intrepid KM100 User manual

User Manual
Knikmops Wheel Loaders

Copyright and contact details
© Miniloaders.com All rights reserved.
This document or parts thereof may not be reproduced, copied, distributed or stored in a search
system, or sent in any form or method, electronic or otherwise, without written permission from
Miniloaders.com.
Specifications and illustrations can be changed without prior notice. Miniloaders.com cannot be
held responsible for any change or typing error. Details and values mentioned in this document are
average values and determined with care. Details and values are not binding. Miniloaders.com
cannot be held liable for damage suffered as a result of reliance on the information provided in this
document or the use of products, processes or equipment to which this document refers.
Introduction
2

Preface
Make sure that the Knikmops wheel loader is always accompanied by this operator manual.
Miniloaders.com is not responsible for damage and indirect damage caused by operator error, lack
of (skilled) maintenance or any other use other than described in this manual. Miniloaders.com
cannot be held liable for any damages resulting from unauthorized modifications or additions to the
Knikmops wheel loader without the written consent of Miniloaders.com
Miniloaders.com continually strives to improve her products and services. We therefore reserve the
right to change the specifications in this operator manual at any time without prior notice.
The content of this manual has been prepared with the utmost care. Nevertheless, some
information may be incomplete, incorrect or may become outdated in time.
TO THE FULLEST EXTENT PERMISSIBLE BY LAW, MINILOADERS.COM MAKES NO
REPRESENTATIONS OR WARRANTIES OF ANY KIND, WHETHER EXPRESS OR IMPLIED,
FOR THE CURRENCY, ACCURACY OR COMPLETNESS OF ANY INFORMATION, AS
DEFINED ABOVE.
FURTHERMORE, MINILOADERS.COM MAKES NO REPRESENTATIONS OR WARRANTIES IN
CONNECTION TO ITS PRODUCTS AND/OR SERVICES, INCLUDING WARRANTIES ABOUT
ITS SERVICES’ AND PRODUCTS’ MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE, UNLESS EXPLICITLY MADE AND PROVIDED BY MINILOADERS.COM IN WRITING
TO THE PURCHASER OF THE SERVICES AND/OR PRODUCTS.
3

© All rights reserved by Miniloaders.com
Use of the operator manual
This operator manual provides detailed operating procedures for safe, effective and proper
machine use. The manual includes chapters about safe operation, machine specification,
maintenance and troubleshooting information.
Improper operation, inspection and maintenance of the machine can result in injury or death. Read
and understand the contents of this manual completely and become familiar with the machine
before operation. Contact your authorized dealer with any questions about information in this
manual or if you need extra manuals or manuals in other languages.
This manual is considered a permanent part of the machine and should be with the machine at all
times. Replace this manual promptly if it becomes damaged, lost, or stolen.
Change of ownership
If the machine is resold, include this operator manual as part of the sale.
Please provide your dealer or Miniloaders.com with the name of the current owner and any new
address, along with the machine model and serial numbers. This makes sure that the registered
owner receives any updated information and can be notified directly in case of an important
product issue, such as a safety update program.
Warning: Do not remove this operator manual from this machine.
Failure to obey safety, operating and maintenance instructions can result in serious injury to the
operator or bystanders, poor operation and costly breakdowns of the machine.
If you have any questions on proper operation, adjustment or maintenance of this machine, contact
your dealer before starting or continuing operation.
Introduction
4

Contents
1 Introduction................................................................................................. 8
1.1 About this manual............................................................................................................................8
1.2 Revision history...............................................................................................................................8
1.3 Related documents......................................................................................................................... 8
1.4 Safety symbols in the document..................................................................................................... 9
1.5 Contact details for North America................................................................................................... 9
2 Safety........................................................................................................10
2.1 Intended use..................................................................................................................................10
2.2 Safety instructions.........................................................................................................................10
2.2.1 Using the machine.............................................................................................................10
2.2.2 Personnel.......................................................................................................................... 11
2.2.3 Organizational measures...................................................................................................11
2.2.4 Safety instructions during certain activities........................................................................12
2.2.5 Instructions concerning certain risks................................................................................. 12
2.2.6 Instructions concerning hydraulic parts............................................................................. 13
2.3 Safety symbols on the machine.................................................................................................... 13
3 Description................................................................................................16
3.1 Overview....................................................................................................................................... 16
3.2 Type plate......................................................................................................................................16
3.3 Dashboard.....................................................................................................................................17
3.3.1 Dashboard types............................................................................................................... 17
3.3.2 Dashboard type 1.............................................................................................................. 17
3.3.3 Dashboard type 2.............................................................................................................. 18
3.4 Hydraulic control............................................................................................................................18
3.5 Mounting plate...............................................................................................................................19
3.6 Sticker for hydraulic control and boom level functions.................................................................. 20
3.7 Driver’s seat.................................................................................................................................. 21
3.8 Operating principle: driving the wheels......................................................................................... 22
4 Daily use................................................................................................... 23
4.1 Starting..........................................................................................................................................23
Preparation....................................................................................................................................23
Start the machine.......................................................................................................................... 23
4.2 Stop...............................................................................................................................................24
4.3 Driving........................................................................................................................................... 24
4.3.1 Driving: safety instructions.................................................................................................24
4.3.2 Driving............................................................................................................................... 25
Contents
- - 5

4.4 Operating the boom.......................................................................................................................25
4.5 Attaching an interchangeable accessory.......................................................................................25
Release the pressure in the hydraulic system for the auxiliary functions......................................26
Attaching....................................................................................................................................... 26
4.6 Detaching an interchangeable accessory..................................................................................... 26
4.7 Refueling....................................................................................................................................... 27
4.8 Engaging and disengaging the differential.................................................................................... 28
4.9 Positioning counterweights............................................................................................................28
Positioning the first counterweight................................................................................................ 28
Positioning the second and third counterweight............................................................................29
4.10 Mounting and removing the jib lock...............................................................................................29
Mounting....................................................................................................................................... 29
Removal........................................................................................................................................ 30
4.11 Preheating.....................................................................................................................................30
Charging........................................................................................................................................30
4.12 Transport and storage...................................................................................................................30
4.12.1 Transport: safety instructions............................................................................................ 30
4.12.2 Driving on the means of transport..................................................................................... 31
4.12.3 Hoisting the machine.........................................................................................................31
4.12.4 Storage..............................................................................................................................31
5 Maintenance............................................................................................. 32
5.1 Daily maintenance.........................................................................................................................32
5.2 Maintenance table: maintenance with the machine switched off.................................................. 32
5.3 Maintenance table: maintenance with the machine switched on.................................................. 33
5.4 Periodic maintenance (qualified service technician)..................................................................... 33
5.5 Opening the engine compartment.................................................................................................34
Opening the engine compartment: type 1 (KM80 to KM100)........................................................34
Opening the engine compartment: type 2 (KM120)...................................................................... 35
5.6 Clean the pre-filter.........................................................................................................................35
5.7 Check the fan belt tension.............................................................................................................36
5.8 Checking the parking brake...........................................................................................................36
5.8.1 Lubricate the hinge points................................................................................................. 37
5.8.2 Procedure: lubrication via grease nipples..........................................................................37
5.8.3 Grease nipples standard versions.....................................................................................37
5.8.4 Grease nipples TE versions.............................................................................................. 38
5.9 Check/top up the engine oil level.................................................................................................. 38
5.10 Check/top up the coolant fluid level...............................................................................................39
Check............................................................................................................................................ 39
Topping up.................................................................................................................................... 39
5.11 Check and top up the hydraulic fluid level.....................................................................................40
5.12 Replace the air filter...................................................................................................................... 40
Remove the cover......................................................................................................................... 40
Replace the filter........................................................................................................................... 41
Contents
6- -

5.13 Replacing the hydraulic fluid filters................................................................................................41
Replace the intake filter.................................................................................................................41
Replacing the return filter (only present on certain machine types).............................................. 42
5.13.1 Other lubrication points......................................................................................................42
5.13.2 Procedure: lubrication via grease nipples..........................................................................42
5.13.3 Other lubrication points......................................................................................................43
6 Resolving problems.................................................................................. 44
6.1 Daily maintenance.........................................................................................................................44
6.2 Troubleshooting table....................................................................................................................44
7 Technical data.......................................................................................... 46
7.1 Consumables................................................................................................................................ 46
7.2 Reference figure: dimensions........................................................................................................46
7.3 Reference figure: maximum load.................................................................................................. 47
7.4 KM80.............................................................................................................................................48
7.5 KM85.............................................................................................................................................49
7.6 KM100...........................................................................................................................................50
7.7 KM100TE...................................................................................................................................... 51
7.8 KM120...........................................................................................................................................52
7.9 KM120TE...................................................................................................................................... 53
Contents
- - 7

1 Introduction
1.1 About this manual
The Knikmops wheel loader is referred to in the rest of this manual by the term
"machine".
This manual is intended for the following target groups:
• Machine operator
• Personnel that carry out daily maintenance on the machine
The manual is applicable for these machine types:
• KM80
• KM85
• KM100
• KM100TE
• KM120
• KM120TE
This manual was originally written in Dutch. All other language versions are translations.
If there is any doubt about the correctness of a translation, the Dutch version takes
precedence.
It is not always possible to show a detailed image of each individual part of the machine.
Therefore, the images in this document can only show a standard layout. The images are
for instruction purposes only.
1.2 Revision history
Date Revision Note
November 2017 001 First version
August 2018 002 Adjustment of the hours for maintenance
Adjustment of contact details naar Miniloaders.com
1.3 Related documents
Document type Document number Target group
User Manual 34 - X - Y • Operator
• Personnel that carry out daily
maintenance on the machine
Diesel engine user manual 16622-8916-8 Qualified maintenance technician
• X: version number of the document
• Y: release date of the document
Introduction
811 - 002 - 30.08.2018

1.4 Safety symbols in the document
Safety symbol Purpose Description
Warning "Warning" means that injury or death is possible if you
do not obey the instructions.
Caution "Caution" means that damage to the equipment is pos-
sible if you do not obey the instructions.
Note "Note" is used to provide additional information.
1.5 Contact details for North America
Miniloaders.com
801 East Second Street
79045 Hereford, TX
Tel. [phone]
E-mail: [email protected]
Introduction
11 - 002 - 30.08.2018 9

2 Safety
2.1 Intended use
The machine is made for carrying out excavation and transport work in road construction,
landscaping and related sectors. By connecting and disconnecting interchangeable
accessories, the machine can be used for different applications.
Use only interchangeable accessories intended for your machine and that have been
approved by the manufacturer.
2.2 Safety instructions
2.2.1 Using the machine
• Read the manual carefully before using the machine.
• Carry out the procedures in the order shown and complete the procedures.
• Keep this manual with the machine. If there is no manual, report it to your employer.
• Replace a damaged safety cabin immediately.
• If there is a fault or damage to the machine, stop the machine and report it to your
employer. Make sure that the fault is resolved immediately.
• Do not modify the machine unless approved in writing by the manufacturer in
advance.
• If the machine is fitted with an interchangeable accessory for which a periodic
inspection is required, proof of this inspection must accompany the machine at all
times.
• Use only interchangeable accessories from the manufacturer.
If using other interchangeable accessories, the manufacturer accepts no responsibility
for the use of the entire combination.
• When using an interchangeable accessory, subtract the weight of the interchangeable
accessory from the load values.
• Use the machine and the interchangeable accessory only as intended. If you want to
use the machine for another application, please contact the manufacturer.
• The manufacturer is not responsible for damage caused by improper use of the
machine or the interchangeable accessory.
• When replacing parts: always contact the manufacturer and only use parts that have
been approved by the manufacturer.
• Use personal protective equipment: safety clothing, safety footwear.
• Use hearing protection. The noise level is more than 93 dB(A).
• Keep the driver's seat, pedals and steps clean.
• Store materials and tools when you are not using them.
• Loads:
• Position loads only as indicated in this document.
• Do not exceed the maximum loading. For the specifications, see chapter # .
• Avoid asymmetrical distributions of the load.
Safety
10 11 - 002 - 30.08.2018