings (left-hand
threads) from the bottles. Loosen the chains and replace the bottles. Frozen bottles may be useable
when they warm up, if they are not too empty.

TM
KM 4-40C1M1 Infrared Asphalt Recycler Manual –v.5.25.21 Page 17
Phone: [phone] Toll Free: 800-492-1757 Fax: [phone]
www.kminternational.com
© 2010 Keizer-Morris International. All Rights Reserved.
WARNING: ENSURE ALL SAFTEY STANDARDS ARE FOLLOWED WHEN PROPANE BOTTLES ARE
UNDER PRESSURE. BURNS MAY OCCUR.
HELPFUL HINTS
REGULATOR OPERATION
Your regulator is equipped with a vent which allows the diaphragm to “breathe”. The diaphragm of the
regulator moves down and draws air into the bonnet or adjustment spring housing. When the
diaphragm moves up, air is expelled through the vent. In the event that excess pressure builds up in the
lower housing or body of the regulator, a relief mechanism vents it to the atmosphere. It is imperative
to check the vent frequently to be sure it is clean and free of water, corrosion or obstruction, as clogging
is a potential cause of regulator malfunction.
Great care has been taken in the manufacture of your regulator and it has been thoroughly tested and
UL listed. However, even a small piece of dirt, corrosion, pipe dope or other foreign material which finds
its way into the regulator can result in higher than normal pressure (high lockup) and/or loss of fuel.
If the vent does become clogged it can easily be cleaned with a toothbrush. In addition, your regulator
should be checked periodically by a competent LP serviceman to be sure it is property adjusted and in
safe working condition. By following these simple precautions your regulator should give you years of
trouble-free service.
Figure 10.
WHAT IS REGULATOR FREEZE UP?
A regulator will not freeze, nor will LP gas under normal atmospheric conditions. However, as the gas
passes through the regulator it expands, cools and moisture in the gas or in the regulator may turn to
ice. This ice can build up and block the orifice and thus partially or totally block the fuel supply. There
are a number of things you can do to prevent this type of freeze up:
1. Be sure your LP cylinder is totally free of moisture before it is filled.
2. Be sure your cylinder is not over filled. This is particularly important if you have a permanently
mounted ASME tank.
3. Keep the valves on empty cylinders closed.
The Regulator is located inside
the control panel .

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KM 4-40C1M1 Infrared Asphalt Recycler Manual –v.5.25.21 Page 18
Phone: [phone] Toll Free: 800-492-1757 Fax: [phone]
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© 2010 Keizer-Morris International. All Rights Reserved.
4. Have your LP gas dealer inject methyl alcohol in your cylinder.
HELPFUL HINTS
WIND SKIRT USE
Every KM International Infrared is delivered with “wind skirts”. The wind skirts provide protection to the
burner and blanket in windy conditions that would otherwise hamper the Infrared’s effective operation
and use. The wind skirts are placed on two adjacent sides on the windward side of the Infrared to
partially block out the wind and to allow the heat to better directly penetrate the asphalt.
WARNING: Gloves MUST be worn when adjusting or removing wind skirts. The skirts are made of
aluminum and quickly become very hot during operation. Handling without proper safety gloves may
cause injury.
Wind Skirt Placement

TM
KM 4-40C1M1 Infrared Asphalt Recycler Manual –v.5.25.21 Page 19
Phone: [phone] Toll Free: 800-492-1757 Fax: [phone]
www.kminternational.com
© 2010 Keizer-Morris International. All Rights Reserved.
HELPFUL HINTS
ASPHALT REPAIR USING THE KM INFRARED ASPHALT RECYCER
Once the bituminous surface has been softened the process of repairing, decorating, adhering
thermoplastics, or otherwise manipulating the pavement in a quality manner is considered
craftsmanship. It is imperative that the operator and/or service crew be properly trained in the
fundamentals of in-place reheating asphalt and asphalt repair. Much like a quality asphalt paving
operator gains knowledge by experience, a quality asphalt repair technician improves craftsmanship
with experience. Hands-on operation in a variety of settings will best train personnel in the craft.
Following is a "basic" step by step fundamental process for in-place asphalt repair using an Infrared
Asphalt Recycler and Asphalt Hotbox Reclaimer.
1. Clean the area to be repaired. Remove all dirt, foreign debris, standing water and loose aggregate.
2. Position the infrared unit over the area to be repaired. Maintain a minimum 3" (75 mm) perimeter
larger than the actual repair.
3. Allow the infrared heating unit to properly soften the pavement to a depth of 1.5" - 2.5" (37 -62 mm).
(Approx time 8-10 mins.)
4. Move the heating unit off of the repair area. Reposition for the next repair when necessary.
5. Scarify (rake) the entire minimum heated depth of the repair area. Note: Frame edges first for an
attractive repair.
6. Optional: Remove material if necessary (high spots). Remove contaminated material.
7. Rejuvenate with a maltenes rejuvenator the heated and raked asphalt. Also, rejuvenate the heated
and un-scarified edges. Application rates are approximately .12 gal/sq yd. (.54 liter /sq meter).
8. Add new asphalt as required per job conditions.
9. Lute the repair area level. Typical practice leaves the repair area 1/4" (6 mm) above surrounding
grade before compaction.
10. Compact the repair.
11. Apply maltenes rejuvenator, .12 gal/sq yd,(.54 liter /sq meter) over the entire repair area. Apply
stone dust and compact or broom into the area.
12. Clean up the repair area and surrounding area.
13. Open repair to straight drive over traffic. Allow sufficient cool down where vehicle stopping or
turning is present.
Every repair requires on site evaluation and proper techniques. The infrared asphalt recycler is a tool
that provides the means to service asphalt in a variety of settings including:
Pothole repair
Water drainage
Trip hazard repair
Paving seam corrections
Speed-bump installation
Pavement imprinting
Oil spot removal
Thermo-plastic installation
Utility joint maintenance