Knikmops KM 80 User manual

Knikmops wheel loader
KM80, KM85, KM90, KM100, KM120, KM125, KM130 and KM 170
User instructions
1.0

Copyright and contact details
© 2021 Gebroeders Geens N.V. All rights reserved.
This document and parts thereof may not be reproduced, copied, distributed or
stored in a search-based system or sent, in whatever form, whether electronic or
otherwise, without the written consent of Gebroeders Geens N.V.
Specifications and illustrations may be modified without prior notification.
Gebroeders Geens N.V. cannot be held liable for modifications or typing errors.
Details and values provided in this document are average values and have been
determined with care. Details and values are non-binding. Gebroeders Geens
N.V. cannot be held for liable for damage sustained as a result of a reliance on
the information provided in this document or the use of products, processes, or
equipment to which this document refers.
Contact details
Gebroeders Geens N.V.
Hinnenboomstraat 5
2320 Hoogstraten (Belgium)
Tel. [phone]
Fax [phone]
E-mail: [email protected]
Copyright and Contact Details

Table of Contents
Contents 1. Introduction_______________________________________________________________________________ 1
1.1 About these instructions_______________________________________________________________ 1
1.2 Version history_________________________________________________________________________1
1.3 Target group___________________________________________________________________________ 1
1.4 Symbols used__________________________________________________________________________ 2
2. Machine numbers_________________________________________________________________________ 3
2.1 Machine identification_________________________________________________________________ 3
2.2 Type plate______________________________________________________________________________3
3. Intended use______________________________________________________________________________ 4
4. Safety______________________________________________________________________________________5
4.1 Safety instructions_____________________________________________________________________ 5
4.1.1 Instructions before use of the machine and attachments____________________ 5
4.1.2 Instructions for the user______________________________________________________7
4.1.3 Instructions for use of the machine and attachments________________________ 7
4.1.4 General safety instructions___________________________________________________ 9
4.2 Safety symbols on the machine_______________________________________________________10
4.2.1 General safety symbols_____________________________________________________ 10
5. Description of components_______________________________________________________________13
5.1 Overview_____________________________________________________________________________ 13
5.2 Dashboard____________________________________________________________________________14
5.2.1 Dashboard type 1 – standard version_______________________________________ 14
5.2.2 Dashboard type 2___________________________________________________________ 15
5.3 Hydraulic operation__________________________________________________________________ 16
5.3.1 Hydraulic operation – standard version_____________________________________ 16
5.3.2 Hydraulic operation – TE version____________________________________________ 16
5.3.3 Hydraulic operation – eHC version__________________________________________ 17
5.3.4 Sticker for hydraulic operation______________________________________________ 19
5.4 Connector plate______________________________________________________________________ 20
5.4.1 Connector plate with manually operated locking pin________________________ 20
5.4.2 Connector plate with hydraulically operated locking pin____________________ 21
6. Operating the machine___________________________________________________________________ 22
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6.1 Operator's seat_______________________________________________________________________ 22
6.2 Starting_______________________________________________________________________________ 22
6.2.1 Preparatory work___________________________________________________________ 22
6.2.2 Starting a machine with a Kubota engine___________________________________ 23
6.2.3 Starting a machine with a Yanmar engine___________________________________ 24
6.3 Stopping______________________________________________________________________________24
6.3.1 Stopping a machine with a Kubota engine__________________________________ 24
6.3.2 Stopping a machine with a Yanmar engine__________________________________ 25
6.4 Driving________________________________________________________________________________26
6.4.1 Operating principle – wheel propulsion_____________________________________ 26
6.4.2 Locking differential__________________________________________________________27
6.4.3 Driving: standard version___________________________________________________ 29
6.4.4 Driving - TE version_________________________________________________________ 30
6.4.5 Driving: eHC version________________________________________________________ 32
6.5 Operating the arm____________________________________________________________________33
6.5.1 Operating the arm – standard version______________________________________ 34
6.5.2 Operating the arm – TE version_____________________________________________ 35
6.5.3 Operating the arm – eHC version___________________________________________ 35
6.6 Coupling an attachment______________________________________________________________ 36
6.6.1 Releasing the hydraulic pressure____________________________________________36
6.6.2 Coupling with a manually operated locking pin_____________________________ 36
6.6.3 Coupling with a hydraulically operated locking pin__________________________ 38
6.7 Uncoupling an attachment___________________________________________________________ 39
6.7.1 Uncoupling with a manually operated locking pin___________________________39
6.7.2 Uncoupling with a hydraulically operated locking pin_______________________ 40
6.8 Checking the fuel tank________________________________________________________________ 42
6.8.1 Checking the fuel tank with dashboard type 1_______________________________42
6.8.2 Checking the fuel tank with dashboard type 2_______________________________42
6.9 Filling the fuel tank___________________________________________________________________ 43
6.10 Fitting counterweights________________________________________________________________ 45
6.10.1 Installing the first weight____________________________________________________ 45
6.10.2 Installing the second and third weight______________________________________ 46
6.11 Installing and removing the articulation lock__________________________________________47
6.11.1 Fitting the articulation lock__________________________________________________ 47
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6.11.2 Removing the articulation lock______________________________________________ 48
6.12 Preheating____________________________________________________________________________49
7. Attachment – bucket_____________________________________________________________________ 50
7.1 Overview_____________________________________________________________________________ 50
7.2 Commissioning_______________________________________________________________________ 50
7.3 Coupling______________________________________________________________________________ 50
7.4 Using_________________________________________________________________________________ 51
7.5 Driving________________________________________________________________________________51
7.6 Uncoupling___________________________________________________________________________ 51
8. Attachment – pallet fork__________________________________________________________________ 52
8.1 Overview_____________________________________________________________________________ 52
8.2 Commissioning_______________________________________________________________________ 52
8.3 Coupling______________________________________________________________________________ 52
8.4 Using_________________________________________________________________________________ 53
8.5 Driving________________________________________________________________________________53
8.6 Uncoupling___________________________________________________________________________ 54
9. Transport and storage____________________________________________________________________55
9.1 Transportation – safety instructions__________________________________________________ 55
9.2 Driving onto the mode of transportation_____________________________________________ 55
9.3 Lifting the machine and attachments_________________________________________________ 55
9.4 Storage_______________________________________________________________________________ 56
10. Maintaining the machine_________________________________________________________________ 57
10.1 Daily maintenance____________________________________________________________________57
10.2 Maintenance table – maintenance of machine when switched off____________________ 58
10.3 Maintenance table – maintenance of machine when switched on____________________ 59
10.4 Periodic maintenance (accredited maintenance engineer)____________________________59
10.5 Opening the engine compartment____________________________________________________62
10.5.1 Opening the engine compartment – type 1_________________________________ 62
10.5.2 Opening the engine compartment – type 2_________________________________ 63
10.5.3 Opening the engine compartment – type 3_________________________________ 64
10.6 Cleaning the cyclone filter____________________________________________________________ 64
10.7 Checking the fan belt tension_________________________________________________________66
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10.8 Checking the parking brake___________________________________________________________67
10.9 Lubricating the hinge points__________________________________________________________ 68
10.9.1 Location of the lubrication nipples – standard version______________________ 68
10.9.2 Location of the lubrication nipples – TE version_____________________________ 69
10.9.3 Location of other lubrication points_________________________________________ 70
10.9.4 Lubricating via the lubrication nipples______________________________________ 70
10.10 Checking/topping up the engine oil___________________________________________________71
10.10.1 Checking the engine oil level________________________________________________ 71
10.10.2 Topping up the engine oil___________________________________________________ 72
10.11 Checking/topping up the coolant_____________________________________________________ 74
10.11.1 Checking the coolant level__________________________________________________ 74
10.11.2 Topping up the coolant_____________________________________________________ 74
10.12 Checking/topping up the hydraulic fluid______________________________________________ 75
10.12.1 Checking the hydraulic fluid level___________________________________________ 76
10.12.2 Topping up the hydraulic fluid______________________________________________ 76
10.13 Replacing the air filter________________________________________________________________ 77
10.13.1 Removing the cover_________________________________________________________ 77
10.13.2 Replacing the air and fine filter______________________________________________78
10.14 Replacing hydraulic fluid filters_______________________________________________________ 78
10.14.1 Replacing the suction filter__________________________________________________ 79
10.14.2 Replacing the return filter___________________________________________________ 80
10.15 Cleaning the machine________________________________________________________________ 81
10.15.1 Cleaning with a high-pressure cleaner______________________________________ 81
10.15.2 Problems caused by improper cleaning_____________________________________ 81
11. Maintaining the buckets and pallet fork__________________________________________________ 83
11.1 Daily maintenance____________________________________________________________________83
11.2 Maintenance and repair______________________________________________________________ 83
12. Decommissioning and disposal__________________________________________________________ 84
13. Troubleshooting__________________________________________________________________________ 85
13.1 Procedure____________________________________________________________________________ 85
13.2 Troubleshooting______________________________________________________________________ 85
14. Technical specification____________________________________________________________________88
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14.1 Consumables_________________________________________________________________________ 88
14.2 Machine dimensions_________________________________________________________________ 89
14.3 Maximum machine load______________________________________________________________ 92
14.4 Other technical machine data________________________________________________________ 94
14.5 Sound level___________________________________________________________________________ 97
14.6 Bucket dimensions___________________________________________________________________ 97
14.7 Pallet fork dimensions________________________________________________________________ 99
15. Options and attachments_______________________________________________________________ 100
15.1 Options______________________________________________________________________________100
15.2 Attachments_________________________________________________________________________102
16. Maintenance carried out________________________________________________________________ 106
17. Glossary_________________________________________________________________________________107
18. CE declaration of conformity____________________________________________________________ 108
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Table of Contents

1. Introduction
1.1 About these instructions
These instructions provide all information required to work with the Knikmops
wheel loader and corresponding attachments – pallet fork, volume buckets, shovel
buckets, and rubble buckets.
The Knikmops wheel loader is referred to as the "machine" in these instructions.
The volume buckets, shovel buckets, and rubble buckets are referred to as the
"buckets" in these instructions. The attachments known as "pallet fork" and
"buckets" are jointly referred to as "attachments" in these instructions.
The instructions apply to the following types of machine: KM80, KM85, KM90,
KM100, KM120, KM125, KM130, KM170, including both the H and TE versions
(telescopic arm).
The "pallet fork" and "buckets" must be coupled to the Knikmops, articulated
loader, wheel loader, telescopic handler, excavator, or a similar machine. The
term "machine" is used in these instructions as a reference term, even if an
intermediate attachment is used.
These instructions were originally compiled in Dutch. All other language versions
are translations of the original. In the event of doubt about the accuracy of a
translation, the Dutch version takes precedence.
It is not always possible to provide a detailed illustration of each separate part of
the machine. The illustrations in this document may, therefore, show a standard
structure. The illustrations are solely for instruction purposes.
1.2 Version history
Date Version Notes
December 2021 1.0 First version
1.3 Target group
These instructions are intended for the following target groups:
• machine operators
• personnel who carry out daily maintenance on the machine
Introduction
1

1.4 Symbols used
The following symbols are used in this document:
Symbol Function Description
Warning! "Warning" means that there is a risk of physical injury or death
if the instructions are not followed.
Caution "Caution" means that there is a risk of damage to the
equipment if the instructions are not followed.
Note "Note" is used to provide additional information.
Introduction
2

2. Machine numbers
2.1 Machine identification
Model:
Chassis number:
Engine number:
Color:
Delivery date:
Stamp of accredited Knikmops distributor:
2.2 Type plate
The figure below shows an example type plate on the machine or the attachment.
The actual type plate shows the correct data according to the type of machine or
attachment.
Machine numbers
3

3. Intended use
The machine has been designed for work and transportation activities in road
construction, garden landscaping, and related industries. Attachments can be
coupled to and uncoupled from the machine for use in different applications.
Only use attachments that are intended for your machine and that have been
approved by the manufacturer.
The "pallet fork" attachment is used for moving pallets.
The "bucket" attachments are used for shoveling, moving, and pouring bulky
goods.
Intended use
4

4. Safety
4.1 Safety instructions
4.1.1 Instructions before use of the machine and attachments
• Read the instructions carefully before using the machine.
• Ensure that no one is at risk.
• Carry out the procedures fully and in the specified order.
• Retain these instructions with the machine and corresponding attachments. If
no instructions are available, inform your employer.
• Ensure that all warning symbols on the machine and attachments are legible.
Replace illegible warning symbols promptly.
• Allow the machine to warm up in a well-ventilated environment before use.
• Assess the terrain on which you intend to drive beforehand and demarcate
hazardous points.
• Use the machine on ground with sufficient load-bearing capacity only.
• Workplace environment:
- The machine is suitable for driving on public roads provided that it has the
correct registration certificates, lighting, and warning elements.
- The operator must comply with the legal traffic regulations if driving on
public roads.
- The workplace must always be sufficiently illuminated.
• Replace damaged protective devices promptly.
• Never remove the safety bar or safety roof.
• Do not modify the machine or attachments unless this has been approved in
advance by the manufacturer.
• Use only attachments and machines from the manufacturer.
• Use the machine and the attachments only as intended. If you intend to use
them for a different purpose, please contact the manufacturer.
• The manufacturer is not liable for damage that results from improper use of
the machine or attachments.
• If you replace parts, always contact the manufacturer and use only parts that
are supplied by the manufacturer.
• Start the machine only when sitting in the operator's seat.
• When starting or switching off the machine's engine, the hydraulic drive unit
must be switched off and the handbrake must be engaged.
• Keep the operator's seat, pedals, and steps clean.
Safety
5

• Stow materials and tools when not in use.
• Avoid prolonged overloading of the hydraulic systems. Failure to do so will
cause the machine to overheat. Always move the hydraulic control of the
machine to the neutral position when starting up.
• Avoid jerky movements, other than necessary for normal use.
• Avoid heavy lifting when the machine is running at fully capacity.
• Avoid excessive swinging of the machine when the attachments is on the
ground.
• All connections between the attachments and machine must be fitted with
proper latches.
• The mechanical and hydraulic coupling parts must be properly lubricated and
accessible.
• If the machine is equipped with an attachment which requires periodic
inspection, evidence of inspection must always be present in the machine.
• If using the attachment in combination with a machine not from the
manufacturer, or if using other attachments, the manufacturer is unable to
accept responsibility for use of the combination.
• Take the weight of the attachment into account when checking the load values
of the machine. This weight is indicated on the type and in the instructions.
• When using an attachment, subtract the weight of the attachment from the
load values.
• The load on the arm must not cause the machine to tip, as this could cause the
machine to tip over.
• The arm must be adjusted such that the load is suspended stationary when the
control lever is in the neutral position.
• Do not operate the arm unnecessarily.
• Ensure that attachments are correctly locked at all times.
• Follow the instructions for the attachment in question.
• The capacity and stability of the machine to which the attachment is coupled
must be matched to the attachment.
• The coupling on the machine must be consistent with the hinge coupling on
the attachment.
• The weights being lifted must not exceed the prescribed value of the machine
and the attachment. The maximum lifting weight is stated on the type plate
and in the instructions.
• Avoid unevenly distributed lifting loads.
• Use of counterweights other than those recommended by the manufacturer
may cause overloading and thus prove hazardous to the operator and
bystanders.
Safety
6

4.1.2 Instructions for the user
• Only personnel who have been trained by the manufacturer or importer are
permitted to use, maintain, and repair the attachments.
• Personnel must:
- be eighteen years of age or older.
- be physically and mentally healthy.
- have the requisite knowledge and skills.
- have a driver's license (for driving on public roads).
• Personnel in training may only use the machine and the attachments under the
supervision of trained personnel.
• Not wear loose clothing of jewelry. Tie long hair back.
• Use personal protective equipment, such as safety clothing, safety shoes,
safety goggles, and proper work gloves.
• Use ear protection. The sound level is more than 93 dB(A).
• It is the operator's responsibility to ensure that bystanders are unable to access
the immediate vicinity of the machine, interchangeable equipment, and loads.
4.1.3 Instructions for use of the machine and attachments
• Observe all safety instructions for the machine while working with the machine
and attachment.
• In the event of a malfunction or damage to the machine, stop the machine and
report it to your employer. Ensure the malfunction is resolved promptly.
• Avoid slopes and bumps to the fullest extent possible. The machine may
become unstable.
• If you must drive on a slope, bear the following in mind:
- Driving on a slope without a safety bar or cab is extremely dangerous and
strictly prohibited.
- Driving parallel to the slope is permitted only if the following conditions are
met:
• The slope must not exceed 10°.
• The arm must be retracted and be as low to the ground as possible.
• The travel speed must not exceed 3km/h.
- If the machine tips over:
• Keep the safety belt on.
• Remain in the machine.
• Switch the machine off completely.
• Always drive with the arm retracted when driving a TE version machine.
Safety
7

• Avoid turning the steering wheel when the machine is stationary.
• Never transport people with the machine or attachments.
• Do not make sharp turns at high speed.
• Keep the safety belt on at all times.
• If you notice that the machine is becoming unstable or skidding, stop the
machine as promptly as possible with the attachment on the ground.
• Avoid high speeds with a low oil temperature – drive at low revolutions
(1,500rpm) unladen for the first five minutes.
• In the event of pending danger, give a warning signal and stop the machine, if
necessary.
• In poor visibility and darkness, always keep the machine's lights on.
• If you do not have sufficient visibility, you must be accompanied by trained
personnel. Personnel must be recognizable as such and always remain in your
line of sight.
• Do not use the machine at landfill sites where there is a risk of the machine
falling unless there are facilities in place to prevent rolling or crashing.
• Never leave the machine running if no one is at the steering wheel.
• Before stopping the machine, lower the attachment as close to the ground as
possible. This prevents people from falling over the attachment and prevents
the arm from suddenly tilting downward.
• If the hydraulic steering cylinder fails, fit the articulation lock.
• If driving the machine with a pallet fork:
- The pallet fork must be suspended low above the ground.
- Draw attention of people around the machine to the risk of falling loads.
• If driving the machine with a bucket:
- The bucket must not be suspended too far above the ground. Bulky goods
may fall from the bucket and impact the operator if the bucket is too far
from the ground, resulting in serious injury.
- The underside of the bucket can only withstand light loads. In the lowermost
position, the edge of the bucket can hit the ground when tilted forward,
which can cause an overload.
- If the bucket is too low to the ground, the ground and the bucket itself may
become permanently damaged.
• If possible, park on level ground and pull the parking brake upward.
• Carefully consider how you use the attachment.
• If the hydraulic fast attachment for connecting the attachment is not working
properly, stop immediately to avoid accidents.
Safety
8

• Lifting and hoisting equipment must not be used if it has not been inspected or
not inspected promptly.
• When the machine is stationary, operations under the attachment, whether the
attachment is laden or unladen, are not permitted.
4.1.4 General safety instructions
• Lifting and hoisting equipment such as chains, plastic straps, and steel straps
must satisfy these requirements:
- sufficiently strong, properly dimensioned, and in good condition
- comply with local labor and safety regulations
• Follow local labor and safety regulations and environmental laws
• Ensure that you know where fire extinguishing equipment is located.
• In the event of a fire, you must keep a sufficient distance from the machine. If
the hydraulic fluid lines become overheated, they are at risk of rupturing and
causing intense flames of burning hydraulic fluid.
• Use only fuses from the manufacturer.
• Ensure that no oil or grease gets on to the machine. In the event of a spillage,
clean it immediately.
• Only use the machine in well-ventilated spaces.
• Never use the machine as an anchoring point.
• The ROPS/FOPS safety cab is compulsory in any situation in which material can
fall downward or the operator is undertaking hazardous activities on a slope.
• To prevent life-threatening situations, do not modify the safety cab in any way.
• Mirrors, light fittings, and similar fixtures may only be fitted to the safety bar
with a clamp.
• Welding, drilling, and similar activities on the bar are not permitted. Replace a
damaged ROPS/FOPS safety cab promptly.
• If you wish to start the regeneration process, take the following into account:
- Regenerate outdoors only or in an adequately ventilated space.
- Keep a safe distance from the machine.
- Do not switch the machine off.
- Keep the engine compartment closed.
Safety
9

4.2 Safety symbols on the machine
The safety symbols on the machine and the attachments must always be legible
and be replaced if damaged.
4.2.1 General safety symbols
Symbol Description
Personnel not operating the machine must stay
out of its vicinity.
Safety instructions that you must read before
starting the machine. You must always follow
these safety instructions carefully.
Standing under the load is prohibited.
Safety instructions that you must read to avoid
overturning the machine.
Safety instructions that you must read to avoid
being crushed by the machine.
Verify the full engagement of the loader
attachment bracket locking pin to the attachment
to avoid being crushed.
Verify Diesel fuel specifications.
Safety
10

Symbol Description
Install the FOPS if there is a risk of falling objects.
Safety instructions on what to do when the
machine tips over.
Use hydraulic fluid only.
Safety instructions that you have to read carefully
to avoid injury or death.
Never remove the ROPS.
Do not open when the engine is running.
Safety
11

Symbol Description
Always read the operator manual and safety
instructions.
Maintain 3-point contact during entry and exit if
your are the operator and keep a safe distance
from the machine during entry and exit if you are
not the operator.
Risk of burns: beware of hot machine parts.
Handbrake on/off.
Valve operation (see Sticker for hydraulic
operation on page 19 for more information).
Safety
12