The provided document is a comprehensive device manual for the WIRTGEN KMA 200, a cold mix asphalt plant. This manual is valid only in conjunction with the SAFETY INSTRUCTIONS (Order number: 76 779).
The KMA 200 is designed for the production of homogeneous cold mixes for various applications. It can mix fillers, cement, lime hydrates, emulsions, hot bitumen, and new or recycled construction minerals. The resulting cold mix can be paved as a base or wearing course on construction sites or stored for longer periods. The unit must be operated on a heavy-duty trailer approved by WIRTGEN. Any other use is considered non-determined, and the manufacturer is not responsible for damages. The machine should not be used to carry passengers (other than operating personnel), as a lifting device, or for transporting individual or bulk goods. It is also not designed to process mineral aggregates larger than 45 mm.
Function Description:
The KMA 200 is equipped with a Cockpit Graphics Monitor (CGM) that allows operators to input, modify, and read work-specific data. The machine features various control panels for different functions:
- Main Functions Control Panel: Includes an emergency stop button, input/output modules, and the CGM. It also has switches for additive material pre-selection and compressed air supply (ON/OFF).
- Engine Station Control Panel: Displays engine speed, oil pressure, coolant level, fuel tank level, hydraulic oil temperature, and battery charge status. It includes controls for engine speed adjustment, start/stop, and air compressor operation.
- Water System Control Panels: Manages the water supply, including water tank filling levels and water pump operation.
- Binder Unit Control Panels: Controls the binder supply, including bitumen pump, bitumen water pump, emulsion pump, and cement feed.
- Conveyor Unit Control Panels: Manages the conveyor system, including hopper grid vibration, dosing conveyor, mixer, and discharge conveyor.
- Other Control Panels: Includes controls for lighting, warning horn, and various fault/error messages.
Important Technical Specifications:
- Max. Mixing Performance: 200 t/h
- Cement-Bound Mix (5% cement): 250 t/h
- Max. Aggregate Size: 45 mm
- Dimensions (w/o cabin / with cabin): 13,400 mm / 14,710 mm (length), 2,500 mm (width), 4,000 mm (height)
- Total Weight: 30,000 daN (kg)
- Proportioner Capacity: 2x 6 m³
- Hatch Width: 3,710 mm
- Hatch Height (average): 3,600 mm
- Mixer Type: Twin-shaft pug-mill, force-feed mixer
- Mixer Rated Power: 2x 30.0 kW
- Engine Manufacturer: DEUTZ BF 6 M 2012 C
- Engine Cooling: Water
- Number of Cylinders: 6
- Engine Rated Output: 131 kW / 175 PS / 178 HP
- Engine Speed: 2,100 min⁻¹
- Stroke Volume: 6,060 cm³
- Fuel Consumption (full load): 32 l/h
- Water Tank Capacity: 4,500 l
- Fuel Tank Capacity: 400 l
- Hydraulic Oil Tank Capacity: 400 l
- Electrical System Voltage: 24 V
- Charging Auger for Hydr. Binder: 13 m³/h
- Water Addition: 250 l/min
- Emulsion Addition: 250 l/min
- Hot Bitumen Addition for Foam Bitumen: 180 kg/min
- Heater for Hot Bitumen System Voltage: 42 V
- Dosing Conveyor Belt Width: 1,000 mm
- Discharge Conveyor Belt Width: 800 mm
- Discharge Conveyor Slewing Angle R/L: 20/35 °
- Tyre Size: 235/75 R 17.5
- Trailer Linkage Height: 1,190 mm
- King-pin: Ø 2 inch
- Ground Clearance: 300 mm
- Inner Turning Circle: 2,350 mm
- Compressed Air Tank Capacity: 80 l
- Permissible Operating Pressure: 10 bar max.
- Cabin Dimensions: 2000x1200x2450 mm (length x width x height)
Usage Features:
- Starting On-Site Operation: Requires the machine to be positioned horizontally on sufficiently compacted ground (min. 200 kN/m²). Air and electrical lines must be disconnected from the traction vehicle. Telescopic supports must be extended, and the machine leveled. Cement charging auger and hopper material deflection plates are adjusted. Water tank is filled with good quality water (no sea or dirty water). Hoses for water, bitumen, and emulsion are connected. Transport locking devices for dosing conveyor scales and cement weighing auger are removed. Emergency STOP switches are checked. The diesel engine is started, and the cabin unfolded. The unit is run in AUTOMATIC mode for approx. 5 minutes. For foam bitumen production, the unit is heated to approx. 160 °C. Dosing conveyor scales and cement weighing auger are tared and dynamically calibrated. The hopper is filled, and material gates are positioned.
- Ending On-Site Operation: The unit is shut down in AUTOMATIC mode. Lines for water, bitumen, and emulsion are manually emptied and disconnected. The emulsion unit is flushed. Hopper, cement charge/weighing auger, dosing/discharge conveyor, and water tank of the bitumen unit are manually emptied. Cement feed input funnel and weighing auger input port are covered. The unit is cleaned. Engine is switched off, and ignition is turned off. Hydraulic telescopic supports are retracted and secured. The traction vehicle is hitched, and telescopic supports on the swan-neck are retracted. Air and electric lines are connected.
- Operator's Stand: Includes controls for air conditioning (ON/OFF, fan regulation) and cabin lights (ON/OFF).
- Remote Control Unit: Used for loading operations, including hopper grids vibration (ON/OFF, UP/DOWN), batch pause (START/STOP), and batch start/stop.
- Dosing Conveyor: Manual operation for troubleshooting or service. Speed is adjusted via a knob (0-100%). Drive roller and return roller bearings are lubricated.
- Cement Charging Auger: Manual operation for troubleshooting or service. Speed is adjusted via arrow keys (0-100%). Bearings are lubricated.
- Cement Weighing Auger: Manual operation for troubleshooting or service. Speed is adjusted via arrow keys (0-100%). Bearings are lubricated.
- Mixer: Manual operation for troubleshooting or service. Forward/reverse drive is controlled by a toggle switch. Mixer gate opening/closing is controlled by a toggle switch. Mixer shafts bearings are lubricated.
- Discharge Conveyor: Manual operation for troubleshooting or service. Speed is adjusted via a knob (0-100%). Drive roller, return roller, and turntable bearings are lubricated.
- Bitumen Water Pump: Forward/reverse drive is controlled by a toggle switch.
- Emulsion Pump: Forward/reverse drive is controlled by a toggle switch.
- High-Pressure Cleaner: ON/OFF control for water pump.
- Binding Unit: Controls for foam bitumen test, binder pumps, and cold mix production.
- Compressed Air System: Defroster activation (summer/winter).
Maintenance Features:
The manual includes a detailed maintenance chart with tasks scheduled at various intervals (10h, 50h, 100h, 250h, 500h, 1000h, yearly, or when necessary).
- Chassis / Safety Devices:
- Safety Devices: Check function prior to starting work, ensure correct function.
- Lights - Warning Devices: Check and clean contacts.
- Cleaning: Complete machine cleaning.
- Semi-Trailer: Check spring system, brake system, container interlocking device, compressed air and electrical connections, lights, tyre profile, and tyre pressure.
- Operator's Stand:
- Air Conditioning Unit: Check connections, switch on unit, check and change air filter.
- Engine / Motor Group:
- Fuel Tank: Check and top-up fuel level frequently.
- Diesel Engine: Check and top-up oil level, change oil and oil filter, check and change fuel filter, check and drain fuel prefilter, check and change coolant level, check and clean air filter elements, check and clean engine cooler fins, drain turbo-charger oil sump, check and renew hoses, check and tighten hose clamps, check and tension V-belt.
- Hydraulic Oil Feed:
- Hydraulic Oil Tank: Check and top-up oil level, change oil, clean/change filter element.
- Hydraulic Pump Drive: Check and top-up oil level, change oil.
- Hydraulic Filters: Check for contamination frequently, renew filter element.
- Conveyor Unit:
- Hopper Grid Vibrators: Change oil.
- Conveyor Unit: Check and set scraper/rollers, check and tension belt, check and renew wire-ropes, set conveyor weigher.
- Dosing Conveyor Gearbox: Check and top-up oil level, change oil.
- Dosing Conveyor: Tare scales.
- Mixer Equalizer Gearbox: Check and top-up free-flow grease level, change free-flow grease.
- Mixer: Check and set/renew blades, check and renew coating.
- Conveyor Stripper Brush: Check for wear, tension, and renew.
- Water System:
- Water Tank: Check and top-up water level frequently, fill anti-freeze, check and clean filter mesh, renew tank protection cartridge.
- Water Filter: Check and clean filter element.
- Binding Unit:
- Bitumen Water Pump: Check and top-up oil level, change oil.
- Binder Pumps: Check and adjust packings, renew packings.
- Compressed Air System and Accessories:
- Compressed Air Tank: Check and clean compressed air connection, release condensation.
- Defroster Unit: Activate (summer/winter), fill with methylated spirits, clean the wick.
- Lubrication: Lubricate/apply grease at all lubrication points.
- All welding work must be carried out by qualified personnel, with specific precautions to protect electronic units.
- The machine must be positioned horizontally during operation, and the ground must be sufficiently compacted (min. 200 kN/m²).
- Working with hot bitumen, bitumen emulsion, binders, lime, cement, and solvents requires protective clothing and goggles. Avoid inhaling vapors. Remove emulsion puddles immediately. Solvents must be collected to prevent ground contamination.
- Release pressure in the pipe system before opening rapid-action connectors.
- Wear a dust protection mask if the machine is not equipped with a cabin and dust is generated.
- Be careful of hot parts in the foam bitumen unit.
- The emergency stop button is for emergencies only, not for normal engine shutdown.
- The air conditioning unit should always be switched off before stopping the engine.
- Ensure all loose components are secured during transportation. The water tank and hopper must be completely empty.
- Do not use force on weight sensors or transport the machine without securing it, as this can cause permanent damage and incorrect measurements.
- Do not stand on the conveyor belt.
- Do not clean electrical cabinets, couplings, or connections with a high-pressure cleaner.
- Do not mix oils of different specifications.
- Use only pre-filtered oil.
- Perform oil changes with warm oil.
- Never start the engine when the hydraulic oil has been drained.
- Use only manometers with sufficient measuring range for pressure tests.
- Always disconnect the earth (minus) cable from the battery when working on the electrical system.
- Use only fuses of the stipulated electrical values.
- Ensure correct battery connection sequence (plus first, then minus; reverse for disconnection).
- The air conditioning unit's crankshaft seal requires regular lubrication through periodic operation (5-10 minutes every 50 hours) to maintain proper function.
- Ensure that only environmentally friendly antifreeze is used. Do not exceed 52% (volume) antifreeze concentration, as this reduces anti-corrosion and heat conduction properties.
The manual also includes detailed fault/error indications displayed on the CGM, such as minimum water tank filling level, material lack in dosing bunker, water/bitumen/additive regulation errors, insufficient compressed air, cement errors, mixer/weigher auger not rotating, and generator frequency faults. Each error has a corresponding text message and recommended actions for rectification.
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