intrepid KM100 User Manual Download

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User Manual

Knikmops Wheel Loaders

Summary of Contents for KM100

Page 1: ...User Manual Knikmops Wheel Loaders ...

Page 2: ...cations 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 o...

Page 3: ...pecifications 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manual has been prepared with the utmost care Nevertheless some information may be incomplete incorrect or may become outdated in time TO THE FULLEST EXTENT PERMISSIBLE BY LAW MINILOADERS COM MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND WHETHER EXPRESS OR IMPLIED FOR THE CURRENCY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 COMPLETNES...

Page 4: ...th 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 ...

Page 5: ...cerning 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 ...

Page 6: ...ance 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...

Page 7: ...ints 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 ...

Page 8: ...s 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...

Page 9: ...y 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 806 376 0166 E mail info miniloaders com Introduction 11 002 30 08 2018 9 ...

Page 10: ...s 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 int...

Page 11: ...hine 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 ...

Page 12: ...d 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 the...

Page 13: ...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 K K L G H Q J R B J D V Symbol Meaning A Only attach...

Page 14: ...sk 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 Pre...

Page 15: ...er 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...

Page 16: ...at 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 Gas pedal Description 16 11 002 30 08 2018 ...

Page 17: ... 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 A Ignition key F Oil pressure lamp Description 11 002 30 08 2018 17 ...

Page 18: ...N M C F A G H I J K L B D A Ignition key I Neutral position indicator B Fuse box J Engine oil pressure C Light switch K Battery voltage D Differential switch L Engine coolant temperature E Operating hours counter M Hydraulic fluid temperature F Fuel indicator N Parking brake G Turn signal optional O Position lights optional H Pre heater lamp for the diesel engine Description 18 11 002 30 08 2018 ...

Page 19: ...cope button extend only for TE versions B Lever for auxiliary hydraulic function right See also section 4 4 F Moving the joystick left and right takes over the function of B C Horn G Button to switch the electrical function of the attachment on and off D Travel direction button Description 11 002 30 08 2018 19 ...

Page 20: ...A Electrical connection for electrical function D Mounting plate B Connection for auxiliary hydraulic function right E Locking handles C Connection for auxiliary hydraulic function left F Locking pins Description 20 11 002 30 08 2018 ...

Page 21: ...y hydraulic function right B RAISE BOOM F Auxiliary hydraulic function left C MOUNTING PLATE FORWARDS G Hydraulic pressure on side hydraulic connection with red dust cap D MOUNTING PLATE BACKWARDS H Hydraulic pressure on side hydraulic connection with green dust cap Description 11 002 30 08 2018 21 ...

Page 22: ...hydraulic pressure comes from a hydraulic pump that is driven in turn by a diesel engine The gas 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 gas pedal for example to drive slowly across rough terrain or to lift h...

Page 23: ...er See section 5 2 4 Make sure that the following controls are in the neutral position Driving direction lever Boom lever Both levers for the auxiliary hydraulic functions 5 Sit on the driver s seat before starting the machine 6 Adjust the driver s seat if necessary 7 Put on the seatbelt and click it tight Start the machine 1 Insert the ignition key into the ignition 2 Turn the ignition key to the...

Page 24: ...wing 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 ...

Page 25: ...want to lower the boom hold the boom level A in the LOWER BOOM position 1 2 If you want to raise the boom hold the boom level A in the RAISE BOOM position 2 3 If you want to tilt the mounting plate backwards hold the boom lever in the MOUNTING PLATE BACKWARD position 3 4 If you want to tilt the mounting plate forwards hold the boom lever in the MOUNTING PLATE FORWARD position 4 5 If you want to ex...

Page 26: ...ccessory is completely against the face of the mounting plate If necessary tilt the mounting plate backwards a little 6 Put the locking pin levers A in the locking position 7 Check that the locking pins B have come out and secure the coupling of the interchangeable accessory 8 If necessary connect the hydraulic hoses and electrical cables of the interchangeable accessory to the connections for the...

Page 27: ...locking pins F are now pushed in and the interchangeable accessory is unlocked 4 Tilt the mounting plate forwards until the interchangeable attachment comes off the mounting plate 4 7 Refueling Before you begin The fuel is flammable and can be dangerous Be careful when handling fuel Warning Use only the right fuel and do not mix it with petrol or alcohol Such a mixture can damage the engine or cau...

Page 28: ... this task Caution In the event of improper use the tires will show extra wear and the machine will be difficult to steer Procedure 1 To engage or disengage the differential press the differential switch 4 9 Positioning counterweights Safety Warning A minimum of two people are needed for lifting the counterweights Each counterweight weighs more than 30 kg A Daily use 28 11 002 30 08 2018 ...

Page 29: ...ht 1 Hang the counterweight A on the previous counterweight with the hooks B 2 Fit the locking bolt C 4 10 Mounting and removing the jib lock The jib lock is intended to prevent the machine from bending in the event of a failure of the control mechanism Safety Warning Make sure the engine is switched off before you perform any actions on the jib lock If the engine is switched on there is a risk of...

Page 30: ...ont part of the machine 4 11 Preheating The machine has a built in heating element Charging 1 Connect the machine to the wall socket and the connection point B on the machine using the cable supplied A 2 Start the preheating at least 1 5 hours before starting the machine 3 At extremely low temperatures lower than 10 C 14 F a longer preheat time may be needed 4 12 Transport and storage B A A B Dail...

Page 31: ...dicated with stickers 4 12 3 Hoisting the machine 1 Make sure that the machine is straight so that it is not bent 2 Turn off the machine completely 3 If there is a problem with the steering fit the jib lock see section 4 10 4 Only use the lifting eyes which are marked with stickers on the machine Use the two lifting eyes at the top or the four lifting eyes at the base of the machine 5 Attach the l...

Page 32: ...e maintenance with the machine switched off Machine part Procedure Rejection criterion Action on rejection Complete machine Visually check for dam age Visible damage Contact a qualified service technician Visually check for liquid leakage WARNING obey the safety instruc tions concerning hy draulic parts See sec tion 2 2 6 Leakage of hydraulic fluid fuel coolant or battery acid Contact a qualified ...

Page 33: ... Contact a qualified service technician Lighting if present Switch the lighting on The lighting does not light Contact a qualified service technician Controls Test the operation of all controls levers steering wheel pedals Not all controls levers steering wheel pedals work correctly Contact a qualified service technician Boom TE models Slide the boom in and out The boom does not slide out or in pr...

Page 34: ...water and remove if present Every 150 hours See the diesel engine user manual Replace Every 300 hours See the diesel engine user manual Hydraulic fluid filters Replace Every 300 hours See section 5 13 Safety stickers Replace if illegible First time after 600 hours then every 1200 hours Hydraulic fluid Replace Every 1200 hours See section 5 13 Fuel tank Check for rust forma tion and damage in side ...

Page 35: ...he lever A with the machine 2 Open the cover B 3 Pull the lever C and open the cover including the driver s seat D 5 6 Clean the pre filter The pre filter is at the back of the machine and is used to filter very coarse dust from the air before it goes to the air filter Before you begin Note The pre filter is not present on all types of machine A B D B A C Maintenance 11 002 30 08 2018 35 ...

Page 36: ...Check the fan belt tension Before you begin Warning Switch off the engine Check that the engine really is off Make sure the engine has cooled down sufficiently before carrying out this procedure Procedure 1 Open the engine compartment See section 5 5 2 Push the belt A with your thumb at the largest span The belt must have a play of between 7 and 9 mm 3 If the belt can move more or less than allowe...

Page 37: ...nipples 1 Add grease through the grease nipples see following sections until grease comes out of the bearing Use a grease gun For the correct type of grease see section 7 1 2 Remove excess grease Note It is possible that grease is still released for a longer period of time after lubrication This is a normal phenomenon 5 8 3 Grease nipples standard versions A A A A A B A A A A Grease nipple B Greas...

Page 38: ... engine oil dipstick A from the holder clean the engine oil dipstick and replace it 3 Remove the engine oil dipstick from the holder again and check that the engine oil level is between the MIN and MAX marks Then replace the engine oil dipstick 4 If the engine oil level is too low a Remove the engine oil cap B b Fill up the oil tank For the correct type of engine oil see section 7 1 A B Maintenanc...

Page 39: ...r the reservoir A contains sufficient coolant fluid The fluid level must be between the FULL and LOW marks 3 If the reservoir is not properly filled top up the coolant fluid See the procedure below 4 Close and lock the engine compartment Topping up 1 Remove the cap A from the radiator First unscrew it 1 turn and allow any overpressure to escape before you completely remove the cap 2 Fill coolant f...

Page 40: ...he bolt and the nut C b Remove the filler cap D c Fill up the tank For the correct type of hydraulic fluid see section 7 1 d Refit the filler cap and secure the filler cap with the bolt and nut 3 If the fluid level is too high contact a qualified service technician 5 12 Replace the air filter Spares For the correct replacement parts contact the manufacturer Safety Note This procedure may only be c...

Page 41: ...ld air filter B 2 Remove the old fine filter C 3 Fit the new filters 4 Replace the cover A and turn it clockwise until the locking tab engages 5 Close the engine compartment 5 13 Replacing the hydraulic fluid filters Spares For the correct replacement parts contact the manufacturer Safety Note This procedure may only be carried out by a qualified service technician A B C B A Maintenance 11 002 30 ...

Page 42: ...raulic fluid needs to be replaced use new hydraulic fluid Replacing the return filter only present on certain machine types 1 Remove these parts Cover A Coil spring B Filter element C 2 Remove the old filter element 3 Fit the new filter element 4 Replace the coil spring and the cover 5 13 1 Other lubrication points 5 13 2 Procedure lubrication via grease nipples Before you begin Note This procedur...

Page 43: ...he bearing Use a grease gun Use the right grease See section 7 1 2 Remove excess grease Note It is possible that grease is still released for a longer period of time after lubrication This is a normal phenomenon 5 13 3 Other lubrication points A A A A A Grease nipple Maintenance 11 002 30 08 2018 43 ...

Page 44: ...r the manufacturer The engine does not start but the start motor does turn Not enough fuel Fill up with fuel The engine has not pre heated long enough Hold the ignition key in the GL position longer when you are starting There is another hydraulic func tion enabled Set all the levers for the auxili ary hydraulic functions to the neutral position See section 3 4 The engine does not have enough powe...

Page 45: ...t is not possible to connect the hydraulic connection of the in terchangeable accessory The machine is still under pres sure 1 Turn the ignition key to the OFF position to switch off the engine 2 Move the levers for the auxiliary hydraulic func tions back and forth sever al times to remove the hy draulic pressure The interchangeable accessory is still under pressure Remove the hydraulic pressure f...

Page 46: ... you are located The use of red diesel is not allowed in certain countries Engine oil Oil API class CD grade or higher for tempera tures higher than 10 C SAE10W 30 or SAE15W 40 other temperatures consult the diesel engine user manual Hydraulic fluid AZOLLA ZS 46 TOTAL Coolant COOLELF AUTO SUPRA 26 C TOTAL Grease General grease classification NLGI 2 Technical data 46 11 002 30 08 2018 ...

Page 47: ...al length without bucket I Seat height C Total length with bucket J Ground clearance D Total width K Tipping in angle from ground surface E Width L Jib hinge height F Maximum turning angle M Transfer height G Outside turning circle N Shovel bucket rotation point maximum height Technical data 11 002 30 08 2018 47 ...

Page 48: ...n 2360 92 91 C Total length with bucket mm in 2935 115 6 D Total width mm in 750 1020 29 53 40 16 E Bucket width mm in 800 100 31 5 3 94 F Max turning angle 50 G Outside turning circle mm in 2120 83 46 H Roll bar height ROPS FOPS height mm in 2040 2100 80 31 82 68 I Seat height mm in 1070 42 16 J Ground clearance mm in 205 8 07 K Tipping in angle from ground surface 30 L Jib hinge height mm in 106...

Page 49: ...otal weight without exchange able accessory kg lbs 820 1810 Lifting power kg lbs 450 992 Breakout force kg lbs 550 1220 Speed km h mph 13 8 1 7 5 KM85 Table 4 Dimensions Posi tion Parameter Unit Value A Wheelbase mm in 1415 55 71 B Total length without bucket mm in 2360 92 91 C Total length with bucket mm in 2935 115 6 D Total width mm in 750 1020 29 53 40 16 E Bucket width mm in 800 100 31 5 3 94...

Page 50: ...ht without exchange able accessory kg lbs 820 1810 Lifting power kg lbs 450 992 Breakout force kg lbs 550 1220 Speed km h mph 13 8 1 7 6 KM100 Table 7 Dimensions Posi tion Parameter Unit Value A Wheelbase mm in 1445 56 89 B Total length without bucket mm in 2400 94 49 C Total length with bucket mm in 2940 115 7 D Total width mm in 930 1180 36 61 46 46 E Width mm in 960 1250 37 8 49 21 F Max turnin...

Page 51: ...ing power kg lbs 650 1433 Breakout force kg lbs 750 1653 Speed km h mph 16 9 9 7 7 KM100TE Table 10 Dimensions Posi tion Parameter Unit Value A Wheelbase mm in 1530 60 24 B Total length without bucket mm in 2610 102 8 C Total length with bucket mm in 3250 128 D Total width mm in 930 1180 36 6 46 5 E Width mm in 960 1250 37 8 49 21 F Max turning angle 45 G Outside turning circle mm in 2380 93 7 H R...

Page 52: ...ylinders 3 Work hydraulics flow l min gpm 28 6 2 Hydraulic operating pressure bar psi 180 2610 Total weight without exchangeable accessory kg lbs 1280 2822 Lifting power kg lbs 675 1488 Breakout force kg lbs 775 1708 Speed km h mph 18 11 7 8 KM120 Table 13 Dimensions Posi tion Parameter Unit Value A Wheelbase mm in 1550 61 02 B Total length without bucket mm in 2710 106 7 C Total length with bucke...

Page 53: ... Hydraulic operating pressure bar psi 180 2610 Total weight without exchange able accessory kg lbs 1300 2866 Lifting power kg lbs 875 1929 Breakout force kg lbs 975 2150 Speed km h mph 18 11 7 9 KM120TE Table 16 Dimensions Posi tion Parameter Unit Value A Wheelbase mm in 1650 64 96 B Total length without bucket mm in 2860 112 6 C Total length with bucket mm in 3540 139 4 D Total width mm in 950 12...

Page 54: ...lbs 840 1852 2 Y 2250 mm Not folded telescopic arm ex tended kg lbs 500 1102 3 Not folded telescopic arm re tracted kg lbs 520 1146 Not folded telescopic arm ex tended kg lbs 380 838 Table 18 Technical data Parameter Unit Value Fuel tank capacity l US gallons 37 9 8 Diesel engine type Kubota D1105 Engine power kW pk 19 25 Number of cylinders 3 Work hydraulics flow l min gpm 33 7 3 Hydraulic operat...

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intrepid KM100, User Manual

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