intrepid KM100 User manual

User Manual
Knikmops Wheel Loaders

Copyright and contact details
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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information may be incomplete, incorrect or may become outdated in time.
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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
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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
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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
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• Counterweights:
• Only counterweights and the counterweight frame from the manufacturer may be
placed on the rear of the machine.
• Persons on the back of the machine are not allowed as counterweight.
• Ensure that the interchangeable accessory parts are properly secured at all times.
• Driving on a slope:
• Driving parallel to the slope is only permitted if the following conditions are met:
• Maximum slope 10°
• Boom retracted and as low as possible close to the ground
• Maximum speed 3 km/h
• Driving on slopes greater than 10° is only permitted if you drive straight up or
straight down, i.e. at right angles to the slope.
• Driving with loads on a slope is only permitted if the following conditions are met:
• Maximum slope 10°
• Load as low as possible close to the ground
• Maximum speed 3 km/h
• If the machine overturns:
• Keep your seat belt on.
• Stay on the machine.
• Turn off the machine completely.
• Always use the locking pin or locking pins to lock interchangeable accessories and
also follow the instructions of the interchangeable accessory.
• Obey the local labor and safety laws and environmental regulations.
2.2.2 Personnel
• The machine may only be used, maintained and repaired by personnel trained by the
manufacturer or by the importer.
• The personnel must:
• be 18 or older.
• be physically and mentally healthy.
• have the relevant knowledge and skills.
• Personnel in training may only use the machine under the supervision of trained
personnel.
2.2.3 Organizational measures
• Do not wear loose clothing or jewelry. Tie up long hair.
• Ensure that all warning symbols on the machine are legible. Replace unreadable
warning symbols immediately.
• Hoisting and lifting tools such as chains, plastic hoisting belts and steel straps must
meet these requirements:
• Be sufficiently strong, correctly dimensioned and in good condition
• Comply with local labor and safety laws
• Workplace environment:
Safety
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• The machine is suitable for driving on the public highway, provided it has the
correct registration documents, the correct traffic lighting and permits.
• The workplace must be sufficiently lit at all times.
• It is the responsibility of the operator to ensure that bystanders (people who are not
the operator) cannot get into the path of the machine, the interchangeable
accessories or the loads.
2.2.4 Safety instructions during certain activities
• Make sure that no one is at risk.
• If there is danger, give a warning signal and stop the machine if necessary.
• Before using the machine, allow the machine to warm up in a well-ventilated area.
• If you do not have sufficient visibility, make sure you are assisted by trained
personnel. This personnel must be recognizable and stay within your field of vision at
all times.
• The machine must not be used in landfills where there is a risk of the machine falling,
unless there are provisions that prevent rolling or crashing.
• When you are no longer using the machine, stop the machine.
• Before stopping the machine, remove the interchangeable accessory according to the
instructions in this manual and place the interchangeable accessory in a safe location.
• If the hydraulic steering cylinder fails, fit the jib lock rod. See section 4.10 .
• At all times prevent persons going under the load.
• People must remain at a distance of 5 meters from the working machine.
• Explore the surrounding area and remove any obstacles.
2.2.5 Instructions concerning certain risks
• Make sure you know where the fire extinguishers are.
• In the event of fire: keep a sufficient distance away from the machine. If the hydraulic
fluid lines overheat, they can break and cause flash fires of burning hydraulic fluid.
• Use only fuses from the manufacturer.
• Avoid prolonged overloading of the hydraulics. This causes overheating of the
machine. Always ensure that the hydraulic control is in the neutral position when
starting the machine.
• Check the hydraulic fluid level daily and top up if necessary.
• Replace the hydraulic fluid filters and the hydraulic fluid at least once a year.
• Be careful when using hydraulic fluid and battery acid.
• Avoid high speeds with a low oil temperature: drive for the first 5 minutes at an
increased engine speed (1500 rpm), without a load.
• Refueling:
• Before refueling:
• Switch off all electrical systems.
• Switch off the engine and allow the engine and exhaust to cool down to a hand-
warm temperature.
• Refuel in a well-ventilated area.
• Do not refuel near open flames or sparks.
• Do not smoke while refueling.
• Make sure that no fuel, oil or grease gets on the machine.
• Only use the machine in well-ventilated areas.
• Only use original parts from the manufacturer.
Safety
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• Avoid shocks and vibrations.
• Do not use the machine as an anchor point.
2.2.6 Instructions concerning hydraulic parts
The machine and its attachments contain hydraulic components. These involve specific
dangers:
• The hydraulic oil heats up during use. Contact with hot hydraulic oil can lead to burns.
• The hydraulic oil is under high pressure. Hydraulic oil that sprays out of the system
under pressure can penetrate the skin and cause serious injuries. Therefore, never
look for leaks by feeling with your bare hand and use the necessary personal
protective equipment.
2.3 Safety symbols on the machine
U
C
A
E
F
A
I
N-O
I
M
S
T
L
I
P
KK
L
G
H
Q
J
R
B
J
D
V
Symbol Meaning
A Only attach the lifting hooks to these locations for transport.
Safety
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Symbol Meaning
B WARNING: Prevent personal injury or risk of death.
• Ensure that safety devices are active.
• Work according to the procedures in the user manual.
• Keep safety guards in place.
• It is forbidden to smoke during maintenance of the machine
or refueling.
• Remove all dirt from the engine compartment every day to
prevent fire. Keep a fire extinguisher nearby.
• Look for hydraulic leaks without using your hands.
• Escaping oil under pressure can be invisible and penetrate
the skin.
• Allow the engine heating to cool down before opening the
engine cap. Open the engine cap slowly to prevent burns.
CWARNING: Prevent personal injury or risk of death.
• Read the manual and all safety stickers before using the
machine.
• The owner is responsible for ensuring that all users of the
machine have been instructed about safe use and mainte-
nance.
• Check the machine before every use. Use the operator
manual for this.
• Contact the supplier or manufacturer for information and
spare parts.
D The operator is advised to use hearing protection.
E WARNING: Prevent physical injuries while getting in and out of
the machine:
• Keep some distance from the machine.
• Ensure you have a 3-point contact with the machine while
getting in or out.
• Do not hold the steering wheel.
F Read the safety instructions before starting the machine. Obey
these safety instructions.
G WARNING: It is forbidden to remove the FOPS.
H During transport, attach the straps only to these locations.
Safety
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Symbol Meaning
I WARNING:
• Personnel not controlling the machine must remain at a
safe distance from the machine.
• Fit the jib lock for maintenance or transport.
J WARNING:
• Before starting the machine, ensure that the interchangea-
ble accessory is secured with both locking pins.
K It is forbidden to stand under the load.
L CAUTION: high temperatures.
M WARNING: Prevent personal injury or risk of death.
• Keep hold of the steering wheel if the machine tilts.
• Never jump out of the machine.
N WARNING: Prevent the machine from tipping over.
• Keep the load low.
• Stay within the prescribed capacity.
• Avoid steep slopes and sharp turns.
O IMPORTANT: Only use hydraulic oil.
P WARNING:
• Do not put your hands into the machine when the engine is
running.
• Leave the engine cover closed when the machine is run-
ning.
• Risk of burns: hot machine parts under the cover.
Q DANGER: Stay at a safe distance. The machine swings out.
R IMPORTANT: Only use diesel that meets the stated specifica-
tions.
S WARNING:
• Have the ROPS replaced immediately after the machine
has been tilted.
• Wear seat belts while using the machine.
Safety
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3 Description
3.1 Overview
A
C
F
F
D
E
F
G
H
L
M
Q
F
N
O
J
K
P
I
P
B
ASafety cabin JDriver’s seat
BInching pedal KCounterweights (optional)
CParking brake LHydraulic control
DSteering wheel MEngine compartment
EDashboard NFuel tank
FLifting eyes and tie-down points OHydraulic fluid tank
GBoom PJib locking pin
HMounting plate QSeatbelt
IGas pedal
Description
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3.2 Type plate
MASS/ GEWIC HT
T YP E
SE RIE NR .
MAX . HYD R. 180 B AR
BO UWJ.
PO WER
MAX . LOA D/L AST
KW
KG
MADE IN B ELGI UM
KG
The illustration shows an example of the layout of the type plate on the machine. The
actual type plate on the machine shows the correct data depending on the type of
machine.
3.3 Dashboard
3.3.1 Dashboard types
Depending on the type of machine, there are different types of dashboard. All dashboards
contain the necessary control instruments.
3.3.2 Dashboard type 1
0000000
E
F
G
H
I
C
D
A
B
AIgnition key FOil pressure lamp
Description
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BFuse box GPre-heater lamp for the diesel engine
CLight switch HMotor temperature lamp
DDifferential switch IOperating hours counter
EBattery voltage lamp
3.3.3 Dashboard type 2
0000000
EONMC F
A
G
H
I
J
K
L
B
D
AIgnition key INeutral position indicator
BFuse box JEngine oil pressure
CLight switch KBattery voltage
DDifferential switch LEngine coolant temperature
EOperating hours counter MHydraulic fluid temperature
FFuel indicator NParking brake
GTurn signal (optional) OPosition lights (optional)
HPre-heater lamp for the diesel engine
Description
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3.4 Hydraulic control
C D E F
G
B
A
ALever for auxiliary hydraulic function
left. See also section 4.4 .
ETelescope button (extend) (only for TE
versions)
BLever for auxiliary hydraulic function
right. See also section 4.4 .
FMoving the joystick left and right takes
over the function of B.
CHorn GButton to switch the electrical function
of the attachment on and off.
DTravel direction button
Description
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3.5 Mounting plate
C
B
D
F
A
E
AElectrical connection for electrical
function.
DMounting plate
BConnection for auxiliary hydraulic
function right.
ELocking handles
CConnection for auxiliary hydraulic
function left.
FLocking pins
Description
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