Knikmops KM 80 User manual

User Manual
Intrepid Wheel Loaders

Introduction
2
Copyright and contact details
© 2018 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 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
3
Preface
Make sure that the Intrepid 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 Intrepid 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may be incomplete, incorrect or may become outdated in time.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 GEBR. GEENS
N.V. IN WRITING TO THE PURCHASER OF THE SERVICES AND/OR PRODUCTS.

Introduction
4
© 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
5
Contents
1 Introduction .................................................................................................................................. 7
About this manual ...................................................................................................... 7
Revision history ......................................................................................................... 7
Related documents .................................................................................................... 7
Safety symbols in the document ................................................................................ 8
Contact details for North America .............................................................................. 8
2 Safety .......................................................................................................................................... 9
Intended use .............................................................................................................. 9
Safety instructions ..................................................................................................... 9
Using the machine ...................................................................................... 9
Personnel .................................................................................................. 10
Organizational measures .......................................................................... 10
Safety instructions during certain activities ............................................... 10
Instructions concerning certain risks ......................................................... 11
Instructions concerning hydraulic parts ..................................................... 11
Safety symbols on the machine ............................................................................... 12
3 Description ................................................................................................................................. 15
Overview .................................................................................................................. 15
Type plate ................................................................................................................ 16
Dashboard ............................................................................................................... 16
Hydraulic control ...................................................................................................... 17
Mounting plate ......................................................................................................... 18
Sticker for hydraulic control and boom level functions ............................................ 19
Driver’s seat ............................................................................................................. 20
Operating principle: driving the wheels .................................................................... 20
4 Daily use .................................................................................................................................... 21
Starting .................................................................................................................... 21
Stop ......................................................................................................................... 22
Driving ..................................................................................................................... 22
Driving: safety instructions ........................................................................ 22
Driving ....................................................................................................... 23
Operating the boom ................................................................................................. 23
Attaching an interchangeable accessory ................................................................. 24
Detaching an interchangeable accessory ................................................................ 25
Operating the interchangeable accessory ............................................................... 25
Refueling ................................................................................................................. 26
Engaging and disengaging the differential .............................................................. 26

Introduction
6
Installing counterweights ......................................................................................... 27
Mounting and removing the jib lock ......................................................................... 28
Preheating ............................................................................................................... 28
Transport and storage ............................................................................................. 29
Transport: safety instructions .................................................................... 29
Driving on the means of transport ............................................................. 29
Hoisting the machine ................................................................................ 29
Storage ..................................................................................................... 29
5 Maintenance .............................................................................................................................. 30
Daily maintenance ................................................................................................... 30
Maintenance table: maintenance with the machine switched off ............................ 30
Maintenance table: Maintenance with the machine switched on ............................ 31
Periodic maintenance (qualified service technician) ................................................ 32
Opening the engine compartment ........................................................................... 33
Clean the pre-filter ................................................................................................... 33
Check the fan belt tension ....................................................................................... 34
Checking the parking brake ..................................................................................... 34
Lubricate the hinge points ....................................................................................... 34
Check/top up the engine oil level ............................................................................. 36
Check/top up the coolant fluid level ......................................................................... 36
Check and top up the hydraulic fluid level ............................................................... 37
Replace the air filter ................................................................................................. 38
Replacing the hydraulic fluid filters .......................................................................... 39
Other lubrication points ............................................................................................ 39
6 Troubleshooting ......................................................................................................................... 41
Daily maintenance ................................................................................................... 41
Troubleshooting table .............................................................................................. 41
7 Technical data ........................................................................................................................... 43
Consumables ........................................................................................................... 43
Reference figure: dimensions .................................................................................. 44
Reference figure: maximum load ............................................................................. 45
KM100TE ................................................................................................................. 45

Introduction
7
1 Introduction
About this manual
The Intrepid wheel loader is referred to in the rest of this manual by the term “machine”.
This machine 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.
Revision history
Date
Revisio
n
Comments
November 2017
001
First version
August 2018
002
Adjustment of the hours for maintenance
Adjustment of contact details to Miniloaders.com
February 2019
002
Addition of Bosch Rexroth joystick
Small changes
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
8
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
possible if you do not obey the instructions.
Note
“Note” is used to provide additional information.
Contact details for North America
Miniloaders.com
801 East Second Street
79045 Hereford, TX
Tel. [phone]
E-mail: [e-mail]

Safety
9
2 Safety
Intended use
The machine is made for carrying out excavation and transport work in road construction,
landscaping and related sectors. By connecting and disconnecting 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.
Safety instructions
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.
When 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 7.
• Avoid asymmetrical distributions of the load.
• 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 close as possible to the ground

Safety
10
• Maximum speed 2 mph
• Driving on slopes greater than 10° is only permitted if you drive straight up or
straight down, i.e. at right angles of the slope.
• Driving with loads on a 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 2 mph
• Driving with loads on a slope is only permitted if the following conditions are met:
• Maximum slope 10°
• Load as close as possible to the ground
• Maximum speed 2 mph
• 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 the interchangeable accessories and
also follow the instructions of the interchangeable accessory.
• Obey the local labor and safety laws and environmental regulations.
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.
Organizational measures
• Do not wear loose clothing or jewelry. Tie up long hair.
• Ensure that all warning symbols on the machine are readable. Replace unreadable
warning symbols immediately.
• Hoisting and lifting tools such as chains, plastic hoisting belts and steel straps must:
• be sufficiently strong, correctly dimensioned and in good condition;
• comply with local labor and safety laws.
• Workplace environment:
• 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.
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.
These 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.

Safety
11
• 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 0.
• At all times prevent persons going under the load.
• People must remain at a distance of 5,5 yards (5 m) from the working machine.
• Explore the surrounding area and remove any obstacles.
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
lukewarm 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.
• Avoid shocks and vibrations.
• Do not use the machine as an anchor point.
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.

Safety
12
Safety symbols on the machine
Symbol
Meaning
A
Only attach the lifting hooks to these locations for transport.
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.
C
WARNING: 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
maintenance.
• 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

Safety
13
Symbol
Meaning
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.
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 inter-
changeable accessory is secured with both locking pins.
K
It is forbidden to stand underneath 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 sleep slopes and sharp turns.
O
IMPORTANT: Only use hydraulic oil.

Safety
14
Symbol
Meaning
P
WARNING:
• Do not put your hands into the machine when the engine
is running.
• Leave the engine cover closed when the machine is
running.
• 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 tated
specifications.
S
WARNING:
• Have the ROPS replaced immediately after the machine
has been tilted.
• Wear seat belts while using the machine.

Description
15
3 Description
Overview
A
Safety cabin
J
Driver’s seat
B
Inching pedal
K
Counterweights (optional)
C
Parking brake
L
Hydraulic control
D
Steering wheel
M
Engine compartment
E
Dashboard
N
Fuel tank
F
Lifting eyes and tie-down points
O
Hydraulic fluid tank
G
Boom
P
Jib locking pin
H
Mounting plate
Q
Seatbelt
I
Accelerator

Description
16
Type plate
The illustrations 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.
Dashboard
A
Ignition key
I
Neutral position indicator
B
Fuse box
J
Engine oil pressure
C
Alternate hydraulic function switch,
see section 4.7.
K
Battery voltage
D
Light switch
L
Engine coolant temperature
E
Operating hours counter
M
Hydraulic fluid temperature
F
Fuel indicator
N
Parking brake
G
Turn signal (optional)
O
Daytime running lights (optional)
H
Pre-heater indicator for the diesel
engine
P
Differential switch, see section 4.9.
Q
Constant hydraulic pressure switch,
see section 4.7.

Description
17
Hydraulic control
A
Lever for auxiliary hydraulic function
left.
E
Button for auxiliary function direction 1
B
Lever for boom extension. See
section 4.4.
F
Button for auxiliary function direction 2
C
Horn
G
No function
D
Travel direction button
H
Button for boom extension and
retraction.

Description
18
Mounting plate
A
Electrical connection for electrical
function
E
Locking pin levers
B
Connection for auxiliary hydraulic
function
F
Locking pins
D
Mounting plate

Description
19
Sticker for hydraulic control and boom level functions
A
Lower boom
F
Auxiliary hydraulic function
B
Raise boom
G
Extend boom
C
Mounting plate forwards
H
Retract boom
D
Mounting plate backwards
I
Interchangeable accessory hydraulic
pressure direction 1
E
Boom extension function
J
Interchangeable accessory hydraulic
pressure direction 2

Description
20
Driver’s seat
A
Lever for adjusting the driver’s seat
forwards and backwards
C
Knob for adjusting the backrest
B
Knob for driver weight adjustment
D
Handle for adjusting the backrest
angle
Operating principle: driving the wheels
Hydraulic wheel motors drive the wheels of the machine, one motor per wheel. The
hydraulic pressure comes from a hydraulic pump that is driven in turn by a diesel engine.
The accelerator pedal of the machine controls the speed of the diesel engine and thus
indirectly the power and the speed of the hydraulics. The inching pedal can be used as a
brake pedal.
Example
You can use the inching pedal simultaneously with the accelerator pedal, for example to
drive slowly across rough terrain or to lift heavy loads and drive slowly. Simultaneously
operate the gas pedal (for the power) and the inching pedal (to limit the speed). When
you press the inching pedal all the way in, the machine stops.